VW Jetta Fog Lightbd8ba3c866c8cbc330ab-7b26c6f3e01bf511d4da3315c66902d6.r6.cf1.rackcdn… · Remove the old headlight switch. With the switch in the off position, push straight in

R

MKVI Jetta Fog Light Kit

Part Number ES2500919VW Jetta Fog Light

InstallationThis tutorial is provided as a courtesy by ECS Tuning.

Proper service and repair procedures are vital to the safe, reliable operation of all motor vehicles as well as the personal safety of those performing the repairs. Standard safety procedures and precautions (including use of safety goggles and proper tools and equipment) should be followed at all times to eliminate the possibility of personal injury or improper service which could damage the vehicle or compromise its safety.

Although this material has been prepared with the intent to provide reliable information, no warranty (express or implied) is made as to its accuracy or completeness. Neither is any liability assumed for loss or damage resulting from reliance on this mate-rial. SPECIFICALLY, NO WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR ANY OTHER WARRANTY IS MADE OR TO BE IMPLIED WITH RESPECT TO THIS MATERIAL. In no event will ECS Tuning, Incorporated or its affiliates be liable for any damages, direct or indirect, consequential or compensatory, arising out of the use of this material.

http://www.ecstuning.com/Search/ES2500919/? utm_source=PDF&utm_campaign=VWMKVI FogLampInstall

Address: 1000 Seville Road, Wadsworth, OH 44281 Phone: 1.800.924.5172 Web: www.ecstuning.com

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VW Jetta MKVIFog Light Installation R

ES2500919

ES2500919Fog Light KitVolkswagen Jetta MKVI

• Foglights(qty2)• Foglightventpanels(qty2)• ECSwiringharnesswithrelay• Euroheadlightswitch(chrometrim)

Tools We UsedThree-footlengthmechanicswire(orwireclotheshanger)

• 3/8-inchratchet• 3/8-inchextension• wirestripper/cutter• T25Torx®driver• T27TorxSocket• 10mmsocket• tape• sandpaper




ES2500919

battery

fuse panel

relay

Euroheadlight

switch

fog light

fog light

bolt to ground

bolt to ground

+ -

MKVI Fog LampWiring

15 A

inline fuse

Component Locations and Wiring SchematicTheillustrationbelowshowstheinstalledlocationsofthefoglampcomponentsincludedinyourkit,andidentifiesgeneralwiringroutingandindividualwireharnesscolors.Theinstallationinstructionsonthefollowingpagesprovidesuggestionsabouthowtoroutethewiringandmountindividualcomponents.

This tutorial is presented in Four Color-Coded Sections

1) Mount the fog light relay2) Route and connect the blue wire3) Connect the power and ground wires4) Install the fog lights

Overview



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ES2500919Step 1Insidetheenginecompartment,unscrewtheroundretainerclipsecuringthetrimpaneltothebody.Thisclipislocatednearthebattery.

Spinitcounterclockwisetoremoveit.

(Thebatterycoverislabeledforreference.)

Step 2Connectthefoglightwiringharnesstotherelay.Slidetheholeintherelaymountbracketoverthethreadedstud;thenpushthecircularclipoverthestud,asshown.

Drapetheindividualwiresintherelayharnessofftotheside,fornow.

Route and Connect the Blue WireThethinbluewireintherelayharnessmustberunintothecabinandconnectedtopin8ofyournewEuroheadlightswitch.Thereareseveralwaystodothis;wefounditeasiesttofishthebluewirethrougharubbergrommetinthefirewall,locatedbehindthebattery.

Mount the Fog Light Relay



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ES2500919Step 1Goinsidethecar.

Workingbeneaththedashintheareatotheleftofthepedals,locatethesmallrubbergrommetsinthefirewall.Pushalengthofmechanicswire(oralengthofcoathanger)throughtherubbergrommetintotheunderhoodareabehindthebattery.

Ourphotoshowsthelocationofthefirewallgrommet.

