Are you looking to enhance the functionality and aesthetics of your VW Jetta? Installing headlight washers is a fantastic upgrade, improving visibility in harsh weather conditions and adding a touch of European sophistication to your vehicle. While official instructions might be scarce, especially specific to the Jetta, this comprehensive guide will walk you through each step of the installation process. Based on proven methods and expert insights, this tutorial ensures a successful DIY project, even if you’re working with a Golf IV kit on your Jetta.
This guide is tailored for VW Jetta owners who want to add headlight washers, addressing the nuances of using a Hella Golf IV retrofit kit on a Jetta. We’ll cover everything from removing the grill and bumper to installing the new washer fluid reservoir and wiring the system. Let’s dive into the steps to equip your Jetta with effective headlight washers.
Step-by-Step Headlight Washer Installation for Your Jetta
Step 1: Accessing the Installation Area
First, ensure your vehicle is safely parked and the engine is off. Open the hood of your VW Jetta to begin the installation process.
Step 2: Grill Removal
Removing the front grill is essential to access the bumper and surrounding components. The Jetta grill is secured by hooks located at its corners, which snap into the bumper cover.
Image: Location of grill hooks on a VW Jetta bumper cover.
To remove the grill:
- Gently lift the edge of the grill to start unsnapping the hooks.
- Pull the top of the grill towards you. Be careful not to pull too forcefully, as the hood release handle is still connected.
- Disconnect the hood release handle from the grill.
- Once disconnected, you can fully remove the grill.
Image: Detaching the hood release handle from the VW Jetta grill.
Image: Front view of a VW Jetta with the grill completely removed.
Step 3: Bumper Removal
With the grill removed, the next step is to detach the bumper. The Jetta bumper is held in place by a combination of screws and bolts:
- Fender Well Screws: Locate and remove the four T25 Torx screws situated inside the front edge of each fender well (two per side). Remember to remove the side marker lights before proceeding. To remove the side markers, push in on the front edge until it recesses into the bumper, then gently pull the rear edge outwards. Avoid prying to prevent damage.
Image: Location of T25 Torx screws within the fender well of a VW Jetta.
- Under Grill Bolts: Identify and remove the five T30 Torx bolts positioned underneath where the grill was located.
Image: T30 Torx bolts located beneath the grill area of a VW Jetta.
- Air Intake Bolts: Find and remove two T30 Torx bolts located inside the bumper air intakes. To access these, you’ll need to remove the plastic intake covers. Simply pinch the two slots on each end of the plastic intake covers to detach them.
Once all the bumper bolts and screws are removed:
- Carefully pull the bumper straight forward to detach it from the vehicle.
- Place the bumper on a soft surface, especially protecting the pointed corners at the rear, to prevent scratches to the paint.
Step 4: Component Overview and Kit Contents
With the bumper removed, you’ll have a clear view of the area where the headlight washer system will be installed.
Image: Front view of a VW Jetta with the bumper completely removed, exposing the front structure.
The headlight washer retrofit kit typically used is the Hella Golf IV headlamp washer retrofit kit #8WS 008 558-001. Despite being a Golf IV kit, it is compatible with the Jetta/Bora.
Image: Components included in the Hella Golf IV headlight washer retrofit kit.
Kit Contents:
- Washer nozzles and covers (Golf type – will need to be replaced for Jetta)
- Washer pump
- Hoses and connectors
- Wiring components
Additional Parts Required for Jetta:
To complete the installation correctly for a Jetta, you will need to acquire the following parts, ideally from Germany, as they might be harder to source elsewhere:
- Bora Headlight Washer Covers:
- 1J5 955 109A (Left)
- 1J5 955 110A (Right)
- Bora Headlight Washer Jet Carriers with Jets:
- 1J5 955 103 (Left)
- 1J5 955 104 (Right)
Optional Relays for Factory Wiring Configuration:
For factory-like operation (headlights sprayed only when lights are ON and every 4th windshield wash), you’ll need to replace the stock windshield wiper relay (usually Relay 377) with:
- Relay 192 (1J0 955 531): For vehicles with a rain sensor (note: intermittent wiper function may be lost without a rain sensor).
- Relay 603 (4B0 955 531 E): For headlight washers without rain sensor compatibility.
Step 5: Euro Rebar and Lock Carrier Support
A crucial component for installing headlight washers on a Jetta is the Euro rebar. This is necessary to provide mounting points for the washer assemblies.
Image: Euro rebar with mounting points for headlight washer assemblies.
Euro Rebar Part Number: 1J0 805 551 E
Note: Ensure you specifically request the “E” version. Ordering may sometimes result in receiving the “C” (US spec) rebar, which lacks the necessary mounts.
It’s also recommended to replace the lock carrier support with the Euro version to properly support the Euro rebar:
Euro Lock Carrier Support Part Number: 1J0 805 567
Note: Verify the correct part number when ordering to avoid receiving the US equivalent (1J0 805 567 B).
