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Discussion Starter · #1 ·
Thought it might be a good idea to have a thread about how I've went about gathering parts to try and make up a set of Bora OEM HIDs. It's too me a while to gather the parts and a fair slab of cash as well but I reckon it'll be worth it when I'm done. This all refers to the pre 2002.5 headlights. I'll take some pics of the parts when I get a chance and add them to the thread. Here's how the story goes.

Headlight Housings

We all know how rare and hard to get a set of RHD Bora Xenons are so I was pretty shocked one night to find a set on ebay. One was a drivers side from one seller and the other a passengers side from a completely different seller. One was a buy it now auction and the other took a generous offer to have the auction ended early. Yes, i know i'm guilty of this but how often do you get the chance to get a full set in one night. Anyway, even better was the fact that they were both new headlights and still in the VW boxes. Not only was this all matching up nicely there was the surprise of them both being Pre-2002.5 headlights. The xenons changed in wiring and function after this. Next was the long adventure to find the ballasts.

Headlight Housings Cost ?280 for the pair.

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Ballasts

I have managed to get myself about 5 now. Don't ask why but it's better safe than sorry. These have been gathered up from germany and the USA. None to be found in the UK ebay or elsewhere. I tried just about every scrap yard i could find the number for. the average price I got them for was about ?55 - ?60 which isn't bad considering that VW charge ?276 each for them. Next was the wiring and brackets to hold the ballast as the pre 2002.5 ballasts are mounted away from the light at the front wings. Connected by a wiring loom of their own and a conduit wrapped around. I managed to wrestle these items from a disgruntled german. German ebay is good to find bits on but make sure you have a good translater. I have a very good friend of mine from america who is fluent in german and was invaluable to me getting parts. If you try and use google translater or babblefish, more often than not you'll appear to be rude or not make any sense whatsoever. Try and find a user who already has international shipping indicated on the auction and takes paypal. This means all the negotiation has already been taken care of and you just have to send the money.

Ballast Cost ?110 for the pair. Got the brackets and wiring for free.

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Igniters

Not so easy to get were the igniters. I have a couple at the minute but need to trim brackets off one to make it fit. The igniters have to be the small 2 pin ones. If you've ever has a look at igniters you'll know what i mean. Igniters can be found on german ebay again but are very hard to fnid the right ones. They are ?80 for the pair from VW and you can only order them in pairs. Some dealers will tell you they're ?80 each. They need slapped. I could see from where I was sitting that the screen said 2 items = ?78. Anyway, typical price on german ebay is about ?10 - ?15 including shipping.

Igniter cost so far ?10 and need to swap a 3 pin for a 2 pin one.

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Bulbs

I ordered 2 x Philips D2S 4300K ultrawhite bulbs from a guy called Chris French on ebay. His username is monsterbikes and the guy is a legend. Very helpful and friendly and at ?28 for the pair of bulbs it's an unreal price. VW will charge you ?114 each for the bulbs.

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I also managed to order a set of H7 4700K bulbs from ebay. Cost was about ?10 including P+P. Lets hope they last.

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Sidelight bulbs were H6W and I got them from ultraleds. They seem very short though and don't realy sit out in the reflector. I'll try and get a pic of it sometime. I'm sure they'll be fine.

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Here's the indicator bulbs needed which are listed wrong in the lucas catalogue because they seem to be unaware of the changes in the versions of these headlights. The proper code is shown clearly.

http://img.photobucket.com/albums/v643/Zinc_Sniper/My%20Car/HIDs/indybulbs.jpg

Bulb cost so far ?52.

Autolevelling

Autolevelling was something I wanted to go with to keep everything OEM. It's not essential and the levelling can be wired to the manual leveller that are on the normal headlights. This is by far and away the hardest parts to find on the pre 2002.5 headlights as the levelling control unit is a seperate box. The control unit has taken me 4 months to find and I ended up paying about ?90 for it. Bear in mind that this is ?405 from VW and not only that, when I phoned my local dealership he was kind enough to do a little research for me and found out that there was only one of these units in the UK out of all the dealers, and it would still be ?405. Off i went on a search from there and again i've tried every scrap yard and not a thing turned up until I found it on german ebay. Funny enough by a german chap who wasn't willing to send it to the UK. German people are VERY stubborn sometimes. (I'm not racist in any way but my experiences lately have reinforced my thoughts on this). After 3 days negotiation with a translator and general begging we managed to agree with the guy that if I won the auction he'd send the item at cost price on the P+P. He turned out to be a pretty agreeable chap after we told him how long i'd been looking for it. Unfortunately that's only part of the battle. I managed to get the front and rear auto-levelling sensors for free from a scrap yard. I have also now managed to get all the wiring and almost all the brackets and fittings. Again I got these thrown in for free. I need a front sensor arm which I'll order today from VW as they seem to be pretty tough to find elsewhere. We'll also be making a custom bracket on the front for lowered cars and we'll be using a multimeter to keep an eye on voltage levels from the control pins and maybe including a potentiometer to resist a little voltage to get it inside the tolerances needed to activate the sensors.

