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Upgrades (non TDI Engine related) The place of handling, lighting and other upgrades that do not relate to the performance or economy of the TDI engine. In other words upgrades to your TDI that don't fit into TDI Fuel Economy & TDI Engine Enhancements.Please note the Performance Disclaimer

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Old August 2nd, 2006, 09:35   #61
pheller
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Wow, I bought all my parts new at Mahag VW in Munich, and Otto Glückler in Frankfurt... and my total cost was about $420, after shipping it all to Denver. And that was with the rebar travelling as a checked bag....

Looks like it might have been easier to just buy all the stuff here.

Oh well, it was an adventure :-)

--phil
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Old August 2nd, 2006, 09:49   #62
tongsli
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Phil, I think it's only been recently that things have gotten more avaiable.
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Old August 11th, 2006, 07:20   #63
mike
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Default euro rebar on ebay

FYI,
aftermarket euro front rebar item on ebay
7995693513 Picture looks like it might be correct.
Someone in the Hollywood area might
stop there to confirm this is euro part.
Hope this helps.
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Old November 24th, 2008, 12:33   #64
mike
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Default Headlight Washer Retrofit

I'm still looking for the complete invoice. But here's some notes I found in my VW folder from around that time.

1J5 955 109 & 110 A (washer covers): USD 25.00 / set
1J5 955 103 & 104 A (jet carrier): USD 25.00 / set

1J0 805 551 E Euro rebar w/mounts: USD 65.00
1J0 805 567 lock carrier support: USD 17.00

I remember the pump, reservoir, hoses and jets, etc. all came all in Hella kit box.
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Old November 24th, 2008, 15:14   #65
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I got mine from Worldimpex. You wouldn't like the bill, however
It took about a month for them to get all the parts (covers, jets etc) from Germany.
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Old November 25th, 2008, 06:37   #66
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Quote:
Originally Posted by jcrews
I got mine from Worldimpex. You wouldn't like the bill, however
It took about a month for them to get all the parts (covers, jets etc) from Germany.
Yeah, John responded with the master list. It was like $630 + tax, and you still need to get the wiring from Kufatec.

I cross referenced the parts with 1stVWParts and they were a little cheaper on some items, but they don't have everything, mainly the special order European items, and Euro Rebar.

TMTuning did get back with me, and apparently they do have at least one more of the Hella kit left in their inventory, even though it's not listed on their web site any more. They also can supply the covers for the Jetta. I think I'm going to go that route, and I'll still have to have John order the remaining parts for me.
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Old November 25th, 2008, 06:39   #67
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Does anybody know what the difference between the Hella wiring, Kennedy's wiring, and Kufatec's wiring is? I know Kennedy just took the diagram and wired it up, but is there something fundamentally different about the Hella kit, other than the relay?

Last edited by tamorgen; November 25th, 2008 at 07:37.
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Old November 25th, 2008, 07:42   #68
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You do not need wiring from Kufatec. You need 5 lousy wires. Follow the steps from the OP; here are my notes.

I went to Ace and bought #14 red and black stranded thin wall chemical resistant wire. You'll need 15 feet at $.23/ft each color. I created an overlay harness by wrapping the wires together with friction tape, and capped the friction tape with electric insulating tape on each end.

I wanted to keep the factory look and rebuilt the right side wire harness that services the side marker, washer pump, sensor, headlight, etc. It had gotten gooped up with age and oil spray from the intake elbow splitting earlier anyway.

It was easy to do, just a little time consuming. NB: The plastic wire guide that goes under the tank will fit. It has to shift forward a few inches, so you just clip it to the body, and disregard the mounting stud. You can optionally get the one that would fit on the mounting stud.

The hard part is getting the wire in the plenum. I found a steel cable from a shredded tire resting on my condenser, and used it to fish through the boot on the right side. It wasn't easy, and I had to disconnect the harness from its mount in order to straighten it enough for the steel cable to find its way through. After a few tries, I was able to get through, and with some cable pulling lubricant, the rest was easy. When pulling the wire, I pulled the short end through, that is the wire was all on the cowl side, and pulled through to the engine room, then I rebuilt the rest of the harness. The left side of the plenum was easy since there's space under the protective wire channel cover.

