Bi-Xenon Gas Discharge Headlamps With Cornering Lamp, Through 05.2008
Bi-Xenon Gas Discharge Headlamps with Cornering Lamp, 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 ]
=> [ HID Headlamp ]
=> [ Daytime Running Lamp Bulb ]
=> [ Parking Lamp Bulb ]
=> [ Low Beam Reflector Motors ]
=> [ Left and Right Dynamic Cornering Lamp Motors ]
=> [ Headlamp Beam Adjustment Motors ]
=> [ Left and Right Swivel Module Position Sensors ]
=> [ Turn Signal Bulb ]
=> [ Headlamp Power Output Stages ]
=> [ Headlamp Housing Repair Set, Installing ]
Preparing to Work on Headlamps
Left headlamp
- Remove the air filter housing.
- Slide both latches in - direction of arrow - and remove the E-box cover.
- Remove bolt - arrow -.
- Remove the relay and fuse box from the engine compartment E-box.
- Release the 26-pin connector - 1 - and the 40-pin connector - 2 - on the engine compartment E-box.
- Remove nuts - 1 - and - 2 -.
- Remove the engine compartment E-box - 3 - upward.
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.
- Remove the EVAP canister bracket - 3 -.
- Remove the screw on the fuel filler tube - 2 - for the washer fluid reservoir.
- Disconnect the engine coolant level warning switch (F66) connector on the coolant reservoir and free up the wiring harness.
- Remove the coolant reservoir screws - 1 - and lay the reservoir with the hoses still connected on the engine; tie it if necessary.
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 TORX wrench 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 the TORX wrench with body adhesive.
- Remove headlamp toward front from body.
- Unplug connector.
Installing
Install in reverse order of removal, observing 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. Refer to => [ Headlamps, Checking and Adjusting Conditions ] Testing and Inspection.
Tightening Specifications
HID Headlamp
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 spring clip - arrow - and remove the HID headlamp housing cover from headlamp housing.
- Disconnect the connector - 3 - using angled needle nose pliers.
- Release spring clips - 2 - and - 4 - and remove gas-discharge lamp - 1 - from housing.
• Ignore the - arrow -.
Installing
Install in reverse order of removal, observing the following:
- Insert the new HID bulb into the housing without touching the bulb with bare hands.
• Observe installation position. Electrical connection must face downward.
- Secure gas-discharge lamp with spring clips.
- Connect the connector and close the housing cover.
- Secure housing cover using wire clamp.
- Install the engine compartment E-box. Refer to => [ Left Engine Compartment E-Box, through 05.2008 ] Left Engine Compartment E-Box, through 05.2008.
- Connect battery.
• Battery in engine compartment => Battery In Engine Compartment, Disconnecting and Connecting
• Battery in luggage compartment => Battery In Luggage Compartment, Disconnecting and Connecting
Daytime Running Lamp 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.
- Turn bulb socket - 1 - counterclockwise - arrow - and remove from headlamp housing.
- Remove lamp from socket.
Installing
Install in reverse order of removal, observing the following:
- Insert bulb in housing, taking care not to touch glass bulb with bare hands.
- Secure socket by turning clockwise.
- Close the housing lid.
- Secure housing cover using wire clamp.
Parking Lamp 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 socket - 1 - from housing - arrow - by releasing two retainer tabs.
- Pull light bulb for parking lamp out of socket.
Installing
Install in reverse order of removal, observing the following:
- Insert new bulb into socket, do not touch glass cone with bare hands when doing so.
- Close the housing lid.
Low Beam Reflector Motors
The lower beam cover sits in the headlamp housing and cannot be replaced separately if it is faulty.
- Replace headlamp.
Left and Right Dynamic Cornering Lamp Motors
The dynamic cornering lamp position motor sits in the headlamp housing and cannot be replaced separately if it is faulty.
- Replace headlamp.
Headlamp Beam Adjustment Motors
The headlamp range control positioning motor sits in the headlamp housing and cannot be replaced separately if it is faulty.
- Replace headlamp.
Left and Right Swivel Module Position Sensors
The swivel module position sensor sits in the headlamp housing and cannot be replaced separately if it is faulty.
- Replace headlamp.
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, observing the following:
- Insert bulb in housing, taking care not to touch glass bulb with bare hands.
- Install front wheel housing liner.
Headlamp Power Output Stages
Danger to life due to high voltage.
• Usage and safety information for gas discharge headlamps.
Removing
- Remove headlamp.
- Remove screws - arrows -.
- Remove the power Output Stage - 1 - from headlamp housing.
- Disconnect the adapter wire - 2 - for the HID headlamp bulb on the power output stage - 1 -.
Installing
Install in reverse order of removal, observing the following:
- Check seal between power output stage and headlamp housing.
- Install 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 tabs.
- Remove remainder of broken mounting tabs on headlamp housing.
- Place mounting straps - 2 - and - 3 - from repair kit on headlamp housing and secure tabs with straps - 1 - and - 4 -.
Tightening Specifications
