Since this is becoming quite a nuisance and others are unable to use the search feature here is the lowdown on the 2009 LED Headlight facelift including electrics (from a 2004 8p chassis onwards to 2008), thanks to NHN and all the others who assisted along the way, This has been quite an expensive little conversion so if you find this info in any way useful feel free to buy us a beer
Any questions keep them in the thread I don’t like repeating myself 1 million times, any clarifications etc I can answer via pm
Firstly this conversion is a lot of money to complete the approximate total cost is £3000-£5000 if you are paying to have this completed properly and depending on the configuration that your car is currently in.
If you are completing all of the work yourself and are purchasing used parts then you should be able to get it all done for just short of £2000.
If you’re still up for it the nitty gritty starts here
Facelift front panel (radiator surround)
Facelift crash bar complete with mounts and polystyrene insert
New headlight washers
Facelift bumper and grill
Facelift wings and fitting kits
Facelift headlight brackets
Facelift headlights ballasts and bulbs
Under engine and front wing arch covers
Central electrics unit – P/N 8P0 907 279 K
Xenon Leveller unit - P/N 4L0 907 357
Wing mirrors complete with indicators (my 10 dumbos or my11)
Door modules: P/N 8P0 959 801 M (Drivers) / P/N 8P0 959 802 M (Passengers)
Bonnet release cable
The work – Note this guide is not a step by step process it only documents the required modifications in order to tweak your vehicle to the new parts
First step is obviously to strip the front end of all body panels
Next is to begin by fitting the front panel, depending on the stack of tolerances in your cars chassis you may need to reposition the captive nut underneath the skin of your inner wing of your chassis
Once this is complete you should be able to bolt down the front panel, crash bar and re-house your radiator.
The wings as we all know by now are a completely different fit in that they mount in 3 places as opposed to 4; the following detail is in my opinion the most OEM looking solution,
Take the largest bracket from your fitting kit and rivet it to the centre mount on your wing, use this as a preset to adjust the remaining brackets to suit your chassis, once you have the wing sitting level and flush with your door I recommend that you drill and tap the centre bracket hole to suit its position, I then used some button head torx screws painted to my chassis colour to fill in the old bracket holes. Once both wings are fitted then you can complete assembling the front end as per ETKA / Elsawin
Now for the fitting of the mirrors, Note that I wouldn’t recommend using mirrors from the wrong door version i.e. 3 door mirrors for a 3door car
These will require your new door modules to be fitted and you to rewire your door card as per the wiring schematics in Elsawin, note if you have puddle lighting some of the earths will require joining this involves almost completely removing all the wire tape from the loom so its best to have some of it to hand.
If anyone does want to add part numbers etc please post them as a replay and mods or myself will add them in.
I will follow up with pictures detailing the fitting of the wings vs. the OEM.