I did not pass the wire through the protective cover under the wipers. I passed it through the wire channel, and bundled it with the harness going through the firewall, ala coolant migration overlay. My rationale was that the area was nasty, still a little moist, and I didn't have a shop vac handy to clean it out. I didn't want to break a waterproof seal for two lousy wires, and I would have wanted to replace the blind cover with a real wire sealing grommet. Additionally, the protective cover houses connectors, so it didn't seem like the factory way to route those particular wires. The firewall route was already poked, is easy to seal, and isn't exposed to as much water if at all compared to the wire box above.

You don't have to do it this way, but I used flat contacts available at the dealership whenever possible to terminate the wires. I used them in the pump connector, and in the fuse box. They were not available for the relay carrier connections, but you can use them for the SRA/56 signal from the light switch to the carrier. NB: For some reason, the OP split the lock entirely from the carrier. All you have to do is spread the long sides slightly with your fingers, and slide the block over to the right. The movement is very small, but you can see the stairstep teeth on the side and recognise the locked and unlocked position. Once the terminals are in, it just slides back. The other wires will not fall out as they are still secured with their barbs.

The fuse box lock is just as easy. Remove the paneling and noise insulation from the steering column area and free the fuse panel from the mount. Use a screwdriver to pry the lock down about 1/4". Insert the contacts in position 33, and close up the box. 33 is on the right side, attached to the battery. Use a ring connector for #14 wire and a 1/4" post. With the battery disconnected, attach the ring to the 30 connection on the relay panel. Use the one with the two thinner wires, not the big thick one. This is based on the location given in the Bentley manual.

I ran the power connections from the fuse box along the left side of the CCM, and all wires were wrapped with friction tape, and secured with teardrops (for service loops) to the original wire harness.

Once everything is bundled up, attach fuse 33 (20A) and attach the battery. Turn on the lights, and spray them with oodles of water. It does deplete the liquid supply fast, at least through a snowstorm, but they work beautifully. After getting a good coating in salt and grime, I stopped to eat somewhere. The lights were nice and clean, and it was visible because the cutoff pattern was still sharp. I have the Golf switch from my MFA installation, so I can push forward to get only the windshield wet, albeit with a slightly weakened spray.

You will need two yellow-orange wire seals for 2.5mm wire where the pump connector is.

You might be wondering why I used 15 feet of black wire instead of finding a ground somewhere near the pump. I attached the ground to the post left of the steering column in order to follow the factory wiring diagram as much as possible. The extra few feet of red wire is for the fuse box, and having too much is better than not having enough, especially for how cheap it is.
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Old November 25th, 2008, 07:47   #69
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Quote:
Originally Posted by tamorgen
Does anybody know what the difference between the Hella wiring, Kennedy's wiring, and Kufatec's wiring is? I know Kennedy just took the diagram and wired it up, but is there something fundamentally different about the Hella kit, other than the relay?
Kufatec is similar to following the repair manual. Hella seems to use a relay powered by the original wiper motor so it always sprays if I recall correctly. The factory way disables the sprayers when the lights are off and limits the run time. The pump runs long enough for the nozzles to come up and sneeze on the lights. The spray is about 1/2 second long and very powerful.

As for your other question about the jets, the jet carrier with jet is the piece that inserts into the pressure cylinder. In other words, just the nozzle. If you had the Hella kit, you'd have to buy Jetta jets to replace the Golf jets. If you can get the Hella kit, get it, and use the #603 relay and wiring instead of the included wiring. Impex stocks the rebar so it's easy to get. You will have to shop modify the tank if you want to keep the sensor. Alternatively you can get the complement connector and some wire seal plugs (without the holes) to cap the wire and recode the cluster for no washer tank warning.

The most expensive parts were the rebar, pressure cylinders, jets, covers, and relay. The rest just added up but was $7 here $10 there, etc.

Last edited by jcrews; November 25th, 2008 at 07:52.
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Old November 25th, 2008, 10:24   #70
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Quote:
Originally Posted by jcrews
Kufatec is similar to following the repair manual. Hella seems to use a relay powered by the original wiper motor so it always sprays if I recall correctly. The factory way disables the sprayers when the lights are off and limits the run time. The pump runs long enough for the nozzles to come up and sneeze on the lights. The spray is about 1/2 second long and very powerful.

