B5 Bumper Cover Mounted Fog Lights - Hella Optilux 1000 Projector Fog Lights - NH VW Junky
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Disclaimer: By reading this, the reader accepts full responsibility in performing the following work at his or her own risk. B5one cannot assume responsibility for any damage, injury, dismemberment or death, as a result of you the reader, following our instructions. We supply this information freely, for those interested in knowing what is involved with such modifications. If you find you would like to perform a similar modification to your vehicle, we urge you to first seek the advice of a qualified mechanic prior to undertaking any of the work. Some work will require physical strength that may be beyond your ability to perform.

DIY Rating:   Moderate (3/5 wrenches)
Time: 3 hours
People Needed:   1

Tools:

• T-20 Torx driver or bit
• Phillips screw driver - Screw Gun preferred.
• Flat blade screwdriver
• Cutting Pliers/Cutting Shears
• Metal File
• Dremel - rotary saw optional
• Multimeter tester - to confirm you are attaching to the correct power source.

PREP
All written as is and just some ideas on how you can get started with a project like this - attempt at your own risk.

1. Remove Front Bumper cover.
    4 torx screws in each fender well (T-20)
    5 screws under the hood right above the grill (Phillips)
    3 twist lock fasterners under front bumper - 2 holding up front of belly pan.



MOUNTING



2. Cut appropriate section of lower grills. (See picture above) I used a combination of snipping pliers, industrial shears and a file. I would also suggest a dremel tool with a rotary bit.
   
   Take lights out of box and use one of the brackets as a guide while cutting.
   
   Cut slowly, and only take a little at a time. You can always go back and trim so be careful not to cut too much at first.





3. Line up the brackets on the openings you have created. Drill small pilot holes to get the larger supplied screws stared. It's important to really center the lights into your grill openings for them to look right. Further, you must securely mount the lights or you will see shake in them.





4. Adjust lights so they are level and aimed where you want them. You won't be able to loosen up the adjustment screws once every thing is reassembled - Do your best to get this right. I laid down on the ground and looked at this closely to make fine adjustments up close.





WIRING

5. I cut up the supplied harness and made 2 harnesses to lead up and connect to the headlight harness. The Fog Light wire is the White with Green stripe on the 99. I suggest using a test light or multimeter to confirm your are tapping onto the right wire. Then I remounted the bumper cover and ran the wire up and made connections using solder and tape. You can tap onto the ground in the same harness. It's the larger Brown wire. Be sure to seal very well all the connections - this powers the main headlight setup and you would not want to comprise its effect. I connected to a large piece of thick wire to ack as a snake and ran the new fog light harness under the existing headlights - being sure to avoid all the areas that get hot when running. Like the radiator and its hoses for example.
   
   Reassemble front bumper cover in reverse order - taking care not to pinch your new fog light leads as you reinstall the cover.

Enjoy!

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