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Alex

Update of my ClubPolo.co.uk Foglight fitting guide

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Alex

Fitting Foglights to a Mk3 Polo bumper.

These instructions are written with OEM foglamps in mind. However, before I fitted these to my car I had a set of universal lamps on with custom brackets. If anyone would like information on how to fit non-OEM lamps there is an e-mail address at the end of this guide. My advice is though, to go for the real thing in the first place. Although they cost more, they fit better and, unlike the lamps I got, they don't rust away after six months.

First up, a soldering iron is really handy. Most of my friends have one, but it's not something everyone has in their tool box. Very handy tool indeed I hasten to add. Much recommended. You will also need a crimping tool.

Step One

Begin by removing your grille. Starting at either end carefully push the centre part of the tabs down and withdraw the grille from the slam panel. Now locate the retaining bolts which are in the recess in front of the radiator, underneath the numberplate. There are four more bolts which need to be removed, these are underneath the grille. Finally there are two clips which hold the bumper on at the wheel arches. These have a central tube roughly 3mm in diameter. Push this out with a small screwdriver then remove the rest of the retaining clip. Carefully unhook the bumper from the wheel arches and withdraw it from the front of the car to reveal the cross member behind.

Now that the bumper is removed it is easier to cut out the foglamp blanks on the front bumper. There's a raised bit in the middle and a "moat" around the edge. Carefully cut the raised centre away with a sharp craft knife, try not to apply too much pressure as you will score your bumper if you do. Once you've done this neaten the edges up with some sand paper or a file.

Once the bumper is ready, locate the four holes which the fog light brackets mount onto. There are two each side, square holes in the crossmember. Bolt the foglights in place and tighten them up firmly so that they don't wobble.

Step Two

The next step is the wiring loom. This is where it gets more complicated. If you want the lamps for show only, and non-functional, you can simply re-attach the front bumper and you're done. Personally though, I don't see the point in fitting foglamps that don't work. It's not particularly difficult to make your own wiring loom either.

These parts can be bought at a scrap yard (my local one gave me them free though!). You need to two of these clips, plus a male connector which clips into them.

wiringloom.jpg

The female connectors can be taken from any Mk3 Polo, they are found in front of the fuse box. The male ones are more tricky to get hold of. These can be found in an '89-'94 Passat (or a Corrado) just behind each headlight. Don't bother with the female connector you will find attached to it though, leave that behind. Make sure that you get around 3-4" of wire as well on each clip. That makes the rest easier.

Next, find your local Maplins or equivalent electronic parts supplier. Maplins are very cheap (plus if you're a student they do discounts if you take your student card with you) and have everything you could need. Buy the following.

- 10m of brown wire (this is 39p per metre)

- 10m of black wire (this is also 39p per metre)

- a waterproof inline fuse holder Click here

- a pack of ten 15A glass fuses (£1.09)

- a 30A relay Click Here

- Ring connectors for the battery terminal

- Fully insulated female spade connectors for the relay terminals

- Shrink wrap, gaffer tape or electrical tape

- A pack of cable ties (optional)

You should end up with spare wire from that, but having that much allows you to make mistakes without having to go back and get more wire.

Cut a length of black and a length of brown wire roughly 3.5m long. Now cut another length of each 2.5m long. The shorter length is for your passenger side foglight, the longer length is for your driver's side one. Don't make this too short as it has a long way to go.

Now do a third set of black/brown wires which are roughly the same width as your car, slightly longer is better than slightly shorter remember. Put these aside for now, this is the wiring for your relay.

Keep any excess wire separate to avoid confusion!

Remove the insulation from the end of all of the wires you have just cut, do the same with all of the clips you got from the scrap yard. Then warm up your soldering iron.

Step Three

Take the longest black and brown wires and one of the female connectors. Cut a 4" length of shrink wrap and slide it over the wires. Solder the black wire to the yellow/white wire coming off the connector and the brown wire to the brown wire on the connector. Wait for the solder to cool, then insulate the bare wire with electrical tape. Finally slide the shrink wrap over the electrical tape and run the soldering iron over it to shrink it.

Repeat this with the shorter length of wire and the other female connector.

What you should have by now is two female connectors, each with a length of black and brown wire soldered to them.

Make sure that these are not tangled at all. Now twist the bare end of the brown wires together (the end without the connector) and slide some shrink wrap over the wires. Then solder this to the brown wire from the male connector off the Passat and insulate with the shrink wrap.

Twist the bare ends of the black wires together and crimp a female spade connector onto them. Crimp another female spade connector onto the black wire from the Passat connector and your basic loom is ready.

Put the loom to one side for now, ensuring that it does not get tangled. Pick up the black and brown relay wires cut earlier. Split the black wire into two pieces and carefully strip the wire. Crimp the fuse holder between the two lengths to make the wire whole again. Finally crimp a ring connector and a female spade connector on opposite ends of the black and brown wires.

Step Four

Now you are ready to fit the loom to your car.

Remove the plastic cover from the scuttle panel for better access and locate your car's foglight loom plug (the white plug in front of the fuse box). Plug the Passat connector into this and run the wires to the foglights, be careful not to get the driver and passenger side wiring mixed up.

Run both wires underneath the washer bottle and past the coil. Now run the passenger side wiring down into the inner wing and plug the white connector into the back of the foglight. The driver's side wiring can be held in place using the metal clips undearneath the grille, run it across the front of the car following the factory headlight wiring and then down into the inner wing behind the headlight. Plug in the other foglight.

Now take your brown relay wire and connect it to the battery negative terminal using the ring connector. Do the same with the black wire. Run the wires back to the fusebox side of the scuttle panel.

You should now have four female spade connectors ready to be plugged into the relay. Plug them in as follows:

Relay Pin 30 -> Battery positive terminal (black relay wire)

Relay Pin 85 -> Battery negative terminal (brown relay wire)

Relay Pin 86 -> Black wire from Passat connector

Relay Pin 87 -> Black wires to the foglights

Finally put a 15A fuse in the fuse holder and you're ready to test your hard work!

Before doing so, check that all wiring is clear of any moving parts. Use cable ties to tie up any loose wire and where possible use original wiring loom clips to hold your loom in place. If these clips are missing, simply cable tie your loom to the wiring loom. This should stop the wires becoming tangled/damaged in moving parts as well as making the whole installation look more factory.

To test your wiring loom turn your electrics on with the ignition. Turn your headlights on (dipped or main beam, doesn't matter) and push the foglight switch under your head unit in half way. Your front fog lights should now be on, but your rear one should be off. Push the foglight switch in fully and both the front and rear lamps should be on.

Don't worry if they're a little dim, that's how they're meant to be (!) Polo foglights, although expensive, aren't very bright.

Please note this installation will not allow you to run your foglights with your sidelights like Saxo-driving Barry boys do. :-p This is as VW intended.

Also, if you drive around with your foglights on when it's not foggy the Police view this as dangerous as you can dazzle other road users. You're unlikely to blind anyone with Polo fog lights, but that doesn't mean you won't get pulled!

Any questions, feel free to e-mail me at SpearmintCoupe@aol.com

Have fun!

Alex Grant

(thanks due to Steve_O for help with the relay wiring)[/b]

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