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    Thread: Retrofitting Dual Xenon Headlamps [TOC, Photos done]

    1. Moderator Prince Ludwig's Avatar
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      08-08-2009 09:34 AM #26
      One final update on this - I've just had the headlamps aligned at a VW dealer and everything is now sorted properly.
      So, retrofit complete!
      Harry

    2. Member plastech's Avatar
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      08-08-2009 01:43 PM #27
      Hi Harry,
      You could make it a full time job.
      Tony

    3. Member adamkodish's Avatar
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      08-08-2009 03:42 PM #28
      Quote, originally posted by Prince Ludwig »
      One final update on this - I've just had the headlamps aligned at a VW dealer and everything is now sorted properly.
      So, retrofit complete!
      Harry

      Harry, you must be feeling quite confident at retro-fitting now....how about a V10 engine?
      http://cgi.ebay.co.uk/2005-Vol...0.m14
      Adam
      Member of Le Club 0P

    4. Moderator Prince Ludwig's Avatar
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      08-08-2009 05:50 PM #29
      Tony,
      Good to see you again! Did you get the link to the HD factory video I sent you?
      Adam,
      Not sure about the engine but the power boot is awfully tempting
      Harry

    5. Member plastech's Avatar
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      08-09-2009 01:00 AM #30
      Morning Harry,
      Yes downloaded and installed.
      Rgds Tony

    6. 11-18-2009 10:17 AM #31
      Hi Michael and "Crew",
      I and also some guys over here in Germany (and I guess, at many other places in the World, too) got one little problem:
      Did EVER anyone of you guys change a bulb on a dual-xenon headlight? So, like the ones Micheal built in his Phaeton (shown below), exchanging the single Xenon Headlamp.
      If so, could this specialist please post some pictures or information on how to open the Headlamps from behind when built in in a car, for to change the Xenon-bulbs? Seems to be totally different from the single xenon ones and I couldn't find any information about it.
      Thank you so much!
      Arne

    7. Senior Member PanEuropean's Avatar
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      11-18-2009 11:30 AM #32
      Hi Arne:
      Dual xenon headlights were not offered in North America (I did a retrofit on my car), so, there might not be anyone from North America who has any experience changing the bulbs in these.
      Touch wood, I have not had to replace a bulb (low or high) in my headlights yet.
      Michael

    8. Moderator Prince Ludwig's Avatar
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      11-18-2009 01:16 PM #33
      Arne,
      Regardless of which bulb it is, I fear you may have to remove the entire headlamp assembly to get at it. Although you can remove the rubber cover for the high beam, I'm not sure you can remove the bulb given the available space and if it's the low beam, one of the controllers is screwed in place on top of it so you can't access it the same way as the single xenon assembly.
      Having said that, removing the front bumper is not the hardest job in the world - I managed it despite the only experience I'd had previously of working on my Phaeton was installing a rear climate control panel!
      Harry

    9. Senior Member PanEuropean's Avatar
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      09-06-2010 06:34 PM #34
      For the record, here are the instructions for removing and replacing the front bumper.

      You will need a helper to lift the bumper cover off, and also to put it back on.

      The instructions need to be followed carefully. If you want to know why, see this post: Crack on front bumper under headlights.

      Michael
      Attached Files

    10. Junior Member Sarmale89's Avatar
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      01-10-2011 12:42 PM #35
      Would either Michael or Harry (or anyone else who has done this mod) confirm or correct my part listing (and part numbers) needed to complete this job? I have an '04 NAR W12 and am considering putting in dual xenons, but want to make sure that I account for all of the parts costs before I pull the trigger.

      (2) Dual Xenon Headlamps (3D1 941 017 & 3D1 941 018)
      (4) Xenon bulbs (I can't find the part number, but here's the item on Partsgeek http://www.partsgeek.com/catalog/200...ight_bulb.html)
      (2) Xenon High beam controllers (3D0 909 391)
      (2) Xenon high beam cables (3D0 971 671) Is this the high beam cable? - http://www.ecstuning.com/Search_VW/3d0971671/ES351106/

      Michael, you mentioned that modifying the wiring to allow for the city lights cost only about $20 in parts. Are there any additional parts needed to made this modification other than the ones I've listed above?

      Bobby

    11. Member tynee's Avatar
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      01-27-2011 07:37 PM #36
      Would it be possible to switch the projector housings with aftermarket units that have halos?
      I'd like to use these if possible, I obviously need to mount the extra power units, what else do I need to consider?

      [IMG][/IMG]
      [IMG][/IMG]
      [IMG][/IMG]
      [IMG][/IMG]

    12. Senior Member PanEuropean's Avatar
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      01-27-2011 10:02 PM #37
      Quote Originally Posted by tynee View Post
      Would it be possible to switch the projector housings with aftermarket units that have halos?
      Oh Lord, please don't consider going down that route - you will wind up with lighting that is absolutely non-compliant with FMVSS (safety standards).

      If you were to do that in Europe, the car would be pulled off the road.

