In an earlier post, I had argued for the benefits of upgrading to European spec headlights. Their performance was far superior to the US mandated DOT headlights that were standard equipment on North American VWs during this era.
One of the drawbacks of this upgrade is that new replacements are expensive, difficult to obtain, and require some rewiring of the stock wiring harness. I still believe the effort is worth it if one plans to continue to own a vintage foreign automobile like the Corrado.
If you are like me, I opted to find a useable set and have them imported from a fellow enthusiast in Germany. This was a substantial savings compared to purchasing a brand new set which can run as much as $600+ USD. US based dealerships are reluctant to order parts such as these since they are considered non-OEM. And if they are cooperative, they add their own profit margin to the cost of these items.
The reason this subject has arisen is that my pair of headlights, like my car, were probably nearing 20 years old.
So when I was installing the headlights, I noticed the inside reflector
assembly was free floating. The deteriorating nylon headlight adjuster on the passenger side headlight was not tight. Upon closer inspection, the nylon seal on the backside was cracked and when I touched it, it crumbled! It's no wonder the internal reflector assembly rattled around inside the headlight. Now what?
Describing my plight to one of the best resources for information, I was able
to find a source for replacement parts. The email discussion group hosted by
the Corrado Club of America (aka CCA) is still frequented by many long time enthusiasts and the collective knowledge of the community is still one of the most valuable resources. This type of obscure information would have otherwise disappeared as the number of these cars dwindles and more and more of these end up in salvage yards.
Previously unknown to me, I was directed to a source in Germany.
www.europeanperformanceproducts.com
European Perfomance products was a revelation. They carry almost every imaginable part and
upgrade for the e-code headlights. For the first time, I've actually found legitimate information on one of the rarest of options, the electronically controlled headlight adjustments that were found on very few of these cars. They also had replacement lenses and other smaller parts which I had assumed were unobtainable. And I sighed relief when I saw the very replacement part I needed. The Price was a reasonable $18 USD. But alas--shipping from Germany was ---$36 USD! Wow! That was the cheapest of shipping options. UPS and FedEx were 3X more! I had no choice, I ordered the part.
Note: This instructional is relevant to manually adjusted headlights. If you are one of the lucky few with the dashboard controlled adjusters, then the following won't be relevant to you.
Two weeks later and with the part in hand, I removed the headlight from the car. Disassembly is simple but must be done with care.
First one must carefully remove the outer black plastic trim. Carefully removing the tabs around the frame is the secret to success. What one will discover with these aging parts is that they are delicate and most of the previously owned samples have broken tabs or cracked lenses. The
majority of the surviving examples have one of more of these tabs missing. These particular tabs are held in by fitting into slots on the other half of the light assembly. However, a couple of steel tabs are used near the top. These steel tabs often need some prying to make them release.
Patience is the key.
Once removed, the lens is fully visable and now one can see the big steel C-clips. There are a
number of these all the way around the glass lens. These can be described as spring loaded and I used a flat head screwdriver to carefully pry these off. Again--CAREFULLY PRY THESE OFF! The inside edge of these clips are positioned against the glass lens.
Too much pressure and these can potentially break the glass and then you'll be faced with replacing the rare and expensive lenses. (Remember that expensive shipping charge from Germany?)
The glass lens should now lift off the casing. There is a compression gasket between the two halves that serve to seal the interior of the e-code from the outside elements. It might take some effort to seperate the two halves. Once inside, you will see the floating reflector assembly. If you lift it outward, you will see the adjustment knob and the long shaft. It is attached by another nylon fitting with a tab that locks into place. With a flat head screwdriver, carefully lift the tab on the end and release the knob from the reflector assembly.
Insert the new replacement knob and snap it into the reflector assembly. Then turn the o-ring/knob into place. It will twist lock into place sealing the back side of the knob.
Reassemble the entire e-code light with the same care as you did when you disassembled it.
I may someday add the motors and the dashboard controller for the headlight adjustments. This would eliminate these knobs. But for now, I'm happy the European spec headlights are now ready.
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