HOW-TO: Install LED Halos on Pre-FL GenIV (WIP)

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HOW-TO: Install LED Halos on Pre-FL GenIV (WIP)

Postby Curley5959 » Sat Sep 19, 2015 11:52 pm

I am halfway through writing up a guide on how to do this. Just need to finish off the section about wiring with a relay and get some final pictures. Some of the below referencing pictures won't make much sense.

1. Start by popping the bonnet.
2. Remove the air intake box (2 plastic screws at front)
3. Remove the four clips attaching the grill to the bumper/body.
4. Push down and release the four clips attaching the grille horizontally into the frame of the car. Pull back on the grill lightly to separate.
5. Using your hands, release the clips attaching the grille to the bumper. There are two opposing plastic clips on either side that clip over the bumper. You need to lift one and pull down on the other one to feed the clips back over the cutout on the number. (You may need an inspection mirror or phone to observe first). Repeat on both sides.
6. Pull back a section of the wheel well guard on both sides at the front to expose a clip that goes vertically through the bumper and into the body. Remove this clip. Repeat on both sides.
7. Under the car, you will find 7 clips attaching the bumper to the car. Remove these. The two denoted with black dots in the center are difficult to see. They are tucked behind the bumper and attach the black underguard to a bracket underneath.
8. Once these clips are removed, gently pull out on one side of the bumper. The bumper should unclick. Repeat on the other side.
9. Whilst the sides are exposed, go underneath the bumper on either side and disconnect the fog lights.
10. The bumper should now be free to remove from the car.
11. Once removed, begin undoing the headlight bracket bolts. There are 4 bolts in total and 2 clips (Clips denoted with black dots in the center). You do not need to undo the bolt marked as yellow yet. The light and bracket will come out as one piece. NOTE: Automatics have the Oil Cooler attaching to the car with the same bolt as the bottom right bolt as shown on the diagram. These contain a rubber grommet. Be careful not to drop this.
12. Disconnect the wiring harness from behind the headlight. It will unplug from the wiring harness attached to the headlight and the clip attaching it to the headlight will need to be pushed through using pliers or similar.
13. Once everything has been disconnected, pull the headlight out. There is a small pin that plugs into the body from the outside of the headlight so the headlight will seem attached but this will pop out. Don’t pull out too far as you will need to unplug the indicator. NOTE: The driver side seems to have extra length compared to passengers, which is very tight to unplug.
14. Set the light aside. It may be best to only attempt one at a time so that you know how everything goes back together.
15. Undo the bolt attaching the headlight to the bracket. Turning it upside down you will see a plug connecting the headlight to the bracket on the other side. Use pliers or similar to push this through. Set the bracket aside.
16. Disconnect and set aside all bulbs from the headlight. Undo the screw attaching the wiring harness plug to the headlight and feed all wiring out of the headlight. The rubber grommet that feeds through to the low-beam just pushes in. Set all of this aside.
17. Undo all Philips head screws around the body of the headlight (where the seal goes around). There may be a hidden one behind a piece of foam near the outside bracket that attaches to the car.
18. Using your heat gun, slowly begin to heat around the edges of the headlight to warm and soften the seal up. Don’t overheat as you can melt the plastic. You should be able to pry the outside edge apart with your hands and a plastic spatula. As you progress, continually heat sections where the seal is sticking. Ensure the seal remains in the channel of the headlight housing. Use your plastic spatula or fingers to help the seal off the headlight lens section. Occasionally heat the seal which will encourage it to soften and retract by itself.
19. After a few minutes (maybe 20 if the seal is difficult and you are taking your time) the lens should be separated from the housing. Set the housing aside.
20. Unscrew the shroud from the lens. There are 3 small black screws. Carefully wiggle the shrouding out from the lens. Set the lens aside. NOTE: Do not attempt to clean the inside of your lens. Over time the UV layer will become very brittle and a single touch will scratch the plastic.
21. With the shroud, drill a small hole on the bottom section of the three chrome sections (The pointy projector shroud bits). Use a drill bit big enough to feed the Halo wires through easily. Make sure you can feed both through. (You will need to separate each wire from the plug using a needle and reattach at a later stage)
22. Test fit your halos to see where they will sit. They should touch on each point of the three chrome pointy sections.
23. Lightly sand the face of each of these to allow the adhesive to bond better.
24. Feed your halo wires through the shroud.
25. Apply a small blob of araldite to each mating point. Set the halo onto this and hold for 5 minutes or until set. NOTE: After the first batch has set, go back again and build up around the backs and front of the halo with araldite to get a better bond. Allow to set for 10mins or so.
26. Lay the shrouding back into the lens and reattach with the 3 black screws from before.
27. Bring the housing of the headlight and lens together and feed the wires under the projector and out the back of the headlight.
28. Before mating the seal together, heat this up for a few minutes using your heat gun. Press the two sections together and clip them together.
29. Continue to heat the seal as you retighten the screws. This ensures the seal is soft often to mould to the necessary shape to prevent leaking.
30. Drill a small hole on the back of the housing (I drilled on top of the low beam section at the back where the dust cap goes). Feed your halo wires through here. Silicone around to seal. Reattach plug to wires. Make sure they are the right way around.
31. Reattach bulbs and wiring.
32. Attach headlight back to bracket and mount back into car.
33. Plug indicator and wiring back in. Put dust cap back onto headlight.
34. Repeat for the other side.
35. Congratulate yourself. Phase 1 Complete.

See Dropbox so far for images. They will be embedded at a later stage - https://www.dropbox.com/sh/dk3dm6auy1jf ... PIIma?dl=0
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Curley5959
 
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