Step 2Reachdownbehindthebatteryandpullthemechanicsup.

Tapethebluewirefromthefoglightwiringharnesstothemechanicswire.Twistthewirestogetherandtapethemtightlysotheywillslidethroughthefirewallgrommeteasily.

Step 3Backinsidethecar,pullthemechanicswiretodrawthebluewirethroughthefirewallgrommetintotheareabeneaththedash.

Untapethewires.Discardthemechanicswireandletthebluewirehangfornow.

Route and Connect the Blue Wire



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ES2500919Step 4Removetheoldheadlightswitch.

Withtheswitchintheoffposition,pushstraightinonthecenterknobandturntheknobclockwiseuntilitstops;thenpullthelightswitchstraightoutofthedash.

Step 5Pushontheretainerclipsatthesidesoftheheadlightconnectorasyouslideitawayfromtheswitch.

Step 6Findthefuseboxcoverlocatedbeneaththelightswitchontheleftsideofthedash.Pulloutontheloweredgeofthecovertopopitfreefromthemetalretainerclips(arrows)thatholditinplace.

Takethebluewireandfishitupthroughthefusepanelopeningtotheheadlightswitchhole.




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ES2500919

Step 7Routethebluewirethroughtheswitchholeandpushitintoharnessconnectorterminal8,asshown.(Eachcavityhasanembossednumber.)

Pushthewireintothecavityfarenoughforthemetallocktabsonthewireterminaltosnapinplaceintheplasticconnectorhousing.(Givethebluewireaslighttugtobesureitwon’tpullorfalloutlater.)

Step 8PlugtheconnectorintothenewEuroheadlightswitchinyourkit.

Makesuretheplasticlockingtabssnapinplacetosecuretheconnectortotheswitch.

Step 9Insertthenewswitchintothedashboardopening,indexedtoitsnormalposition.Thenpushstraightinuntiltheswitchsitsflushandyouhearthelocktabclickinplace.

Reachupunderthedashandsecureanylooselengthofbluewirewithzipties.Dothesameinsidetheenginecompartment,securinganylengthofbluewirethatremains.

Replacethefusepanelcover.




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ES2500919

Inthissectionwewillroutetheredandbrownwiresfromtherelayharnesstowardthebatteryandlargepowerdistributionboxlocatednexttothebattery.Ourphotosshowhowtoconnectthewiresthatprovidepowerandgroundtotherelay.

Step 1 - Connection to voltageRemovetheplasticcoverfromthepowerdistributionpanel,locatednexttothebattery.

Step 2 - Connection to voltageUnscrewthehexnutretainerholdingthelargeredpowercabletothestudinsidethepowerpanel.Liftitoffanddroptheeyeletfromtheredpowerwireintherelayharnessoverthestud(arrow).

Reinstallthepowercableandtightenthenut.Makeittight,butdon’tovertightenit.

Step 3 - Connect to voltageUseaziptietosecurethewiresandreplacethefusepanelcover.

Takeamomenttoattachanyexcesswirewithaziptie.Positiontheinlinefuseholderatanaccessiblelocationandsecureit.

Connect the power and ground wires



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ES2500919Step 4 - Connection to groundRemovethebatterycover.Loosenandremovethenutonthebatterynegativecable.

Sliptheeyeletoftherelayharnessgroundwire(brownwire)overtheboltinthebatteryclamp.Replacethenutandhandtightenasyouwouldnormally.

Step 1 - Remove the front grilleRemovethefronttopgrille.

RemovethefourTorx®screwsfromthereartopedgeofthegrille.

Step 2 - Remove the front grilleTipuptherearedgeofthegrilleslightlyasyoupullitforward,andremoveit

Install the Fog LightsNowthatwehavetheheadlightswitchtriggerwire(bluewire),power,andgroundallconnected,it’stimetorunthepowerfeedwirestothefoglights.