      Michael

    13. Member tynee's Avatar
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      01-28-2011 12:16 AM #38
      Yeah, I know. I hate the cars I see that have aftermarket lights that blind all oncoming traffic, and that's why I asked. I would really like to have halo rings as my DRL's, like the BMW's, and burn the HID's only at night. Since I'm going to do the headlight retrofit anyways, I figured I'd ask how complicated it would be to do correctly and keep the beams in line with the safety standard. I don't want to be the guy that looks like I have my brights on all the time. Unfortunately The new LED lights seem to have a hard time syncing with an 04 model, so I'm trying a different route.

    14. Junior Member Sarmale89's Avatar
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      01-31-2011 10:13 PM #39
      Quote Originally Posted by PanEuropean View Post
      Attached is a document that partially explains how to adjust Phaeton headlights. When you install new headlights, 'basic settings' need to be performed to the motors that automatically adjust the elevation of the low beam light in response to changes in the suspension loading of the car. To complete this 'basic settings' function, you need to have a diagnostic scan tool such as a VAS 5052 or a VAG-COM. Instructions for completing the 'basic settings' are provided by prompts on the VAS 5052. If anyone needs detailed instructions for doing this with a VAG-COM, let me know and I will write the instructions up.
      Michael
      Michael,

      I am planning on doing my dual xenon retrofit sometime this week. Would you mind going over how perform the settings adjustment with a VAG-COM? I just got my VAG-COM last week and would appreciate the tutorial.

      Bobby

    15. Senior Member PanEuropean's Avatar
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      02-01-2011 09:26 AM #40
      Bobby:

      I would like to help, but I am out of the country right now (in the Seychelles, which is on the opposite side of the world to North America) and I will be working every day from now to Feb 12 training pilots.

      I will do my best to try and dig up some information that I can post in text format, but I won't be available for back-and-forth text conversation until I get back to Canada, which is foreseen for about mid-February.

      Michael

    16. Junior Member Sarmale89's Avatar
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      02-01-2011 09:50 AM #41
      Quote Originally Posted by PanEuropean View Post
      Bobby:

      I would like to help, but I am out of the country right now (in the Seychelles, which is on the opposite side of the world to North America) and I will be working every day from now to Feb 12 training pilots.

      I will do my best to try and dig up some information that I can post in text format, but I won't be available for back-and-forth text conversation until I get back to Canada, which is foreseen for about mid-February.

      Michael
      Michael:

      Thanks for the response and for your willingness to share your expertise. I'll see what I can figure out on my own. If I can't figure it out, I'll just have my dealer do the basic coding when they align the headlamps.

      Bobby

    17. Moderator Prince Ludwig's Avatar
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      02-01-2011 10:53 AM #42
      Hi Bobby,

      You might as well have it done by the dealer since your headlamps will have been set up for the UK so will probably need to be aligned anyway.

      Harry

    18. Junior Member Sarmale89's Avatar
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      02-01-2011 10:54 AM #43
      Quote Originally Posted by Prince Ludwig View Post
      Hi Bobby,

      You might as well have it done by the dealer since your headlamps will have been set up for the UK so will probably need to be aligned anyway.

      Harry
      Will do. thanks.

      Bobby

    19. Senior Member PanEuropean's Avatar
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      02-01-2011 03:35 PM #44
      Quote Originally Posted by Prince Ludwig View Post
      ...your headlamps will have been set up for the UK so will probably need to be aligned anyway.
      WHAT??? You have installed UK spec headlights on a North American car? That is NOT going to work. The European spec headlights (both left or right hand drive) have a beam pattern that provides about a 15 degree uptick towards the curb side of the car. If you put RHD headlights on a LHD car, that uptick is going to go towards the eyes of the oncoming driver, not towards the curbside.

      This cannot be corrected by headlight alignment. The internal construction of the headlights is very different between RHD and LHD cars. The headlight casings are welded shut, I don't think it would be possible to modify the internal design of the headlights even if you had a very well equipped machine shop and considerable expertise in tool-making.

      Michael

    20. Junior Member Sarmale89's Avatar
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      02-01-2011 03:45 PM #45
      Quote Originally Posted by PanEuropean View Post
      WHAT??? You have installed UK spec headlights on a North American car? That is NOT going to work. The European spec headlights (both left or right hand drive) have a beam pattern that provides about a 15 degree uptick towards the curb side of the car. If you put RHD headlights on a LHD car, that uptick is going to go towards the eyes of the oncoming driver, not towards the curbside.

      This cannot be corrected by headlight alignment. The internal construction of the headlights is very different between RHD and LHD cars. The headlight casings are welded shut, I don't think it would be possible to modify the internal design of the headlights even if you had a very well equipped machine shop and considerable expertise in tool-making.

      Michael
      Michael,

      No, I am NOT installing RHD headlamps "as is" on my NAR Phaeton. As demonstrated by Harry and as stated in my post (linked below), I will be swapping out the beam cutouts so that the beam pattern conforms to U.S. regulations.

      http://forums.vwvortex.com/showthrea...1#post69571956

      I will be removing my NAR headlamps tonight and making the cutout swap.

