UrKurt

So, it is technically possible to install bi-xenon headlights without removing the bumper (see steps 1-9). Also, I've detailed wiring the new Kufatec harness because I found it difficult to source solid information on how to do this (see steps 9 to 17).

First of all, I caution anyone considering doing this mod without bumper removal. <b>If you are doing this mod, DO NOT follow my lead! Remove your bumper!!</b> This was an absolute headache, and if I'd do it again, I'd take off the bumper. Unless you have a really good reason, take off your damn bumper, you'll be glad you did.

Please check <a href="https://forums.audiworld.com/a4b7/msgs/14104.phtml">this</a> thread for general information on bumper removal.

At this point, you've undoubtedly done this the correct way and removed your bumper. You may skip to step ~9 to see how to do the wiring for the high beams with the new Kufatec harness.

If you're still here, we'll be doing the same thing as the smart folks who removed their bumpers, but one side at a time. I'm not responsible for the fact that you may develop an aneurism trying to do it this way.

1. Turn your wheels to access the torx screws on the outer edge of the wheel well. Remove enough of them so you can pull back the liner and access the two screws that attach the bumper. If you decide to remove the two plastic flat head screws that attach the wheel liner to the belly pan (I did) take note of the way they're seated, and remember they turn 90 degrees to pop out.
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164097904377602"><img src="http://lh4.google.com/kekiefer/R0dSCNO0fwI/AAAAAAAAAF0/JsxO53cl9z8/s800/IMG_0591.JPG" /></a>

2. Get your deep 10mm socket on a small (1/4" drive, perhaps) wrench and stick your arm into the cavity you made in the wheel liner. You're looking for these guys. They attach the just below the headlights and the bolts protrude quite a bit. Go back and forth between the two bolts and get them all the way off. Be very careful not to drop these down onto the belly pan!
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136163973350325986"><img src="http://lh3.google.com/kekiefer/R0dR69O0fuI/AAAAAAAAAFk/BiEpobNY0CI/s800/IMG_0586.JPG" /></a>

3. Get out from behind the wheel and admire your handy work. At this point your can loosen the three torx screws on the headlights and the bumper. Actually, you could have done this before too. This is really like choose your own adventure. The bottom of the bumper pulls out to the side with a little force, and then you can pull it forward enough to allow you to remove the headlight. Just be careful not to scratch anything.
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136163930400653010"><img src="http://lh5.google.com/kekiefer/R0dR4dO0ftI/AAAAAAAAAFc/HRXFAb1VPHg/s800/IMG_0585.JPG" /></a>

4. Put the long end of your Kufatec harness on the passenger side. The two wires will go up to the cabin on the drivers side. You can route the wire in front of the radiator here.
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164050659737330"><img src="http://lh5.google.com/kekiefer/R0dR_dO0fvI/AAAAAAAAAFs/vpyvptWVYUc/s800/IMG_0588.JPG" /></a>

5. Stick in your new headlight and hook up the harness. I kept the wire holder from my old headlight.
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164158033919762"><img src="http://lh6.google.com/kekiefer/R0dSFtO0fxI/AAAAAAAAAF8/p94zuQAA8Fs/s800/IMG_0595.JPG" /></a>

6. Go drink a beer and cry a little inside, you're not even half way done.

<i>The next two steps lack pictures due to my heightened state of frustration. I apologize for this.</i>

7. Do the drivers side. Don't bother taking off so much of the wheel liner since you'll never be able to stick your hand up there the way you did on the passenger side. From back here, you only need to remove the two torx bumper screws. The 10mm bolts must be accessed from between your headlight and the washer reservoir. This is VERY tight and difficult, and probably the hardest part of this procedure, but if you've got tricky fingers and a small wrench, you can do it.

<b>8. After removing the bumper bolts and replacing the headlight, proceed to bang your head against the wall and wish you'd taken the f***ing bumper off. You won't be able to put the bumper bolts back on due to lack of clearance between the headlight and the washer reservoir. You could probably remove the reservoir; I didn't try. On the plus side, once I put mine back together, even minus those bolts, the bumper still sat flush.</b>

9. Put it all back together and breathe a sigh of relief. The worst part is over. Looks pretty damn good, doesn't it? You can test the low beams if you'd like, but if you're coded for halogens, the high beams will only flash the DRLs. At this point, I VAG-COMed the car for bi-xenon. This is definitely necessary, despite popular belief.

10. OK, now it's time to hook up your high beam motors. Jack up your car on the drivers side. You don't have to remove the wheel or wheel liner.