Connect the power and ground wires



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ES2500919Step 3 - Run Yellow Wires to Grille Routethetwoyellowfoglightpowerwiresaroundthefusedistributionpanelandforwardtowardthefrontofthecar.Securethewireswithziptiesatseverallocations.

Feedthewires(withshortgroundwireattached)throughtheopeningnexttotheleftheadlight,asshown.

Step 4 - Remove lower grillesUseanon-marringplastictrimremovaltooltopryattheedgesofthelower,outergrilles.Workyourwayaroundtheouteredge,releasingtheplasticsnapretainersuntilthegrillecomesout.Repeatthisattheoppositesideoutergrille.

Step 5 - Remove lower grillesWithbothoutergrillesremoved,repeattheprocessatthecentergrillesection.

Removingthegrillesopensuptheentirelowersectionofthefrontbumperfascia,makingiteasytorunandsecuretheyellowfoglampwires.

Install the Fog Lights



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ES2500919Step 6 - Route fog light wiresRoutethelongerfoglightyellowwiredownandacrosstheinnerbumpercovertotherightgrilleopening.Secureitatseveralpointswithzipties.

Routetheshorteryellowwiretotheleftsidegrilleopening,securingitwithzipties

Leavetheyellowwireshangintheopeningsfornowwhileyouconnectthefoglampgroundwires,oneoneachside.

Step 7 - Connect ground wiresMakeabolt-to-groundconnectionforthebrowngroundwires.Forconvenience,we’llusetheT27Torxheadboltsoneithersideoftheradiator.

Removethebolts;cleantheboltwashersandthefacesofthemetalbracketsonbothsideswithsandpapertomakeagoodmetal-to-metalconnection.

Step 8 - Connect ground wiresInserttheboltthroughthebrowngroundwireeyeletasshown,andtightenit.

(Dothisonbothsides.Youmaywishtospraypaintanyexposedbaremetal–after making the connection–topreventrust.)




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ES2500919

Step 9 - Connect the lightsPlugthewireconnectorsintothefoglights.Pushtheminuntilthelockclipssnapinplace.Thislockstheconnectorinplaceandcompressestheweath-er-tightsealtokeeptheelectricalcontactsdry.

Step 10 - Install the fog lightsInsertthefoglightsontothecavitiesinthefrontbumper.

Step 11 - Install the fog lightsScrewthelightsinplace.

Tidyupanyloosewiring,makingsurethatnoneofthewiresrunfromtherelaytothefoglightscanbind,rub,orbepinchedoncethecarisfullyreas-sembled.

Testthelightsbeforereinstallingthegrilles.

Note:Ifeitherfoglightdoesnotcomeoninitially,themostcommonreasonwillbeapoorgroundconnection(steps7and8).




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ES2500919Step 12 - Reinstall the grillesWiththelightstestedandworking,snapthelowercentergrillesectioninplace.

Step 13 - Reinstall the grillesSnapthenewfoglightgrillesinplacetocompletethelowerinstallation.

Step 14 - Reinstall the grillesReinstallthetopgrille;replacethescrewsremovedearlier.

Checkallinstalledwiringonlasttimetoensurethatitissafelyroutedandsecured.




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ES2500919

This concludes the installation of the VW MKVI Fog Light Kit

Thanks!ThankyouforpurchasingtheECSTuningMKVIFogLightInstallationKit.Weappreciateyourbusiness,andhopethisguidehasbeenhelpful.

ES2500919

MakethejobeasierandpreventdamagetoplastictrimpieceswithECS Tuning Trim and Molding Removal Tool Sets:

ES2500877 and ES517779.


http://www.ecstuning.com/ES2500877/?utm_source=PDF&utm_campaign=TrimRemovalKit1

http://www.ecstuning.com/ES517779/?utm_source=PDF&utm_campaign=TrimRemoval Kit2

Documents

VW Jetta Fog Lightbd8ba3c866c8cbc330ab-7b26c6f3e01bf511d4da3315c66902d6.r6.cf1.rackcdn… · Remove the old headlight switch. With the switch in the off position, push straight in