HID Headlamps, Through 05.2008

HID Headlamps, through 05.2008

Observe notes on contact corrosion. Refer to => [ Contact Corrosion ] Service Precautions.

• After any measures that could affect headlamp aim, headlamps must be readjusted. Refer to => [ Headlamps, Checking and Adjusting Conditions ] Testing and Inspection.

=> [ Preparing to Work on Headlamps ]

=> [ Headlamps ]

=> [ Gas Discharge Bulb for Low Beam Lamp, Replacing ]

=> [ High Beam Bulb ]

=> [ Bulb for Parking Lamp, Replacing ]

=> [ Turn Signal Bulb ]

=> [ Headlamp Range Control Positioning Motor ]

=> [ HID Headlamp Control Module ]

=> [ Ignition Coil for Gas Discharge Lamp ]

=> [ Headlamp Housing Repair Set, Installing ]

Preparing to Work on Headlamps

Left headlamp

- Remove the air filter housing.

Right headlamp

- Vehicles with gasoline engine, move the EVAP canister, with the lines still connected, to the side.

- Vehicles with TDI engine, move the fuel filter, with the hoses still connected, to the side.

Headlamps

Danger to life due to high voltage.

• Usage and safety information for gas discharge headlamps.

Removing

- With ignition switched off, disconnect ground cable at battery:

• Battery in engine compartment, refer to => [ Battery in Engine Compartment, Disconnecting and Connecting ] Battery In Engine Compartment, Disconnecting and Connecting

• Battery in luggage compartment, refer to => [ Battery in Luggage Compartment, Disconnecting and Connecting ] Battery In Luggage Compartment, Disconnecting and Connecting

- Remove front bumper cover.

- Remove bolt - 1 -.

- Insert long hex socket into opening - arrow 2 - and remove retaining screw on bottom of headlamp housing.

- Insert long TORX wrench into opening - arrow 1 - and remove retaining screw from headlamp housing.

• Secure screw to hex socket with body adhesive.

- Remove headlamp toward front from body.

- Unplug connector.

Installing

Install in reverse order of removal, noting the following:

- Check adjustment nuts - 3 - on adjusters - 1 - and - 2 - for ease of movement.

- Screw adjuster as far down as it will go, but do not tighten.

- Insert headlamp and hand tighten upper screw - 1 -.

- Install the front bumper cover.

- Align headlamp to contours of body (gap widths).

- Tighten screws - arrow 1 - and - arrow 2 -.

• When tightening the screws, the adjusting nuts on the adjusters rotate toward headlamp housing mounting point and secure it.

- Connect battery. Actions to be taken:

• Battery in engine compartment => Battery In Engine Compartment, Disconnecting and Connecting

• Battery in luggage compartment => Battery In Luggage Compartment, Disconnecting and Connecting

- Adjust headlamps => [ Headlamps, Checking and Adjusting Conditions ] Testing and Inspection.

Tightening Specifications

Gas Discharge Bulb for Low Beam Lamp, Replacing

Risk of death due to high voltage, injury risk and environmental hazard.

• Usage and safety information for gas discharge headlamps.

Removing

- With ignition switched off, disconnect ground cable at battery.

• Battery in engine compartment, refer to => [ Battery in Engine Compartment, Disconnecting and Connecting ] Battery In Engine Compartment, Disconnecting and Connecting

• Battery in luggage compartment, refer to=> [ Battery in Luggage Compartment, Disconnecting and Connecting ] Battery In Luggage Compartment, Disconnecting and Connecting

- Preparations for working on headlamps.

- Release retainer tab - arrow - and detach housing cover for dipped beam from headlamp housing.

Left headlamp

- Remove the headlamp range control positioning motor screws - 3 -.

Continuation for both sides

- Turn ignition coil - 2 - for gas-discharge lamp counter-clockwise - arrow - and detach.

• When rotating the ignition coil, the connector - 1 - will automatically come out of the connector housing.

• The ignition coil on the left headlamp can be removed only after the HID headlamp motor has been loosened.

- Remove the retaining ring for the HID headlamp by turning it counter-clockwise - arrow -.

- Remove gas discharge lamp from headlamp housing.

Installing

Install in reverse order of removal, noting the following:

- Insert bulb in housing, taking care not to touch glass bulb with bare hands. Installation location:

• Upper tab at bulb socket must engage at recess for light bulb.

• The retaining ring can be installed in only one position.

- Secure gas discharge lamp using retaining ring.

• Harness connector must only be connected with ignition coil installed.

- Check if recess in housing of ignition coil for gas discharge lamp and recess in pressure ring align completely with each other - arrows -.

- Mount the HID headlamp ignition coil to the headlamp.

• The tab on the ignition coil - 1 - must be inserted into the open hole on the retaining ring - 2 -.

• In the illustration the retaining ring is shown removed.

- Rotate the HID headlamp ignition coil clockwise all the way.

• Ignition coil must turn freely.

- Connect the connector and close the housing cover.

- Connect battery. Actions to be taken:

• Battery in engine compartment => Battery In Engine Compartment, Disconnecting and Connecting

• Battery in luggage compartment => Battery In Luggage Compartment, Disconnecting and Connecting

Tightening Specifications

High Beam Bulb

Removing

- Switch off ignition and remove ignition key.

- Turn light switch to 0 position.

- To work on the left headlamp, remove the air filter housing.

- Release spring clip - arrow - and remove high beam/parking lamp housing cover from headlamp housing.

- Remove bulb - 2 - from spring clips - arrows -.

