Removing and installing headlight dipped beam bulb (LED)

Special tools and workshop equipment required

Front-end hook -3370-

Torque wrench -V.A.G 1783-

Torque screwdriver -VAS 6494-

ESD (electrostatic discharge) workplace -VAS 6613-

Caution Work on LED modules should be performed only at designated ESD workplaces.

Removing

• Remove headlight → Chapter.
• Using a hammer, carefully release housing cover -1- along predetermined breaking line -2-.
• Remove housing cover -1- from headlight.

• For fine adjustment, unscrew bolt -1- completely from bracket -2--arrow-.

• Remove bolts -2-.
• Remove bracket -1-.
• Release connectors -5- and pull off.
• Using front-end hook -3370-, pull retaining clip -3- slightly towards rear to release.
• At the same time, swing retaining clip -3- upwards -arrows-.
• Remove LED modules for dipped beam headlight -4- towards rear from headlight.

Installing

WARNING Avoid any skin contact with the heat-conductive paste! If heat-conductive paste did get onto the skin, clean the affected area thoroughly using soap solution, for example.

• Apply a thin coat of heat-conductive paste -1- and -2- ( → Electronic Parts Catalogue “ETKA”) at side contact surfaces of LED modules -3-.

• Insert LED modules for dipped beam headlight -4- into headlight, and fit them in installation position.
• Swing retaining clips -3- downwards in opposite -direction of arrows-, and engage them audibly.
• Fit connectors -5-.
• Install bracket -1-, and tighten bolts -2-.

• Position template -1- ( → Electronic Parts Catalogue “ETKA”) relative to contour on headlight lens, and fix it in place.

• Position headlight in horizontal position at a distance of 3 to 5 m in front of a white wall.
• Turn lateral adjustment screws on outside at top of headlight to stop:

Turn towards right on front left headlight -MX1- (clockwise)

Turn towards left on front right headlight -MX2- (anticlockwise)

• Connect connector for headlight in vehicle and connector on removed headlight using adapter cable.
• Switch on light via rotary light switch -EX1-.

Fine adjustment on front left headlight -MX1-

• For fine adjustment, slowly screw in bolt -1- on bracket -2--arrow A-.

• Continue to slowly screw in bolt -1--arrow A- until the upper edge -4- of the brighter area and the upper edge -3- of the darker area line up with each other.

Fine adjustment on front right headlight -MX2-

• For fine adjustment, slowly screw in bolt -1- on bracket -2--arrow A-.

• Continue to slowly screw in bolt -1--arrow A- until the upper edge -4- of the brighter area and the horizontal edge -3- of the darker area line up with each other.

The darker area must remain visible on the right from the inflexion point.

Continued for both headlights

Caution Risk of damage to the headlight. Make sure the housing cover is correctly seated when installing. The ingress of water will lead to permanent damage to the headlight.

• Fit new housing cover -1- onto headlight.
• Screw in and tighten bolts -arrows A-.
• Install headlight → Chapter.
• Check headlight setting and adjust headlight if necessary → Booklet36.1

Specified torques

→ Chapter „Assembly overview - LED headlights“