Step 6: Headlight Assembly and Washer Fluid Reservoir
-
Remove Headlight Assemblies: Detach the headlight assemblies by removing the four T25 Torx screws securing each one.
-
Prepare Washer Fluid Reservoir:
- Siphon the existing washer fluid from the stock 3-liter reservoir into a clean container.
- Remove the stock reservoir by loosening two 10mm nuts and one 10mm screw. Disconnect the pump and fluid level sensor wires.
-
Install New Reservoir Components:
- Install the filter into the neck of the new, larger washer fluid reservoir from the kit.
- Fit the headlight washer pump with the new grommet (from the kit) into the front hole of the new reservoir.
- Install the original windshield washer pump with its old grommet in the back hole of the new reservoir.
- If your new tank has a level sensor hole, install the old level sensor using its original grommet.
- If your tank lacks a level sensor hole, carefully drill one using a 1-inch Forstner bit at the corresponding location as the original tank. Clean any ridges from drilling to ensure a tight, leak-proof sensor fit.
Image: Drilling a hole for the level sensor in the new washer fluid reservoir.
Image: Level sensor correctly installed in the modified washer fluid reservoir.
Image: Both washer pumps installed in their respective positions in the new reservoir.
Image: New washer fluid reservoir fully assembled with filter cap and pumps.
- Install New Reservoir: Installing the new, larger reservoir can be challenging due to limited space. For easier installation:
- Remove the fuel filter (no need to disconnect fuel lines, just unbolt and move aside).
- Remove upper and lower intercooler hoses and the intercooler itself.
- Remove the wire loom guide/support on the right side of the washer bottle ledge.
Once these components are moved, maneuver the new reservoir into place. Reconnect all wires and hoses in reverse order of removal.
Image: New, larger washer fluid reservoir successfully installed in the VW Jetta engine bay.
Image: Engine bay view showing the completed installation of the new washer fluid reservoir and associated components.
Step 7: Rebar and Washer Pump Installation
- Replace Rebar: Remove the US rebar and install the Euro rebar (1J0 805 551 E). Ensure the Euro rebar is correctly mounted and secured.
- Install Washer Pumps: Mount the washer pumps onto the Euro rebar. They are side-specific (left and right), marked on the pump body, so ensure correct placement.
Image: Washer pumps correctly mounted onto the Euro rebar assembly.
Image: Close-up showing the orientation and markings on the headlight washer pumps.
Adjust the orientation of the pump outlets if necessary by rotating the bottom part of the pumps to align correctly with hose routing.
Step 8: Hose Routing and Nozzle Connection
Connect the hoses to each washer nozzle. Route the hoses neatly and securely from the washer pumps to the intended nozzle locations on the bumper.
Image: Hoses routed from the washer pumps to the headlight washer nozzle locations.
Image: Close-up of hose connections at the headlight washer nozzles.
Step 9: Bumper Modification and Nozzle Installation
-
Bumper Marking: If your bumper has dimples on the inside face indicating nozzle locations (some Jetta wagons may have these), use them as guides. Otherwise, measure and mark the desired locations for the headlight washer nozzles.
-
Cutting Bumper:
- Drill a pilot hole using a 1 3/8″ Forstner bit.
- Enlarge and shape the hole into an oval using a rotary tool (Dremel) with a cut-off wheel.
- Refine the shape and size using a sanding drum, checking the fit of the washer covers frequently until they fit snugly without excessive side-to-side play.
-
Install Nozzles and Covers: Fit the Bora headlight washer nozzles and covers into the newly cut openings in the bumper.
Step 10: Reassemble and Wiring
- Reassemble Bumper and Grill: Reinstall the bumper and grill in reverse order of removal.
- Wiring: For wiring, you can follow the Hella wiring instructions or opt for OEM-like wiring for more refined operation (spraying only with headlights on and intermittently). For OEM wiring, you’ll need to connect wires to the headlight switch, fuse box, and relay plate. Refer to wiring diagrams for precise connections.
Wiring Notes:
- For Hella wiring, consult Roger Moore’s explanation.
- For OEM-style wiring, consider Chris Kennedy’s instructions. You’ll need specific wires and potentially a new relay plate connector (T18a).
Relay Plate Access: Accessing the relay plate (T18a) can be challenging. Use caution or refer to guides like Relay Plate Separation for tips on separating it without damage.
Conclusion
Installing headlight washers on your VW Jetta is a rewarding upgrade that enhances both functionality and aesthetics. By following these detailed steps, you can successfully retrofit your vehicle with this desirable feature. Although it requires careful work and attention to detail, especially with wiring, the improved headlight cleaning and sophisticated look are well worth the effort. Remember to source the correct parts, particularly the Euro rebar and Bora nozzles, for a seamless and professional installation. Enjoy the enhanced visibility and added convenience of your new headlight washers!
