South African Grill Kit Installation

1980-1991 VW Vanagon

Required Tools:

Flathead screwdriver, Philips screwdriver, wire stripper, wire crimper/cutter, drill with magnetic #2 Philips head. (1/8” drill bit required for installation on 1986-91 models)

1. Remove existing grill

2. Identify your inner 5” headlights, boxes marked “RH” and “LH”

3. The Vanagon does NOT have pre stamped holes for the inner lights, so here comes the fun part. Hold the inner lights up to the body of the van to test fit the location using the grill as a template. (the center of the inner light grill opening is a good point to mark)

4. Use the sharpie to mark your attachment points for the inner lights. (remember: measure twice, drill once)

5. ***FOR 1986-91 INSTALLATION PLEASE SEE STEP 14 THEN RETURN TO STEP 6***

6. Now it’s time to cut some wires. Cut off the factory inner and outer headlight plugs. (be sure to leave yourself as much wire as possible)

7. Strip all wire ends and prepare them to be crimped to new wiring harness.

8. Match up all wire colors (i.e. brown-brown, yellow-yellow) from wiring harness on van to new harness supplied with the kit. Make sure your crimp connections are tight and secure.

9. Use a heat gun (or lighter) to shrink the wire connectors to give them a water tight seal.

10. Install all bulbs into your lenses and mount your inner headlight brackets using the marks you made earlier and with the supplied self-tapping screws.

11. Mount the outer lights and test to see that all lights function properly. Adjust angles and position of headlight.

12. Before installing your new South African grill you will need to remove one of the fastening screws and install it in the center hole of the grill to secure it to the van. 13. Install your new grill and enjoy being able to see at night

14. ***Use the drill and drill bit to remove the bracket rivets that holds the inner screw of your old headlight housing, you will be able to use the existing far outer screw locations from your square headlight housings for your new 7” round H4 headlights, the two inboard ones will need to be self-tapped***