As for your other question about the jets, the jet carrier with jet is the piece that inserts into the pressure cylinder. In other words, just the nozzle. If you had the Hella kit, you'd have to buy Jetta jets to replace the Golf jets. If you can get the Hella kit, get it, and use the #603 relay and wiring instead of the included wiring. Impex stocks the rebar so it's easy to get. You will have to shop modify the tank if you want to keep the sensor. Alternatively you can get the complement connector and some wire seal plugs (without the holes) to cap the wire and recode the cluster for no washer tank warning.

The most expensive parts were the rebar, pressure cylinders, jets, covers, and relay. The rest just added up but was $7 here $10 there, etc.
Thanks guys. Now, the million dollar question. TMTuning's kit, which is the Hella kit, but they sell two different versions, Golf & Bora. Are they providing the correct Bora washer carrier with that, so I don't have to order them from Impex? I know I read that normally the Hella kit only comes with the Golf carriers, but since TMT's kit lists Bora & Golf versions, I'm thinking the correct carriers are included.
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Old November 25th, 2008, 12:14   #71
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If there's a Bora version then they already would pacakge the covers and jets else it's misrepresentation.
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Old December 1st, 2008, 12:01   #72
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Quote:
Originally Posted by jcrews
If there's a Bora version then they already would pacakge the covers and jets else it's misrepresentation.
That's my guess. I'll just have to check the part numbers when they finally arrive. The receipt that TMTuning sent me says the week of December 15th, but it could be sooner or later, since it's so hard to gauge from Europe.
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Old December 8th, 2008, 05:09   #73
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Hello tamorgen,

-What was the price for the Hella washer retrofit kit for Bora, and where do you think it's possible to order from Europe?

-Do you know the Hella part number of the kit for Bora you will buy from TMTuning? (I found a universal Hella washer kit with telescopic double nozzles - Hella part number : 8WT 008 549-201, but I'm not sure if this will fit to my VW Bora - http://b2c.hella.com/b2c_hella/b2c/i...o.xcm=hella_gb and choose >Diverse>Headlight Cleaning System electric, 12 V on page 17).

-Does the kit you will buy include the 5.5 liters water tank?

Thanks in advance.

Last edited by esilviu; December 8th, 2008 at 06:25.
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Old December 8th, 2008, 12:56   #74
tamorgen
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Quote:
Originally Posted by esilviu
Hello tamorgen,

-What was the price for the Hella washer retrofit kit for Bora, and where do you think it's possible to order from Europe?

-Do you know the Hella part number of the kit for Bora you will buy from TMTuning? (I found a universal Hella washer kit with telescopic double nozzles - Hella part number : 8WT 008 549-201, but I'm not sure if this will fit to my VW Bora - http://b2c.hella.com/b2c_hella/b2c/i...o.xcm=hella_gb and choose >Diverse>Headlight Cleaning System electric, 12 V on page 17).

-Does the kit you will buy include the 5.5 liters water tank?

Thanks in advance.
Esilviu,
I purchased the kit from http://www.tmtuning.com/vw/. I must have purchased one of their last ones, because they do not list it on their web site anymore. I'm not sure of the exact part number from Hella. The one in your link is a unversal kit, which could be used on any car, but isn't a Bora/Golf specific kit. I did come with the 5.5 liter washer tank. My understanding is that Hella stopped producing it. You have two options: You can try the OEM route, which will run you quite a bit of money...$600 or $700 US. You can try and locate the kit, and see if anyone still has any left. TMTuning may still have some left, but have taken it off their site. It doesn't hurt to ask the question. Hope this helps.
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Old December 8th, 2008, 19:26   #75
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Quote:
Originally Posted by esilviu
Hello tamorgen,

-What was the price for the Hella washer retrofit kit for Bora, and where do you think it's possible to order from Europe?

-Do you know the Hella part number of the kit for Bora you will buy from TMTuning? (I found a universal Hella washer kit with telescopic double nozzles - Hella part number : 8WT 008 549-201, but I'm not sure if this will fit to my VW Bora - http://b2c.hella.com/b2c_hella/b2c/i...o.xcm=hella_gb and choose >Diverse>Headlight Cleaning System electric, 12 V on page 17).

-Does the kit you will buy include the 5.5 liters water tank?





Thanks in advance.

This looks like the kit I got from TMtuning. I don't think the 5.5 litre tank was extra.
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