Removing and installing gas discharge bulb, headlights with gas discharge bulbs, vehicles up to 04.2011 — AUDI

🧭 Before you start

Fits: VW Transporter T5 (7H), VW Transporter T5 (7J), VW Transporter T6 (7E), VW Transporter T6 (7F)

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• When installing, make sure cover cap is correctly seated. The ingress of water will lead to permanent damage to the headlight. — Fit cover on headlight housing.

📋 Procedure

1. ⚠ Risk of death due to high voltage! Risk of injury and environmental pollution!High voltage is supplied to the gas discharge bulbs. If they are not handled properly they can cause serious or fatal injuries.If work on high-voltage components is to be performed after a headlight has been removed (e.g change gas discharge bulb), the battery earth strap must be disconnected and the residual voltage in the headlight must be discharged before the headlight is removed.Observe operation and safety notes for gas discharge bulbs Electrical System, General Information94Operation and safety notes for gas discharge bulbs. — Switch off ignition and all electrical loads, and pull out ignition key.
2. Remove gas discharge bulb starter unit .
3. Release retaining clamps (1) from mountings (arrows).
4. ⚠ Within the glass bulb of a gas discharge bulb, pressure can range from between 7 bar (cold) and 100 bar (hot). Temperatures can reach up to 700 degrees Celsius on the glass bulb.Should the glass bulb explode, there is a risk of injury from burning.Always wear safety goggles and gloves when removing and installing gas discharge bulbs! — Carefully pull out gas discharge bulb (arrow).
5. ⚠ Do not touch bulb glass when installing a bulb. Fingers leave traces of grease on the glass, which evaporate when the gas discharge bulb is switched on and cause the glass to cloud over.Do not expose glass of gas discharge bulb to mechanical stress of any kind. The glass bulb is extremely sensitive and is also under a high internal pressure.Avoid looking directly into the collimated beam as the UV radiation from the gas discharge bulb is about 2.5 times higher than from normal halogen bulbs. — Insert new gas discharge bulb so that locking lugs are positioned in recesses on reflector.

6. Connect connector and engage it.
7. ⚠ When installing, make sure cover cap is correctly seated. The ingress of water will lead to permanent damage to the headlight. — Fit cover on headlight housing.
8. Install gas discharge bulb starter unit .
9. Check functions of headlight.
10. Check headlight setting and adjust headlight as necessary .

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