Trevor Ng
Volkswagen Golf enthusiasts often seek to install E-code headlights, which require a variety of tools and procedures. The installation process involves removing the front stock headlights, unbolting and taking out the original headlights, and bending the upper fender corner headlight support frame. Additionally, the right-side E-code headlight may require trimming to clear the radiator. The installation of E-code headlights also necessitates the purchase of specific items, such as bolts, washers, and a clear spray can. While some Volkswagen service centers recommend coding new batteries, others suggest that coding is unnecessary, especially for electric vehicles.
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What You'll Learn
Removing the NA headlights
First, you need to remove the front grille. This involves taking out the screws from the wheel arch liner using a ratchet and a T25 Torx screwdriver. There are four screws in total. Next, remove the three screws from the front bumper using a T30 Torx screwdriver.
After the screws are removed, take out the lower grilles and locate the hidden bolt. Now you can carefully remove the headlight washer caps and then the Torx screws around the wheel liners (the bumper portion) and under the tray. With these screws removed, the bumper should slide off, revealing the lower two of the four headlight assembly bolts.
With the bumper removed, you can now access the headlight assembly. The assembly includes two adjustment devices for aiming the lights while mounted in the car. Disconnect the wiring harness from the unit by squeezing the plug and pulling it straight out. There are four T25 Torx screws holding the assembly in place; two on the upper section and two located below the lens. Remove these screws, and then pull the unit out of the front of the car and place it lens-down on a soft cloth or rag.
From the back of the headlight assembly, you can access the high beam, low beam, turn signal, and fog light bulbs. To replace a bulb, first, remove the connector from the bulb and push the retaining clip over the lugs to release it. Pull the bulb out of the reflector and replace it with a new one, being careful not to touch the bulb with your bare skin as the oils can cause premature failure.
The process of removing the NA headlights from a Volkswagen Golf Mk4 involves disassembling the front bumper and grille, accessing the headlight assembly, disconnecting the wiring, and then removing and replacing the bulbs as needed. It is important to be careful throughout the process to avoid damage to the car's components and to ensure a proper fit and function of the new headlights.
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Preparing E-code headlight components
To prepare the E-code headlight components, you will need the following items:
- 6 8mm bolts saved from the previous headlight removal
- #12 speed washers (x4)
- #10-24x2" Machine screws (x2)
- 1/4" 6.4 Solid flat washers (x4)
- 2 1/2" 6.4 hose
You will also need the following tools:
- Flat-head screwdriver
- Adjustable wrench
- Die grinder tool
- Air compressor (125 PSI or more)
Firstly, remove the E-code headlight plastic rear cover to maximize installation clearance. Then, grab the right-side E-code headlight and face it downwards. Locate the upper left support tab closest to the radiator and trim with the die grinder slanted to clear the radiator for installation.
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Installing the E-code headlight bracket
Step 1: Front Radiator Grill Removal
Open the hood and locate the lower end clips of the front grill near the fenders. Using a flat-head screwdriver, carefully unclip the grill from the bumper. This step is crucial to accessing the headlight area for installation.
Step 2: Removing the NA Headlights
Unbolt and remove the 8mm bolts supporting the headlights to the radiator support frame. There will be a total of 8 bolts, 4 on each side of the headlights. Remove the clips from the bumper support frame, with a total of 2 clips on each side. Set these aside as some of these bolts will be used later during the installation.
Step 3: Bending the Upper Fender Corner Headlight Support
Locate the upper corner headlight support frame of the radiator support frame closest to the fender. Using an adjustable wrench, carefully bend this support frame upwards at a 45-degree angle. Perform this step on both sides to ensure symmetry.
Step 4: Cutting the Radiator Support Frame (Right Side ONLY)
Using a die grinder tool, cut out the radiator support frame on the passenger side where it is marked. This step is specific to the right side of the vehicle, so ensure you are working on the correct side.
Step 5: E-Code Headlight Bracket Installation
Pay attention to the shape of the bracket. The longer side of the U-shaped bracket mounts outward towards the bumper, while the shorter side mounts to the E-code headlights on the lower part, closest to the fenders. The Z-bracket mounts to the lower part of the E-code headlights, closer to the radiator. Secure the brackets firmly in place.
Step 6: E-Code Headlight Components Preparation
Gather the 6 8mm bolts that were previously removed and set aside during the NA headlights removal. Along with these bolts, you will need #12 speed washers (4), #10-24x2" machine screws (2), 1/4" 6.4 solid flat washers (4), and a 2 1/2" 6.4 hose. These components will be used in the final assembly.
