Hi Everyone,

Recently got myself some Standard Headlights and Last Weekend I went about removing the Morrettes and fitting the Standard Headlights for a cleaner look on the Front End of the Saph. However, Once I attempted to fit them I realised that they are NOT going to fit. Due to the Rad/Intercooler being so Big/Wide.

I haven't given up with the Idea of Fitting the Standard Headlights but I do need some help with working out how to get them fitted. I didn't get any Spares when I bought the car originally so I am now having to source everything I'm going to need.

Any Help/Advice would be Appreciated.

Smudge

 

I would have thought that when the intercooler and radiator were originally fitted it would have had the standard headlights? I have got an RS500 style intercooler and wider alloy radiator plus pre-turbo cooler and my 2wd has always had standard lights with no clearance problems.

 

It sits so far forward that the Inside of the Headlights sit out at an angle and can't be seated at all. As if the Rad is too far forward

 

I would think that the Morettes, being single lamp units, are not as deep at the point they cover the edge of the rad, thus giving the clearance required.
As the standard units are one big, moulded unit, they're going to be that much deeper, and so will foul the rad.
I can see from the pics that there's no space to move everything back, as the fans will start fouling on the belts.
I'd suggest that if you want the standard lights on, then something has to give.
Cutting the rad isn't an option, but what about cutting a notch out of the headlamp casing. Once you have enough clearance, the hole could be sealed up.
How about moving the fans to the front of the rad, and then moving the whole lot back an inch or so? Lots of work, but it's an idea....

 

Didn't think of it like that. Could always trim off some of the Hoses and sit the entire Rad Assembly back an inch or so... Should give enough clearance I think

 

Can't help with the fitting issue but glad you are going to standard headlights! That will change the car completely!

 

Cheers mate. Yeah looking to pot my own touches on the car now and the front end is something I'd like to sort for sure

 

Each to there own of course but I hate Morrettes on a Saff lol!

Mine has standard headlights and RS500 style cooler but wasn't me who fitted them to give you any advice, looks like there is plenty space though?

 

Yeah I like them but fancy something different. The headlights fit but can't get properly seated where they should be. It is literally an inch out

 

I've got a big RS500 cooler and it's mm's from the headlamp but it all fits nice.

Are you sure they are Cosworth headlamps and not std sapphire ones as the brackets are different? Might be your problem

http://ebayapi.loc8apartltd.netdna-cdn.com/00/s/NTQwWDk2MA==/z/WvQAAOSwk1JWhFoq/$_1.JPG

Cosworth ^^^

http://ebayapi.loc8apartltd.netdna-cdn.com/00/s/OTYwWDEyODA=/z/FOMAAOSwk1JWgGCA/$_1.JPG

standard ^^^

 

This is what I've got mate.

 

Anyone know what relay is for the heated front screen??



Any help?? Only passenger side is working <br/>

 

Is it an after market alloy radiator? If so maybe it was mounted to far forward? As a matter of interest I am pretty sure you can still buy brand new headlights for a Sapphire Cosworth.

 

Yeah I believe it is mate. I'll have to have a look at some new lights then if they are still together

 

They are correct for yours

I believe that the relay is under the glovebox next to the ecu (grey one)

 

it's the screen then, the relay is under the dash in the main loom and a dash out job to get to

as for the lights, they are proper sierra cosworth lights

you can move the intercooler forwards by putting the bolts in different holes, have you tried that?

 

Ive got a big intercooler on mine it fits the lights ok.

It is a bit of a tight fit though.

 

Glenn any chance you can take some photos of the intercooler and headlights please mate? Just curious to see how its fitted/spaced?

 

That looks like a Radtec cooler which I also have on my sapphire. I had the same problem and had to cut the back of the headlamp about around the main beam bulb cover to get them to fit right.

 

Not much help but here's the only pics I have that are close

 

I hope these help.

 

Jeez they are tight aren't they. Gonna have a go at fitting them again today since it's dry and the sun is out. Will give me a few hours to try get them fitted. Might have to trim the headlight casing though if I can't get the Rad moved back at all

 

Cheers for the Photos mate. Made me notice just how little room there is. But WOW yours is clean