This is the procedure I followed for installing new speakers in my car. All info/pictures given to me by Richard Hamilton (thank you very much![
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What you need to buy
The speaker grilles all need to be replaced for blanks
(4 x Speaker blanks part no 996.645.049.02.01C) They are all identical so you will need 4 for front and rears. This is because the existing grille mouldings for the bass/mid units are raised and angled forwards, making it difficult to attach new ones. This also gives you the option of replacing the originals at any time. These cost £19.30 each
Then you will need to buy some VW connectors and repair wires to connect them to the original plugs in the loom, so that you can swap them back if need be.The wires have a terminal on each end, so you need one wire per speaker, and cut them in half.
(4x VW Speaker Connector: 1HO-906-712, 4 x VW Repair Wire: 000-979-129). These cost around £12 all in from your local VW supplier.
You will then need to buy the speakers themselves. I bought
2 Pairs of Pioneer e-motion TS-E1076 co-axials as Richard recommended them to me, they fit well and have a seperate tweeter and mid/bass unit fitted together. I could have used a seperate mid/bass unit and tweeter, but I didn't have time to find out which units would fit and would work well with the mid/bass units. They're nice speakers with a Kevlar weave. I bough them off Ebay for £59.98 for the 2 pairs.
Fitting Them
I marked a 10cm circle on the rear of the speaker grille blanks with a compass and cut them out with a flat blade fitted onto my soldering iron. With some careful positioning as per the pictures, I got 3 self tappers to hold them on the grilles, and bent down the other tag. I also 'burned off' the two protruding bits of plastic found between the tweeter- mid/bass blank areas.
I attached the connectors to the wires and the wires to the speaker tags (making sure I didn't invert polarity).i then soldered them aswell. I then undid the existing grilles in the car using an offset Torx key (can't remember what size), and pulled them out, and fitted the new ones, new VW connector to existing VW connector.
Job done. Total time - around 2 hours.
I noticed an instant massive improvement. Much more defined/deeper bass (ie not the one note thumping from the old units), much clearer mids, especially at higher volumes, and much better treble extension.Voices sound so much more open, and there is much less congestion in complex music. There is still not much bass, But I wasn't about to install bass units in my car.