H3/H4 eurolight installation

[Phil Rose <pjrose@servtech.com>]

After installing my Eurolights it seems the main installation difficulties
('91 200q) were trim related. I thought I'd offer a few hints based on my
experience this week.

(1) Although the old DOTs could be pulled out, the new headlights wouldn't
slide in 'till I completely removed the chrome bumper-trim pieces on each
side (the center trim must obviously be removed, but I thought I could get
away with just loosening the sides--uh, uh.

(2) To *replace* each side bumper-trim, 3 screws need to be inserted though
a slot between the trim and the bumper cover. It's a _very_ tight squeeze,
and the screws readily fall away--into never-never land. Easy solution for
me was to make a set of paper washers which keep the screws loosely
retained in their slots _before_ the chrome piece is put in place. I cut
the retainers from very thin cardboard (really just heavy paper)--about 1
cm X 1 cm, and pierced their centers with an awl. Then I placed each screw
through its mounting slot before affixing the paper "washer". No dropped
screws!

(3) The Eurolights lack one crucial hole at the lower, outer corners of the
headlight units. This hole is needed for a screw that secures the center
and the side bumper-trim at the point where they overlap. It was no problem
to drill a 1/8" hole in the plastic where needed. This was done _after_ the
lights were installed. Best to look at the old DOTs to see the placement
needed--or wait 'till each side chrome piece is back in place before you
drill.

(4) I bought a bunch of the little nylon butterfly clips for retaining the
upper and lower (grill) trim strips (p/n 0447853674C). Each new light
already has 4 of these installed--two each at top and bottom. You'll need
about a dozen additional to replace all the missing, broken or badly
decayed clips on the grill. The clips are easy to insert in the grill, but
they have a small nylon pin at their center, and these take a *lot* of
effort to push all the way in. The pins expand the prongs (of the insert)
and prevent the clips from pulling out of the grill. Here's what my local
Audi wrench suggested for getting the pins pushed in:
(a) lubricate the clip (saliva seems useful and convenient for this)
(b) after inserting (and aligning) clip in grill, press against pin firmly
using the end of a 3/8 socket extension. It takes a lot of force, but they
will slide in--with a sudden "thud". A few went only about halfway. I
sliced off the excess with a razor blade.

Then, pushing the steel trim strips onto these clips also required a fair
amount of effort. Unless you hear a loud "snap" each time, they're probably
not secured. I can imagine a special VAG tool for this, but the palm of my
hand worked OK.

Someone recently commented on the structural function of the grill trim. I
now realize just how loose the top of my grill _used_ to be with all those
missing and/or damaged clips. It's now held in place very solidly.


Phil Rose				Rochester, NY
'91 200q				mailto:pjrose@servtech.com
'89 100