Lessons Learned: Headlights II - Done! (Almost. Grrr.)

[ProZak]

OK, fellow 5ers, here's where I'm at.

Remember the wiring harness?



I went to Napa to tell my tale of woe, and with the guy's help, here's what I came up with:

Step 1 - crimp / solder / silicone blade connectors to headlight sockets:





Step 2 - snip / crimp / solder blade connectors to wiring harness adapters provided by eBay seller. Sorry, somewhere in the middle I burned the crap out of my finger and forgot to take pics of the wiring harness out of the car.

Step 3 - Mount everything up, plug everything in.



(continued)

[ProZak]

For those of you who need some assistance deciphering, here are the factory wires:



Here are the new wires:



And here are the city lights that I haven't yet hooked up.



I guess those go inline with the side markers, right? If I splice into those existing wires, will it screw up the voltage / wattage enough to set a code? At only 5w bulbs, I'd think not, but I'd appreciate an educated guess before I dive in.

(continued)

[ProZak]

And for those of you still wondering:



...right side screws. The third one is buried, *way* up where you can't see it. Now, imagine that on the left hand side, but add ...



... the evaporator cannister. Holy crap, what a pain in the ass. These freaking things had better not break, is all I'm sayin.

Once I get them lined up right and the city lights wired, I'll post more pics.

-Zak-

[ProZak]

Oh, yeah, and god help you if the city lights ever burn out. Getting those things into the sockets after the assemblies are installed is *not* fun.

I'll pretty up the wires and such after I get the city lights working. But for now, all the bulbs come on and my factory fog lights work. Woo-hoo!

[angrypancake]

I guess those go inline with the side markers, right? If I splice into those existing wires, will it screw up the voltage / wattage enough to set a code? At only 5w bulbs, I'd think not, but I'd appreciate an educated guess before I dive in.

(continued)

yes they do, and if you get some euro trim then you can just use the wiring from the side markers for the city lights (thats what i did)

[SC David]

yes they do, and if you get some euro trim then you can just use the wiring from the side markers for the city lights (thats what i did)

Same. Easy as can be. Good to hear you got it all done, it took me forever.

[Rodericb]

Thank you so much for this write up. I have the same lights and wiring harness and have spent the last 2 months trying to figure out how I was going to install them. Thanks again. Looks like I have a project next weekend. That and installing some rear door panels with wood trim. Thanks again.

[Qube]

Genius! You know, that will work great for any of those damn euro connectors. I have lots of those spade connectors and I love silicon sealant heh!

[Jon K]

Yeah I've done something similar - I didn't require any extra parts though. After wiring the 6 coil igintion system for my custom ECU, none of this stuff looks daunting anymore.

[ProZak]

OK, so I went out to align the beams tonight. Trouble with the low beams already. Argh! Trouble shooting results in the following:

1 - Don't leave naked blades on the back of the light assembly exposed to be bent together by the plastic cover that links to the alternator vent. No pictures, I'm too embarrassed. Oh, and I'll be covering those with electrical tape or some other such non-conductive solution shortly.

2 - Be better than I am with a soldering iron. The connections on the right side are flaky. I'll be re-doing those.

3 - Make sure you use hi-temp silicone. I think the stuff I went with will be too soft at operating temps. I expect I'll be re-doing all that too.

-Zak-