Removing and installing headlights, headlights with gas discharge lamps and cornering light — VW

Removing and installing headlights, headlights with gas discharge lamps and cornering light
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
.
Special tools and workshop equipment required
Torque wrench
V.A.G 1331
Note
Illustrations show removal and installation of the left headlight. Removal and installation of the right headlight are carried out in the same way.
If a headlight is removed, the alignment should always be checked following installation
Chapter
.
Removing:
Switch off ignition and all electrical loads, and pull out ignition key.
Caution
Risk of damage to component.
Carefully pull off bumper. When doing this, ensure that the bumper is not being deformed or torn.
In order to avoid scratches on the surfaces when removing the headlight, mask off the surrounding areas.
Using commercially available adhesive tape, mask off any potential contact areas between bumper cover, wing and headlight to avoid any scratches when removing and installing the headlight.
Unscrew bolts
2
.
Unscrew bolts
3
of wheel housing (facing upwards) on the respective side.
Unscrew bolts
4
and
5
of wheel housing on the respective side.
Unscrew bolts
6
from below.
Release catches at top of radiator grille from lock carrier.
Further removal is only possible with a second mechanic.
Pull front bumper cover
1
on the respective side out of catches of guides on wing
arrows a
until all securing bolts for the headlight are accessible and the headlight can be pulled out of the assembly aperture.
Release and disconnect connector
1
.
Loosen, but do not unscrew completely, securing bolt
2
at rear of headlight.
Remove three securing bolts
arrows
.
Remove headlight forwards out of body aperture.
Installing:
Installation is carried out in the reverse order. When installing observe the following:
First tighten bolts
arrows
to specified torque
Chapter
.
Tighten bolt
2
at rear of headlight to specified torque
Chapter
.
Check installation position so that shut lines/gaps around headlight are even.
If the shut lines/gaps around the headlight are uneven, the installation position must be adjusted
Chapter
.
Check functions of headlight.
Note
If a headlight is removed or adjusted to fit more accurately to the vehicle body, it must be aligned following such measures
Chapter
.