http://img.photobucket.com/albums/v643/Zinc_Sniper/My%20Car/HIDs/Auto-LevellingControlUnit.jpg

Auto-levelling wiring loom with spade connectors for attaching them to the 10-12 pin adapters during installation.

http://img.photobucket.com/albums/v643/Zinc_Sniper/My%20Car/HIDs/Auto-LevellingLoom.jpg

Here's the bracket which cost me about ?40. It had to be ordered from the factory in Germany because the total amount in stock in the UK was 0. As you can see there is a piece detached from the main bracket. This is because the screws supplied by VW (with the correct part number) don't fit.

http://img.photobucket.com/albums/v643/Zinc_Sniper/My%20Car/HIDs/Rearlevellingbracket.jpg

Here's the Bracket screwed together. I drilled the holes with a 4mm bit if i remember correctly.

http://img.photobucket.com/albums/v643/Zinc_Sniper/My%20Car/HIDs/rearlevbrack2.jpg

http://img.photobucket.com/albums/v643/Zinc_Sniper/My%20Car/HIDs/rearlevbrack1.jpg

Autolevelling cost so far ?130

Headlight Washers

The headlight washers again are something that aren't needed but I want them to keep the whole HID system as OEM as possible. So far I've managed to get the 5.5L washer bottle and secondary water pump with wiring and headlight washer jets all for ?20. I also just got the piping and a headlight washer jet carrier for FREE. I managed to get a full second set of headlight washers and a passenger's side washer cap. So roughly that works out at about another ?10. The drivers side cap should be about ?5 but I need to check.

Here's my full setup. I have new jets ready to go into them. As you can see I have loads of spare piping as well.

http://img.photobucket.com/albums/v643/Zinc_Sniper/My%20Car/HIDs/washerstuff.jpg

And here's the 5L washer bottle with the secondary water pump for the washer jets.

http://img.photobucket.com/albums/v643/Zinc_Sniper/My%20Car/HIDs/5Lwasherbot.jpg

And the washer cap that I got a hold of was no good because it was from a golf and won't fit my bumper so I ordered new Bora ones and jets to match. I'll just sell the golf jets I have.

Headlight washer cost ?40

Wiring - 10-12 pin Adapters

The 10-12 pin Adapters have just been finished. It's not as simple as whacking in the ones we've seen everywhere in diagrams as the pre2002.5 adapters are not only different from the 2003 ones but the left one is different from the right one. This is made even more complicated by the fact i'm including the autolevelling. I'd like to also mention that Bosch and their suppliers are pretty useless and were no help what-so-ever when it came to the pin outs for these parts. Also Kufatec.de were pretty ignorant and only aggreed to tell me how they were wired if i bought the sensors and wiring package from them at about ?130.

Below is a diagram I've just put together to show the wiring connections for the adpaters and the sensors. It shows every wire needed.

