Removing and installing headlights, headlights with gas discharge bulbs, vehicles as of 05.2011 — 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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• Insert headlight into holder. When doing this, ensure that guide at the side is seated correctly on the wing.
• Start all securing bolts, but do not tighten firmly yet.

📋 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. Detach front bumper cover General body repairs, exterior63Front bumper. [Note: The bumper cover does not have to be removed completely. For the headlight in question, it is sufficient to remove the fastenings at the front and at the sides of the bumper cover. The bumper cover can then be press downwards carefully until the lower bolt securing the headlight can be reached.In the area of the two bolts securing the bumper at the sides, it must be ensured that the bolts exposed when the bumper cover is removed do not scratch the wing. Protect this area with foam padding during assembly work.]
3. Release and disconnect connector (arrow) on headlight.
4. Unscrew upper securing bolts (arrows).
5. Unscrews lower securing bolts (arrow), while lightly pressing bumper cover downwards.

6. Unscrew securing bolt (arrow) on side of headlight.
7. Carefully remove headlight from body aperture, making sure to avoid damage to the paintwork on the bumper cover. If necessary, cover the bumper cover in the area of the headlight.
8. Insert headlight into holder. When doing this, ensure that guide at the side is seated correctly on the wing.
9. Start all securing bolts, but do not tighten firmly yet.
10. Using adjustment bushes (A), adjust position of the headlight in relation to body, while ensuring that gaps are uniform.
11. Tighten all securing bolts to specified torques .
12. Check position of headlight in relation to body and, if necessary, adjust again with the help of the adjustment bushes.
13. Check functions of headlight.
14. Checking and, if necessary, adjusting headlight setting .

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