Bi-Xenon Gas Discharge Headlamps With Cornering Lamp, From 06.2008
Bi-Xenon Gas Discharge Headlamps with Cornering Lamp, from 06.2008
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 ]
=> [ Headlamp Housing ]
=> [ Headlamp Housing Mount ]
=> [ HID Headlamp Bulbs ]
=> [ LED Parking Lamp/DRL Modules ]
=> [ Low Beam Reflector Motors ]
=> [ Headlamp Beam Adjustment Motor ]
=> [ Left and Right Dynamic Cornering Lamp Motors ]
=> [ Front Turn Signal Bulb ]
=> [ HID Lamp Control Module ]
=> [ Headlamp Power Output Stages ]
=> [ 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.
Headlamp Housing
Danger to life due to high voltage.
• Usage and safety information for gas discharge headlamps.
Removing
- With ignition switched off, disconnect battery ground wire. Refer to => [ Battery in Engine Compartment, Disconnecting and Connecting ] Battery In Engine Compartment, Disconnecting and Connecting.
- Remove front bumper cover.
- If equipped, remove the nozzle for the headlamp washer system. Refer to => [ Headlamp Washer System Spray Nozzles ] Headlamp Washer System Spray Nozzles.
- Disconnect the electrical connector.
- Remove the bolts - 2, 3 and 5 -.
- Release the clamps on the back side of the fender - arrow - and then remove the headlamp housing - 4 - and mount - 1 - forward and out of the body.
Installing
Install in reverse order of removal, observing the following:
- Install the headlamp housing and mount to the lock carrier and fender and tighten the screws - 2, 3 and 5 - by hand.
- Install the front bumper cover.
- Align the headlamp housing gap dimensions according to the body contours.
- Tighten the screws - 2, 3 and 5 -.
- Connect battery. Required actions => Battery In Engine Compartment, Disconnecting and Connecting.
- Adjust headlamps. Refer to => [ Headlamps, Checking and Adjusting Conditions ] Testing and Inspection.
Tightening Specifications
Headlamp Housing Mount
Removing
- Remove headlamp housings.
- Remove screws - 1 - and - 3 -.
- Remove the headlamp housing - 2 - from the mount - 4 - by moving the headlamp housing forward and up - arrow -.
Installing
Install in reverse order of removal, observing the following:
- Check adjustment nuts - 2 - on adjusters - 1 - and - 3 - for ease of movement - arrows -.
- Screw adjuster as far down as it will go, but do not tighten.
- Install the headlamp housing - 2 - into the mount - 1 -; the guide ridges on the headlamp housing must fit into the guides on the mount - arrows -.
- Install the mount and headlamp housing to the lock carrier and fender and tighten the screws by hand.
- Install the front bumper cover.
- Align the headlamp housing gap dimensions according to the body contours.
- Tighten the screws in sequence - 1 through 4 -.
• When tightening the screws - 2 - and - 3 - the adjusting nut on the adjusting element will turn by itself against the mounting point of the headlamp housing and secure it.
- Adjust headlamps. Refer to => [ Headlamps, Checking and Adjusting Conditions ] Testing and Inspection.
Tightening Specifications
HID Headlamp Bulbs
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 battery ground wire. Refer to => [ Battery in Engine Compartment, Disconnecting and Connecting ] Battery In Engine Compartment, Disconnecting and Connecting.
- Remove the front wheel housing liner.
- Remove the low beam housing cover - 1 - from the headlamp housing - arrow -.
- Rotate the HID bulb - 2 - in the - direction of the arrow - and remove it from the housing.
- Disconnect the electrical connector - 1 -.
- Release the clamp - arrow A - and open the adapter ring - 2 - - arrow B -.
- Remove the adapter ring on the HID headlamp - 1 - - arrow C -.
Installing
Install in reverse order of removal, observing the following:
- Mount half of the adapter ring - 3 - with the securing tabs onto the HID headlamp - 2 -.
• The securing tabs - 4 - and - 5 - must be inserted into the mounts.
- Close the second half - 1 - until it engages audibly.
- Connect the connector and insert the new HID bulb in the housing. Do not touch the glass bulb with bare hands.
• Installation location is in the electrical connection faces down.
- Install the front wheel housing liner.
- Connect battery. Required actions => Battery In Engine Compartment, Disconnecting and Connecting.
LED Parking Lamp/DRL Modules
The DRL bulbs are LEDs and are integrated inside the headlamp housing. The LEDs cannot be replaced. The entire headlamp must be replaced.
Low Beam Reflector Motors
The lower beam cover sits in the headlamp housing and cannot be replaced separately if it is faulty.
Headlamp Beam Adjustment Motor
The headlamp beam adjustment motor cannot be replaced individually.
Left and Right Dynamic Cornering Lamp Motors
The dynamic cornering lamp motor cannot be replaced individually.
- Replace the headlamp housing.
Front Turn Signal Bulb
Removing
- Switch off ignition and remove ignition key.
- Preparations for working on headlamps.
- Remove the high beam housing cover - 1 - from the headlamp housing - arrow -.
- Turn socket - 1 - counterclockwise - arrow - and remove from housing.
- Press the release downward - arrow - and disconnect the connector - 2 - from the lamp - 1 -.
Installing
Install in reverse order of removal, observing the following:
- Insert the new bulb into the housing without touching the bulb with bare hands.
- Close the housing cover.
HID Lamp Control Module
Danger to life due to high voltage.
• Usage and safety information for gas discharge headlamps.
Removing
- Remove headlamp housings.
- Remove the bolts - arrows -.
- Remove control module - 1 - from headlamp housing.
- Disconnect the adapter cable - 4 - and the electrical connector - 3 - on the HID headlamp control module.
- Remove the HID headlamp control module.
Installing
Install in reverse order of removal, observing the following:
- Check seal - 2 - between gas discharge headlamp control module and headlamp housing for damage.
- Install the headlamp housing.
Tightening Specifications
Headlamp Power Output Stages
Danger to life due to high voltage.
• Usage and safety information for gas discharge headlamps.
Removing
- With ignition switched off, disconnect battery ground wire. Refer to => [ Battery in Engine Compartment, Disconnecting and Connecting ] Battery In Engine Compartment, Disconnecting and Connecting.
- Remove headlamp housings.
- Remove the bolts - arrows -.
- Remove the headlamp power output stage - 1 - from the headlamp housing.
Installing
Install in reverse order of removal, observing the following:
- Check the seal - 2 - between the power output stage and headlamp housing.
- Install the headlamp housing.
Tightening Specifications
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 - 1 - and - 3 - from repair kit on headlamp housing and secure tabs with straps - 2 - and - 4 -.
Tightening Specifications