Wiring and plugs for adapters - Approx ?20

10 pin Stock Wiring

1. Level Motor (+)<?xml:namespace prefix = o ns = "urn:schemas-microsoft-com:eek:ffice:eek:ffice" /><o:p></o:p>

2. Front Fogs (+)<o:p></o:p>

3. Negative (Level motor)<o:p></o:p>

4. Negative (Low Beam, Indicators, Sidelights)<o:p></o:p>

5. Level Motor Control (+)<o:p></o:p>

6. Indicator (+)<o:p></o:p>

7. Low Beam (+)<o:p></o:p>

8. Negative (Front Fogs, High Beam)<o:p></o:p>

9. High Beam (+)<o:p></o:p>

10. Sidelight (+)

<o:p> </o:p>

<o:p>

12 Pin Left Headlight<o:p></o:p>

1. Black ? Level Motor (+)/Purple ? Levelling Controller (+)<o:p></o:p>

2. K Wire ? OBDII socket pin 7 or T32/25 (Blue plug on clocks)<o:p></o:p>

3. Sidelight (+)<o:p></o:p>

4. Indicator (+)<o:p></o:p>

5. Main Beam (+)<o:p></o:p>

6. Ballast (+)<o:p></o:p>

7. Negative (Main Beam, Levelling Motor, Levelling Controller)<o:p></o:p>

8. Negative (Ballast, Sidelight, Indicator)<o:p></o:p>

9. Suspension Sensors (+). Pin 5 on both sensors (black wire)<o:p></o:p>

10. Rear Suspension Sensor. Pin 4 (blue wire)<o:p></o:p>

11. Levelling Motor Control<o:p></o:p>

12. Front Suspension Sensor Pin 4 (red wire)<o:p></o:p>

<o:p> </o:p>

12 Pin Right Headlight<o:p></o:p>

1. Level Motor (+) ? T12a/1<o:p></o:p>

2. K Wire ? T12a/2<o:p></o:p>

3. Sidelight (+)<o:p></o:p>

4. Indicator (+)<o:p></o:p>

5. Main Beam (+)<o:p></o:p>

6. Ballast (+)<o:p></o:p>

7. Negative (Main Beam, Levelling Motor)<o:p></o:p>

8. Negative (Ballast, Sidelight, Indicator)<o:p></o:p>

9.<o:p></o:p>

10.<o:p></o:p>

11. Levelling Motor Control ? T12a/11<o:p></o:p>

12.

<o:p></o:p>

http://img.photobucket.com/albums/v643/Zinc_Sniper/My%20Car/HIDs/2002HIDWiring.jpg

On the left 12 pin adapter, all pins must included and are all utilised.<o:p></o:p>

On the right 12 pin adapter, Pins 1, 2, 3, 4, 5, 6, 7, 8, and 11 are used.<o:p></o:p>

<o:p> </o:p>

<o:p>Here's what the adpters look like now. I used a glue gun to seal up the back of the connectors and then wrapped them all in cloth tape. As you can see I'm using spade connectors to hook it all up for the auto-levelling parts and extra connections. These will be wrapped in heat shrink sleeve and taped up when the installation takes place.</o:p>

<o:p> http://img.photobucket.com/albums/v643/Zinc_Sniper/My%20Car/HIDs/Adapters.jpg</o:p>

</o:p>

Here's the tapes I'm using. One is a standard rol of insulating tape and the other roll is the type that's used on the original loom. It's a cloth tape and is excellent. It wraps in pretty tight and is easy to work with. It's about ?4 per roll.

http://img.photobucket.com/albums/v643/Zinc_Sniper/My%20Car/HIDs/Tape.jpg

Other Bits

Lexan Headlight Protectors - ?30

Various nuts, bolts, and other stuff ?10

Part Numbers (some VW prices)

Left Headlight Housing - 1J5 941 017 AN - ?276

Right Headlight Housing - 1J5 941 018 AN

Auto-Levelling Control Unit - 1J0 941 651 - ?405

Ballast - 1J0 941 641

Igniter - 1J0 941 641 A - ?80 per pair

Igniter Holding Bracket - 1J0 941 613 A

Bulb Retaining Ring - 1C0 941 621

Left Ballast Holding Bracket - 1J0 941 613

Right Ballast Holding Bracket - 1J0 941 614

Screws for Ballast Brackets (x2) - N 904 556 03

Wiring Harness to Left Ballast - 1J0 972 813

Wiring Harness to Right Ballast - 1J0 972 813 A

Left Ballast Wiring Conduit - 1J0 971 821 C

Right Ballast Wiring Conduit - 1J0 971 822

Wiring and plugs for adapters - Approx ?20

TOTAL COST FOR ME SO FAR: ?682 I think this price isn't too bad considering It's all OEM and i'm installing headlight washers and autolevelling.

Well, that's the story so far. I'll try and get a few updates and pictures as soon as I get a chance. I'm almost ready for installation now. About time too. My first move will be pulling the autolevelling wiring down the side of the car. Then I'll need to install the headlight washers as it's only 2 wires and the washer bottle. I'll leave the cutting of the bumper to a good friend and professional bodywork geezer and painter.