- Disconnect harness connector - 1 - at high beam bulb.

Installing

Install in reverse order of removal, noting the following:

- Insert bulb in housing, taking care not to touch glass bulb with bare hands.

- Place bulb on lower spring clip.

- Press bulb in housing over upper spring clamp resistance.

- Connect the connector and close the housing cover.

- Secure housing cover using wire clamp.

Bulb for Parking Lamp, Replacing

Removing

- Pull light bulb for parking lamp out of socket.

Installing

Install in reverse order of removal, noting the following:

- Insert new bulb into socket, do not touch glass cone with bare hands when doing so.

- Push socket into reflector until it engages noticeably.

- Close the housing lid.

- Secure housing cover using wire clamp.

Turn Signal Bulb

Removing

- Switch off ignition and remove ignition key.

- Remove appropriate front wheel.

- Remove appropriate front wheel housing liner.

- Turn bulb socket counter-clockwise - arrow - and remove from housing.

- Remove lamp from socket.

Installing

Install in reverse order of removal, noting the following:

- Insert bulb in housing, taking care not to touch glass bulb with bare hands.

- Install front wheel housing liner.

Headlamp Range Control Positioning Motor

Danger to life due to high voltage.

• Usage and safety information for gas discharge headlamps.

Removing

- With ignition switched off, disconnect ground cable at battery.

• Battery in engine compartment, refer to => [ Battery in Engine Compartment, Disconnecting and Connecting ] Battery In Engine Compartment, Disconnecting and Connecting

• Battery in luggage compartment, refer to => [ Battery in Luggage Compartment, Disconnecting and Connecting ] Battery In Luggage Compartment, Disconnecting and Connecting

- To work on the left headlamp, remove the air filter housing.

Right headlamp - all vehicles

- Remove headlamp.

Continuation for both sides

- Release retainer tab - arrow - and detach housing cover for dipped beam from headlamp housing.

- Remove the headlamp range control positioning motor screws - 3 -.

- Turn ignition coil - 2 - for gas-discharge lamp counter-clockwise - arrow - and detach.

• When rotating the ignition coil, the connector - 1 - will automatically come out of the connector housing.

- Remove the headlamp range control positioning motor from the ball head mount - arrow -.

- Disconnect electrical connector - 1 -.

Installing

Install in reverse order of removal, noting the following:

- To make it easier to install the motor, remove the high beam/parking lamp housing cover from the headlamp housing and counterhold the reflector.

- Install the headlamp range control positioning motor into the reflector ball head mount.

- Install ignition coil.

• If the motors were removed and installed or replaced, then the headlamps must be adjusted. Refer to => [ Headlamps, Checking and Adjusting Conditions ] Testing and Inspection.

- Close the housing lid.

- Connect battery. Actions to be taken:

• Battery in engine compartment => Battery In Engine Compartment, Disconnecting and Connecting

• Battery in luggage compartment => Battery In Luggage Compartment, Disconnecting and Connecting

Tightening Specifications

HID Headlamp Control Module

Danger to life due to high voltage.

• Usage and safety information for gas discharge headlamps.

Removing

- With ignition switched off, disconnect ground cable at battery.

• Battery in engine compartment, refer to => [ Battery in Engine Compartment, Disconnecting and Connecting ] Battery In Engine Compartment, Disconnecting and Connecting

• Battery in luggage compartment, refer to => [ Battery in Luggage Compartment, Disconnecting and Connecting ] Battery In Luggage Compartment, Disconnecting and Connecting

- Remove headlamp.

- Remove screws - arrows -.

- Remove the HID headlamp control module from the headlamp housing.

Installing

Install in reverse order of removal, noting the following:

- Check seal between High-intensity Gas Discharge Lamp Control Module and headlamp housing.

- Install headlamp.

- Connect battery. Actions to be taken:

• Battery in engine compartment => Battery In Engine Compartment, Disconnecting and Connecting

• Battery in luggage compartment => Battery In Luggage Compartment, Disconnecting and Connecting

Tightening Specifications

Ignition Coil for Gas Discharge Lamp

Danger to life due to high voltage.

• Usage and safety information for gas discharge headlamps.

Removing

- With ignition switched off, disconnect ground cable at battery.

• Battery in engine compartment, refer to => [ Battery in Engine Compartment, Disconnecting and Connecting ] Battery In Engine Compartment, Disconnecting and Connecting

• Battery in luggage compartment, refer to => [ Battery in Luggage Compartment, Disconnecting and Connecting ] Battery In Luggage Compartment, Disconnecting and Connecting

- Preparations for working on headlamps.

- Release retainer tab - arrow - and detach housing cover for dipped beam from headlamp housing.

Left headlamp

Install in reverse order of removal, noting the following:

• Harness connector must only be connected with ignition coil installed.

- Check if recess in housing of ignition coil for gas discharge lamp and recess in pressure ring align completely with each other - arrows -.

- Mount the HID headlamp ignition coil to the headlamp.

Headlamp Housing Repair Set, Installing

• Headlamp mounting tabs that have broken off can be replaced by installing the repair set. Completely replacing the headlamp is not necessary.

• There are different repair kits for left and right headlamps. Refer to the electronic parts catalog ETKA.

Procedure

- Remove headlamp with broken mounting tab.

- Remove remains of broken mounting tab at headlamp housing.

- Place mounting straps - 2 - and - 3 - from repair kit on headlamp housing and secure tabs with straps - 1 - and - 4 -.

Tightening Specifications