Headlamp Reflector: Service and Repair

Replacing Reflector For Headlight







Remove complete headlight assembly.
ZKW headlights:
Unclip at top and bottom.







Installation:
Different clips are used.
Bevelled clips (1) are installed at top.







Pry off holders on left and right sides and remove frame with lens.







Press down on clips and take off both bulb covers.







Pull off earthing cable (1). Remove bulbs (2) and wires. Pull out bulb holder (3) for parking light.







Fully unscrew adjusting screws (4 and 5) for vertical and lateral headlight adjustment. Remove reflector.

Installation:
Screw studs in reflector at approximately the same position.







Rotate vertical aim adjuster approx. 45 ° and lever ball pin (1) laterally out of bracket.







Bosch headlights
Unclip at top and bottom. Remove frame with lens.







Press down on clips and take off both bulb covers.







Pull off earthing cable (1). Remove bulbs (2) and wires. Pull out bulb holder (3) for parking light.







Rotate vertical aim adjuster approx. 45 ° and lever ball pin (2) downwards out of bracket.







If elypsoidal headlights fitted:
Fully unscrew adjusting screws (4 and 5) for vertical and lateral headlight adjustment. Remove reflector.

Installation:
Screw studs in reflector at approximately the same position







If free-form headlights fitted:
Heat up clip and pry reflector forwards to remove.







Compact
Unfasten all clips and remove glass cover.







Fold back rubber seals (1).
Unfasten screws (2).







Lever out lens in forward direction.







Unclip bracket and remove reflector.