Step 7: Headlight Assembly and Adjustment
Refer to the previous steps in reverse to place back the front radiator grill and the E-code headlight rear housing cover. Once the physical installation is complete, headlight alignment is required. Ensure you follow the correct procedure for aligning the E-code headlights to achieve optimal performance.
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Removing the E-code headlight plastic rear cover
Step 1: Open the Hood
Start by opening the hood of your car to access the headlight area.
Step 2: Locate the Headlight Assembly
Identify the E-code headlight assembly, which is typically located on the right side of the vehicle.
Step 3: Remove the Headlight Bulb
If you haven't already, remove the headlight bulb from the assembly. This will give you better access to the rear cover.
Step 4: Identify the Rear Cover
Locate the plastic rear cover at the back of the E-code headlight assembly. It may have tabs or clips holding it in place.
Step 5: Remove the Rear Cover
Using a screwdriver or an appropriate tool, gently remove the rear cover. Be careful not to break any tabs or clips. You may need to unscrew or unclip the cover, depending on its design.
Step 6: Set the Rear Cover Aside
Once removed, set the plastic rear cover aside in a safe place. Ensure it is not misplaced, as you will need to reinstall it later.
Step 7: Continue with Installation
With the rear cover removed, you can now have better access and clearance for installing the new E-code headlights. Proceed with the installation process, following the manufacturer's instructions or a reliable guide.
Remember, it is important to handle the headlight components with care and avoid touching the glass parts of the bulbs with your fingers, as the natural oils from your skin can affect their performance. Always refer to a qualified mechanic or a detailed installation guide for specific instructions regarding your vehicle.
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Placing the E-code headlight rear housing cover
To place the E-code headlight rear housing cover, you must first complete the E-code headlights installation. The following tools are required:
- An air compressor (125 PSI or more is required, and more gallons are better) if using an air tool die grinder.
- A flat-head screwdriver.
- An adjustable wrench.
- A die grinder tool.
To begin the installation, open the hood and locate the lower end clips of the front grill near the fenders. Unclip the grill from the bumper. Next, unbolt and remove the 8mm bolts supporting the headlights to the radiator support frame. There will be a total of 8 bolts, 4 on each side of the headlights. Remove the clips from the bumper support frame—2 clips, one on each side. The headlights should now be out. Save at least 6 of the 8mm bolts, as these will be used later for installation.
Now, bend the upper corner headlight support frame of the radiator support frame closest to the fender to a 45-degree angle, performing this action on both sides. For the right side only, grab the die grinder tool and cut out the radiator support frame where it is marked. Now, remove the E-code headlight plastic rear cover to maximise installation clearance. Grab the right-side E-code headlight and have it facing downwards. Locate the upper left support tab closest to the radiator and trim with the die grinder, slanting it to clear the radiator for installation.
The E-code headlight bracket should be installed with the longer side of the U-bracket mounting outward towards the bumper, and the shorter side mounting to the E-code headlights on the lower part closest to the fenders. The Z-bracket mounts to the lower part of the E-code headlights closest to the radiator. Now, grab the 6 8mm bolts saved from the previous step, along with the #12 speed washers (x4), #10-24x2" machine screws (x2), 1/4" 6.4 solid flat washers (x4), and 2 1/2" 6.4 hose. With these components, you can now complete the E-code headlights installation. Finally, place back the E-code headlight rear housing cover and the front radiator grill. Headlight alignment is required.
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Frequently asked questions
This answer will explain how to install E-code headlights on a MK3 Jetta/Golf. First, open the hood and remove the front stock headlights. Then, unbolt and remove the 8mm bolts supporting the headlights. Next, bend the upper corner headlight support frame to a 45-degree angle. After that, cut out the radiator support frame on the passenger side. Now you can remove the E-code headlight plastic rear cover to maximise installation clearance. Grab the right-side E-code headlight and trim the upper left support tab closest to the radiator. Install the E-code headlight bracket, with the longer side of the U-bracket mounting outward towards the bumper. Finally, place back the E-code headlight rear housing cover and the front radiator grill.
You will need an air compressor (125 PSI or more) and a die grinder tool. You will also need a flat-head screwdriver and an adjustable wrench.
You will need to save 6 of the 8 8mm bolts from the original headlights, as these will be used later for installation. You will also need #12 speed washers (x4), #10-24x2" machine screws (x2), 1/4" 6.4 solid flat washers (x4), and a 2 1/2" 6.4 hose.
E-code headlights are an upgrade for the MK3 Jetta/Golf that can improve visibility and lighting performance.
While some mechanical knowledge and skills are required, installing E-code headlights on a MK3 Jetta/Golf can be done as a DIY project, as demonstrated by the step-by-step guide provided by a user on the Jettajunkie forum.
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