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

Removing and installing headlights, headlights with gas discharge bulbs, vehicles up to 04.2011
WARNING
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 Information
Rep. gr.
94
Operation and safety notes for gas discharge bulbs
.
Note
If a headlight with automatic range control is removed, the basic setting of the headlight should always be checked when reinstalling
Chapter
.
Special tools and workshop equipment required
Torque wrench
V.A.G 1783
Removing:
Switch off ignition and all electrical loads, and pull out ignition key.
Unscrew rotary fasteners
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and remove battery cover.
Note
On vehicles as of 07.2009, the battery cover is discontinued.
Release and disconnect connector on headlight.
Unbolt cable
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from battery terminal.
Detach front bumper cover
General body repairs, exterior
Rep. gr.
63
Front 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.
Unscrew lower securing bolts
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.
Unscrew upper securing bolts
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.
Take headlight out forwards.
Installing:
Install in the reverse order of removal. When doing this, note the following:
When fitting headlight in bracket, ensure side guide is seated correctly
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.
Screw in all securing bolts.
Align headlight with wing.
Tighten all securing bolts to specified torques
Chapter
.
Check functions of headlight.
Checking and, if necessary, adjusting headlight setting
Chapter
.
Note
If lower headlight holder was unscrewed from headlight, it must also be realigned!