      Bobby

    21. Senior Member PanEuropean's Avatar
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      02-01-2011 10:09 PM #46
      Ah - OK, sorry, I have not been following the post that closely - I did not realize you were doing that.

      Michael

    22. Junior Member Sarmale89's Avatar
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      02-10-2011 01:41 PM #47
      Quote Originally Posted by PanEuropean View Post
      Bobby:

      I would like to help, but I am out of the country right now (in the Seychelles, which is on the opposite side of the world to North America) and I will be working every day from now to Feb 12 training pilots.

      I will do my best to try and dig up some information that I can post in text format, but I won't be available for back-and-forth text conversation until I get back to Canada, which is foreseen for about mid-February.

      Michael
      Michael,

      Is the procedure for coding the dual xenons in the VW Repair Manual? I seem to recall seeing something in there about this. If so, is the procedure the same on the VAG-COM or is it a different animal? I'd like to do this part myself as I already have the VAG-COM and may as well use it. Also, if the dealer has to clear fault codes, code the headlamps, AND align them then they'll charge me (as they well should). My service adviser indicated to me a few weeks ago, after my telling him about my dual xenon retrofit project, that I could just bring my car in anytime to have them align the headlamps free of charge.

      Bobby

    23. Senior Member PanEuropean's Avatar
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      02-11-2011 02:19 AM #48
      Bobby:

      The dual xenon headlights don't have to be "coded" per se, because when you install the two headlight assemblies, you also install new controllers for the high beams at the same time. The low beam controllers on dual xenon headlights are the same as the low beam controllers on single xenon headlights In a dual xenon installation, these controllers don't interact with the car any differently than single xenon installation. It is actually the same controller for the low beam circuit - and the only interaction with other systems that involves that controller is watching the suspension system to see how the car is sitting, for the purpose of keeping the low beam lights correctly positioned in the vertical range of movement.

      There is a "basic settings" or "adaptation" script (I'm not sure which) that is invoked when you align the headlights. I carried this work out using the VAS 5052 diagnostic scan tool at my VW dealer, and using the Hella Beamsetter (headlight alignment tool) at my VW dealer. I used the "guided functions" capability of the VAS 5052 to put the headlights into the alignment mode - this whole process is well explained in the VW service manual documentation and in the guided functions portion of the VAS 5052.

      Once the alignment is complete - and the alignment itself is accomplished manually, using adjustment screws on the headlights - the two low beam controllers are then set back to normal operations mode. The whole low beam alignment process is identical to what is done with Phaetons that have only single xenon headlights. Alignment of the high beams (xenon or halogen, doesn't matter) is strictly a manual process, like it would be on any 1960s car with four headlights.

      You can probably invoke the alignment setting using a VAG-COM, but I didn't bother even looking into how to do that, because although I have a VAG-COM, I don't have a Hella Beamsetter... so, I had to go to the dealership to use the Beamsetter, and it was much easier for me to just use the VAS 5052, complete with guided functions.

      Michael

    24. Junior Member Sarmale89's Avatar
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      02-11-2011 08:04 AM #49
      Quote Originally Posted by PanEuropean View Post
      Bobby:

      The dual xenon headlights don't have to be "coded" per se, because when you install the two headlight assemblies, you also install new controllers for the high beams at the same time. The low beam controllers on dual xenon headlights are the same as the low beam controllers on single xenon headlights In a dual xenon installation, these controllers don't interact with the car any differently than single xenon installation. It is actually the same controller for the low beam circuit - and the only interaction with other systems that involves that controller is watching the suspension system to see how the car is sitting, for the purpose of keeping the low beam lights correctly positioned in the vertical range of movement.

      There is a "basic settings" or "adaptation" script (I'm not sure which) that is invoked when you align the headlights. I carried this work out using the VAS 5052 diagnostic scan tool at my VW dealer, and using the Hella Beamsetter (headlight alignment tool) at my VW dealer. I used the "guided functions" capability of the VAS 5052 to put the headlights into the alignment mode - this whole process is well explained in the VW service manual documentation and in the guided functions portion of the VAS 5052.

      Once the alignment is complete - and the alignment itself is accomplished manually, using adjustment screws on the headlights - the two low beam controllers are then set back to normal operations mode. The whole low beam alignment process is identical to what is done with Phaetons that have only single xenon headlights. Alignment of the high beams (xenon or halogen, doesn't matter) is strictly a manual process, like it would be on any 1960s car with four headlights.

      You can probably invoke the alignment setting using a VAG-COM, but I didn't bother even looking into how to do that, because although I have a VAG-COM, I don't have a Hella Beamsetter... so, I had to go to the dealership to use the Beamsetter, and it was much easier for me to just use the VAS 5052, complete with guided functions.

      Michael
      Michael,

      Thanks for the explanation. I'm taking my Phaeton in this morning to have them align the headlights and won't worry about trying to do anything with my VAG-COM.

      Bobby

    25. Member EnglishPhaeton's Avatar
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      07-01-2011 03:16 AM #50
      Michael,

      early on in this thread you point out that you can pull the washer nozzle cover open and it locks in place, true, but how do you then close it? Mine is now just flapping around when previously all was well

      Cheers
      Stu

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