11. Route the wires along the side of the engine bay along side this hose.
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164252523200306"><img src="http://lh4.google.com/kekiefer/R0dSLNO0fzI/AAAAAAAAAGQ/9qBDJuKYtNk/s800/IMG_0641.JPG" /></a>

12. You'll want the wires to come out by these lines here.
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164205278560034"><img src="http://lh5.google.com/kekiefer/R0dSIdO0fyI/AAAAAAAAAGI/6WQR8zrkjgc/s800/IMG_0638.JPG" /></a>

13. Here you can see the rubber nipples that will allow you to run the wires into the under dash. I started cutting the nipple closest to us, but my helper poked an auger through the wrong one. I sealed the gaping hole with electrical tape after pulling the slack through.
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164299767840578"><img src="http://lh3.google.com/kekiefer/R0dSN9O0f0I/AAAAAAAAAGY/qN8H6nelQ1A/s800/IMG_0643.JPG" /></a>

14. Remove the panel under your dash. Here is a terrible picture of the ECM underneath the relays. In this picture the gray plug is removed, you'll want to do the same.
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164497336336258"><img src="http://lh5.google.com/kekiefer/R0dSZdO0f4I/AAAAAAAAAG4/1nowuUYG9jE/s800/IMG_0651.JPG" /></a>

15. Slide down the purple clip on the side of the gray plug. It will come all the way off. You can also slide up the tack tie holding the wires on so you don't have to replace it.
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164364192350034"><img src="http://lh6.google.com/kekiefer/R0dSRtO0f1I/AAAAAAAAAGg/8ocO04v6ZIw/s400/IMG_0644.JPG" /></a>

The innards removed from the gray plug:
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164424321892194"><img src="http://lh4.google.com/kekiefer/R0dSVNO0f2I/AAAAAAAAAGo/kjKR7XgdH8k/s400/IMG_0645.JPG" /></a>

16. Route your Kufatec wires through the tack tie and put the pins into empty slots 21 and 22. Note the markings for pin numbers on the connectors and the wires. If you're on the correct side, the connector should say "17" and "32" on the left and right ends of the connector, and the wires say "32 B7 21" and "32 B7 22". These should click in nicely, provided you inserted them with the jagged-looking sides out.
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164462976597874"><img src="http://lh5.google.com/kekiefer/R0dSXdO0f3I/AAAAAAAAAGw/8uXxdw063SI/s400/IMG_0647.JPG" /></a>

17. Put the gray plug back together and plug it back in. Don't forget to test! If the high beams don't work, maybe you didn't recode properly. You can always recode at this point if you forgot. Tie up the excess Kufatec wiring and put it all back together.
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164557465878418"><img src="http://lh3.google.com/kekiefer/R0dSc9O0f5I/AAAAAAAAAI0/eUw11bjU2UM/s400/IMG_0652.JPG" /></a>

BTW, the panel should fit back in like this:
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164604710518690"><img src="http://lh6.google.com/kekiefer/R0dSftO0f6I/AAAAAAAAAHI/NFHXSj-1B2w/s400/IMG_0653.JPG" /></a>

And you're all done!
<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164677724962738"><img src="http://lh3.google.com/kekiefer/R0dSj9O0f7I/AAAAAAAAAHU/FegC_Fa-Pxc/s800/IMG_0654.JPG" /></a>

Ahh, ECode bi-xenon heaven...

<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164737854504898"><img src="http://lh5.google.com/kekiefer/R0dSndO0f8I/AAAAAAAAAHc/IPbpWBzjlRM/s800/IMG_0658.JPG" /></a>

<a href="http://picasaweb.google.com/kekiefer/B7A4ECodeUSBiXenonInstallation/photo#5136164819458883538"><img src="http://lh4.google.com/kekiefer/R0dSsNO0f9I/AAAAAAAAAHk/zHFT0-8s0jM/s800/IMG_0659.JPG" /></a>


edit (26 Dec 2007): fixed links to pictures on picasaweb

jayulzvern

get amber plasic in the headlight to be clear? it looks just like the amber mold was filled with clear...where did you get the part and who did the install?

tboned

These are euro headlights, hence no amber stock.

jayulzvern

and does that "technically" make the car illegal on us streets?

GodBlessQuattro

are they considerably brighter? same color? what advantage to they have to OEM?

UrKurt

forum classifieds, try ebay etc. &amp; correct, no DOT approval = off road use only

UrKurt

as far as I know, the only advantage these have over US bi-xenons is the clear corners (still flash orange, though)

ddonggangaji

i have 06 A4 quttro is this projecto light will fit on my car too?

if it is where did you get it?

PetrolDave

Early Euro headlights still have amber stock - like those originally fitted to my RS4.

a4sline2

hello there,

great write up.

i have small question, i bought the xenon adapters from kfz-kabelbaum from germany.

each adapter has two additional cables available. one yellow and one black.

on step 16 "16. Route your Kufatec wires through the tack tie and put the pins into empty slots 21 and 22..." you are instructing to put the pins into empty slots 21 and 22. am I supposed to put the yellow or black coming from each adapter? and if so, what should i do the with the one that is not used?

also, how about the cables from left or right headlight? should they go into a specific slot. i.e. left headlight to 21 and right headlight to 22?

final question, how do you VAG-COM so the car recognises the xenons?

many thanks.