All the best and if anyone has any questions just ask. I might even have a few spare parts left over when I'm finished.

Cheers

Baz
 

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Hi Baz,

I've got mine on already, but will be interested to see what happens with main beam on yours.

With
mine, when main beam is s elected dipped beam goes off, so I've had to
use some of the bits from my bixenon retrofit kit. I'm wondering if I
need a Golf head lamp switch or relay. With standard lights, the Golf
dipped beam stays on with main beam, so it may be something quite
simple. The dealers can't see anything in the wiring diagrams and
suggested it may be something to do with the levelling ECU, so I'd like to see if you get the same result.

Simon
 

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Simon, have you simply used the OEM housings with the ballasts & wiring from the bi-xenon kit? I have not fitted my bi-xenon kit yet, just not had the time, bt if I have same issues which you have had I will obviously have to consider the alternatives. One is OEM units, the other being some sort of conversion to projector lights with seperate main beam.

How much did you pay for your OEM housings? (if you don't mindme asking)
 

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I have indeed used OEM xenon housings along with the bixenon wiring
and ballasts. The housings came with the levelling motors in place
which was a bonus. The improvement over the bixenon kit is excellent,
clean light, no shadows and a nice crisp cut off.

<>I got one of
the housings off ebay for ?50 and the other came from my local friendly
VW stealer at a heavily discounted rate (still not cheap though). The
D2S burners came from a friend who had upgraded the ones in his Fabia
and I got the 10 to 12 pin adapters from Baker21.

<>I was
going to get the housings from our local Bosch agent who quoted me
about ?150 + VAT each for the 2002 on version, but then I found one of
the earlier type on ebay and had to get the matching one from the
stealers.
 

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Discussion Starter · #5 ·
I just added some part numbers and prices and stuff. I'll be adding pics this weekend when i get a chance and hopefully I can get some 10 - 12 Pin adapters made up.

Baz
 

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Baz, I think that the little wiring harnesses to the ballasts are about ?105 each. I found out when I was trying to get the 4 pin connector to go to the headlight.
 

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Discussion Starter · #7 ·
I wasn't too sure about them myself. I've got ?114 written down here and ?120 somewhere else.

I'll put a few more prices on this weekend.

Cheers

Baz
 

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Hi Baz,

I've got mine on already, but will be interested to see what happens with main beam on yours.

With
mine, when main beam is s elected dipped beam goes off, so I've had to
use some of the bits from my bixenon retrofit kit. I'm wondering if I
need a Golf head lamp switch or relay. With standard lights, the Golf
dipped beam stays on with main beam, so it may be something quite
simple. The dealers can't see anything in the wiring diagrams and
suggested it may be something to do with the levelling ECU, so I'd like to see if you get the same result.

Simon
Simon, this is fix for the xenon and main beam issue you have:

It's an easy fix, all you have to
do is run a wire from pin no.7 on the headlight switch to pin no.8 on
the main beam switch as this is missing on the Bora.
There is a wire already in pin no.8 on the main beam switch, you just have to solder or join your new wire to it.

[:)]
 

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Baz - By the time you have all your lamps built and working it will have cost you the same as the 'real deal' surely?
 

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Discussion Starter · #10 ·
Look again. I only need a couple of small pieces and i'm still well under what it would cost to buy just one headlight housing and the autoleveller.

Cheers

Baz
 

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Hi Baz,

I've got mine on already, but will be interested to see what happens with main beam on yours.

With
mine, when main beam is s elected dipped beam goes off, so I've had to
use some of the bits from my bixenon retrofit kit. I'm wondering if I
need a Golf head lamp switch or relay. With standard lights, the Golf
dipped beam stays on with main beam, so it may be something quite
simple. The dealers can't see anything in the wiring diagrams and
suggested it may be something to do with the levelling ECU, so I'd like to see if you get the same result.

Simon
Simon, this is fix for the xenon and main beam issue you have:

It's an easy fix, all you have to
do is run a wire from pin no.7 on the headlight switch to pin no.8 on
the main beam switch as this is missing on the Bora.
There is a wire already in pin no.8 on the main beam switch, you just have to solder or join your new wire to it.

[:)]

Cheers Ray, I knew that someone would be able to come up with an answer and that it would be fairly simple to fix!
 

