Volkswagen Workshop Service and Repair Manuals

Removing and installing headlights with halogen bulbs Special tools and workshop equipment required t  Torque wrench -V.A.G 1331- Removing:   Note t  There is no requirement to disconnect the battery earth strap. t  The vehicle is fitted with headlights from two different manufacturers; removal and installation of both headlight versions are identical. t  Illustrations show removal and installation of the left headlight. Removal and installation of the right headlight are carried out in the same way. t  If a headlight is removed, it should always be adjusted following installation: „Maintenance manual“ → Booklet. –  Switch off ignition and all electrical consumers and remove ignition key. –  Remove radiator grille → General body repairs, exterior; Rep. gr.66 –  Remove front bumper cover → General body repairs, exterior; Rep. gr.63.

–  Release and disconnect multi-pin connector -1-. –  Remove securing bolt -2- on inner part of headlight.

–  Remove the three securing bolts -arrows-. –  Pull headlight forwards and straight out of body aperture. Installing: Installation is carried out in the reverse order. When installing observe the following:

–  Insert headlight with the three guides on underside into mountings -arrows- on guide and push into body aperture.

–  First fit the three securing bolts -arrows-.

–  Then fit securing bolt -2- on rear of headlight. –  Tighten securing bolts on headlight to torques specified in assembly overview → Chapter. –  Check headlight installation position is central, i.e. shut lines/gaps are equal around headlight. If the shut lines/gaps around the headlight are uneven, the installation position must be adjusted → Chapter. –  Check headlight functions.   Note If a headlight is removed, it should always be adjusted following installation. –  Checking headlight settings and adjusting headlight if necessary „Maintenance manual“ → Booklet