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Nova
Euro Cluster Conversion
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| DISCLAIMER: The information in these documents are a collection from experience (friends or myself), magazine articles, mailing lists and Internet web sites etc. So don't take these as 100% correct gospel, hence I don't take any responsibility for any of these guides. | |
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Created: 17th April 2001 Updated: 15 Dec 2002 Revision 2 |
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PARTS
Option A
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PARTS
Option B
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COST
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| Crimmper | Crimmper | Euro Cluster (any side) | £20 |
| Socket Set (metric) | Socket Set (metric) | Astra Fog lamp (original vaux) | £6.60 |
| Various bullet plugs | Various bullet plugs | Wire 7/0.2 or 16/0.2 per meter | 20p+ |
| Various bullet sockets | Various bullet sockets | 20 bullet plugs or sockets | £2 |
| Offside Euro cluster | Nearside Euro cluster | Hand crimmper | £6+ |
| 10 foot of wire (max) | 5 foot of wire (max) | You can import the Euro clusters if you wish (about £35), or you could go to the Offers Page and get either side for £20 inc P&P (this is what I did). The part number for the Astra fog lamps are 90243431 which also come with a fixing brace. You'll only need two size bullet plugs, mostly red and a few blue size ones. | |
| Haynes book (very useful) | Haynes book (very useful) | ||
| Wire cutters | Wire cutters | ||
| Fog lamp(s) | Another Fog bulb | ||
| Another Reverse bulb | |||
| Pad saw or Jig saw | |||
| Option 1: Twin Reverse |
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Just before you start, make sure you note the following:
OK, got all the above? Then follow the steps below (remember to click on the pics for a bigger view): |
| Step 1 | Step 2 | Step 3 |
| First of all look at the circuit diagram above and take note of what to do. There are actually only 2 wires to cut and 3 new wires to add. |
First is preparation, so make up the Y adapter as shown, just 2 wires and 3 bullet connectors. This will feed the reverse signal onto the Euro cluster. |
Open up the little door in the boot to get at the back of the offside cluster. Remove the multi-plug by pulling it and pressing down on the clip. |
| Step 4 | Step 5 | Step 6 |
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Follow the circuit diagram and cut the Fog lamp wire (Black wire with Blue tracer). Connect a plug bullet at the multi-plug end and a socket bullet at the GM loom end. |
Now go to the nearside cluster and pull off the multi-plug. You need to locate the Reverse wire, which is White/Black. But there are 2 of them! Find the White wire with Black tracer. | Cut the reverse wire and put a plug at the multi-plug end and a socket on the GM loom end. Now connect the Y adapter to the bullet plugs. Note: the other bullet plugs is were I cocked up, I cut the wrong wire. Opps! |
| Step 7 | Step 8 | Step 9 |
| With the Y adapter fitted, cut some wire which feeds from the Y adapter (blue socket), along the bottom of the boot and into the offside cluster area. This is the reverse feed wire, just follow the circuit diagram. | With the nearside complete, go back to the offside cluster and remove the bulb holder by pulling it off. Then remove the Nova cluster (3 bolts) and swap it for the Euro cluster. Try and retain the sponge on the Nova cluster. | With the Euro cluster in place, push back the bulb holder on. Refit the multi-plug and connect the reverse feed wire onto the plug bullet (now making the fog bulb a reverse lamp). Now cut another wire for the fog(s) and connect it to the socket bullet. |
| Step 10 | Step 11 | Step 12 |
| Feed the fog lamp wire from the offside cluster through the same grommet used by the number plate light (tight fit). Depending if two fog lamps connected, you may have to 'piggy back' a 2nd wire to the 2nd fog lamp. | With my particular fog lamp, I didn't have the correct plug that fit's for it. So I used some small bullet spades to fit on the terminals. This is a trial and error method to see what fits. | With all the wires and the lamps in place, put everything back together. Now for the big test, switch on the lights, fog and put it into reverse and stand back to see what happens. Note: that you need to replace the fog bulb with a reverse one (Euro cluster end). |
Not finished just yet.....Once you've done the above steps, you've just converted your Nova to have twin reverse lamps and have fog lights. You should ideally change the offside fog bulb (where the Euro cluster is now) with a lower wattage reverse lamp bulb. This is because is still has the fog bulb in a reverse lamp cluster. So when you switch on the reverse, the offside fog looks very bright. Remember that both reverse lights might look dull anyway because there are two bulbs in series now. In otherwords where before there used to a 12v drop across the one bulb, there is now only a 6v drop across both bulbs. So naturally they will not appear so bright. But other than that, job well done :) |
| Option 2: Twin Fog |
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Just before you start, make sure you note the following:
OK, got all the above? Then follow the steps below (remember to click on the pics for a bigger view): |
| Step 1 | Step 2 | Step 3 |
| First of all look at the circuit diagram above and take note of what to do. There are actually only 2 wires to cut and 1 new wire to add. |
First is preparation, so make up the Y adapter as shown, just 2 wires and 3 bullet connectors. This will feed the fog signal onto the Euro cluster. |
Open up the little door in the boot to get at the back of the offside cluster. Remove the multi-plug by pulling it and pressing down on the clip. |
| Step 4 | Step 5 | Step 6 |
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Follow the circuit diagram and cut the fog lamp wire (Black wire with Blue tracer). Connect a plug bullet at the multi-plug end and a socket bullet at the GM loom end. |
Now connect the Y adapter to the bullet plugs. This will feed the Fog signal to the Euro cluster's fog light bulb. |
With the Y adapter fitted, cut some wire which feeds from the Y adapter (blue socket), along the bottom of the boot and into the nearside cluster. |
| Step 7 | Step 8 | Step 9 |
| Now go to the nearside cluster and pull off the multi-plug. You need to locate the Reverse wire, which is White/Black. But there are 2 of them! Find the White wire with Black tracer. Fit a socket to the GM loom half and a plug to the multi-plug end. | The reverse signal from the GM Loom is no longer used. Remove the bulb holder by pulling it off. Then remove the Nova cluster (3 bolts) and swap it for the Euro cluster. Try and retain the sponge on the Nova cluster. | With the Euro cluster in place, push back the bulb holder on. Refit the multi-plug and connect the fog feed wire onto the plug bullet (now making the reverse bulb a fog lamp). Just follow the circuit diagram. AND THAT'S IT! |
Not finished just yet.....Once you've done the above steps, you've just converted your Nova to have twin fog lamps, but no reverse. You should ideally change the nearside reversing bulb (where the Euro cluster is now) with a higher wattage fog lamp bulb. This is because is still has the normal bulb in a fog lamp cluster. So when you switch on the fogs, the nearside fog looks very dull. Remember that both fogs might look dull anyway because there are two bulbs in series now. In otherwords where before there used to a 12v drop across the one bulb, there is now only a 6v drop across both bulbs. So naturally they will not appear so bright. But other than that, job well done :) |
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