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The headlight washers again are something that aren't needed but I want them to keep the whole HID system as OEM as possible. So far I still need some parts for this system but I have some stuff. So far I've managed to get the 5.5L washer bottle and secondary water pump with wiring and headlight washer jets all for ?20. I still need some piping and the headlight washer jet carriers. These are the small canisters which force the water through the jets. Very hard to find. I'll keep you all informed if i get them.

Headlight washer cost so far ?20
Baz you need to replace your existing wiper relay with one that has the headlamp washer feature. I think I've got a spare one. If I was you buy new jets, they're around ?12 a side.
 

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Discussion Starter · #13 ·
Hi m8. I have an autodimming mirror and 3 of those relays here anyway. The washer jets are new as well.

Cheers

Baz
 

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Autolevelling

Autolevelling was something I wanted to go with to keep everything OEM. It's not essential and the levelling can be wired to the manual leveller that are on the normal headlights.

Headlight Washers

The headlight washers again are something that aren't needed but I want them to keep the whole HID system as OEM as possible.
How come both autolevelling and headlight washers aren't required (for passing an MOT i presume), when all cars with OEM HIDs have them as standard?

I've always been curious to this, as half of the aftermarket kits i've seen actually state "Not for road use", whilst others omit this altogether. My mate recently bought an aftermarket kit, and whilst it looks reasonably good, i'm still unsure as to the legality of it as well as the consequences of if anything were to go wrong with it.

[Y]
 

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There is no UK legislation governing the use of HIDs, at all. Last time UK passed any legislation for vehicle lighting was back 1989. European law states that OEM HID installations must have auto-levelling and washers. Technically, aftermarket kits are not illegal, as long as your lights are adjusted correctly (which they have to be to pass an MOT). UK legislation refers to the amount of power drawn (ie 55w) not light level or type of bulb. As HIDs draw about 35w they are within UK law. I haven't heard of anyone ever being challenged during an MOT, as they only thing they are required to check is beam pattern & height adjustment
 

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There is no UK legislation governing the use of HIDs, at all. Last time UK passed any legislation for vehicle lighting was back 1989. European law states that OEM HID installations must have auto-levelling and washers. Technically, aftermarket kits are not illegal, as long as your lights are adjusted correctly (which they have to be to pass an MOT). UK legislation refers to the amount of power drawn (ie 55w) not light level or type of bulb. As HIDs draw about 35w they are within UK law. I haven't heard of anyone ever being challenged during an MOT, as they only thing they are required to check is beam pattern & height adjustment
However, if you modify an OEM lamp that has been approved for either the ECE or SAE market then the approval mark that it carries is no longer valid and registers the lamp illegal.
 

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However, if you modify an OEM lamp that has been approved for either the ECE or SAE market then the approval mark that it carries is no longer valid and registers the lamp illegal.
Ok, that makes sense, but presumably fitting a HID kit you are simply changing the bulb and not modifying the lamp itself in anyway?
 

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Ok, that makes sense, but presumably fitting a HID kit you are simply changing the bulb and not modifying the lamp itself in anyway?
Technically no.

If the lamp is a Halogen lamp then the Type Approval Markings show that the lamp and it's 'bulbs' have been approved, if you then fit a Xenon bulb then this invalidates the Type Approval Markings as you will no longer have a H7 bulb but instead a D1S for example.

A Halogen Free-Form Reflector or Module is designed for a Halogen bulb and a Xenon Free-Form Reflector or Module is designed for a Xenon bulb .
 

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Baz nice thread mate.

Very informative.

I was very lucky to get a set from a friend of mine. (cheers Tom)

Although mine are LHD i just set them on flat and they are fine.

Good luck mate. [Y]
 

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Ok, that makes sense, but presumably fitting a HID kit you are simply changing the bulb and not modifying the lamp itself in anyway?
Technically no.

If the lamp is a Halogen lamp then the Type Approval Markings show that the lamp and it's 'bulbs' have been approved, if you then fit a Xenon bulb then this invalidates the Type Approval Markings as you will no longer have a H7 bulb but instead a D1S for example.

A Halogen Free-Form Reflector or Module is designed for a Halogen bulb and a Xenon Free-Form Reflector or Module is designed for a Xenon bulb .
Hmm ok, I didn't know that. I had HID kit on my IS200 for most the time I had it, and it went through two MOTs no problems. I guess its simply down to individual then to decide. Thanks for the info :)
 
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