Replacing gas discharge headlight bulb — VW

Replacing gas discharge system dipped beam bulb

Warning, high voltage!
It is absolutely essential to ensure that the battery earth strap is disconnected before working on components of the gas discharge (xenon) system which are marked with a yellow high voltage symbol.
Then subsequently switch the dipped beam on and off. This discharges any residual voltage.
Removing

Remove screw -1- and open sealing cap after releasing spring clip -2-.
Pull sealing cap out of retainer -3-.

Release connector -1- by turning connector through 90°- -arrow- to the left and then pull it off.
Turn gas discharge lamp retaining ring -2- to the left and take it out.

Always use eye protection when removing and installing the gas discharge lamp bulb!
Eye protection is necessary because the glass bulb is very sensitive due to an internal pressure of 10 bar.

Pull gas discharge lamp bulb out very carefully.

Installing

Note:

Do not touch bulb glass when fitting a new gas discharge lamp bulb. Fingers leave traces of grease on the glass, which when switching the gas discharge lamp bulb on, evaporate and cause the glass to cloud over.

Use extreme care when fitting a new gas discharge lamp bulb and do not subject the bulb to mechanical stress. The glass bulb is extremely sensitive and its internals are subjected to a very high pressure.

Insert new bulb so that the lug on the plate is lying in the groove in the reflector.

Align the retaining ring -1 - locking lugs-2 - of the gas discharge lamp - 3- over both cut-outs -arrow-, insert and secure by turning clockwise.
Check function of headlight after replacing a gas discharge (xenon) lamp bulb.
Adjusting headlight with gas discharge (xenon) lamps, => page
94-25
.

Replacing main beam bulb

Removing

Remove headlight housing, => page
94-23
.
Remove sealing cap => page
94-18
.
Turn lever -1- on bulb holder to left -arrow-to release.
Pull main beam bulb with holder out of reflector.

Installing

Note:

Do not touch bulb glass when fitting a new bulb. Fingers leave traces of grease on the glass, which when switching the bulb on, evaporate and cause the glass to cloud over.

Install in reverse order.

Check function of headlight after replacing a bulb.
Adjusting headlight with gas discharge (xenon) lamps, => page
94-25
.

Replacing side light bulb

Removing

Remove headlight housing, => page
94-23
.
Remove sealing cap => page
94-18
.

Pull side light bulb with holder -arrow- out of reflector.

Installing

Install in reverse order.

Check function of headlight after replacing a bulb.
Adjusting headlight with gas discharge (xenon) lamps, => page
94-25
.