VW Passat & Audi A4 1990-2000

Headlights

Print


CAUTION
NEVER touch the clear lens of a headlight bulb prior to installation. If the bulb has been touched or come in contact with debris, use a clean soft cloth dampened with rubbing alcohol and clean the bulb, then wipe dry before installing.

REMOVAL & INSTALLATION
  1. Open the hood and if equipped with a rubber access cover, remove the cover over the back of the headlight assembly, and then disconnect the electrical connector from the bulb.
  2.  
  3. If a rubber seal/cover is mounted around the bulb, disconnect the electrical connector from the bulb, and then remove the rubber seal/cover.
  4.  
  5. Once the electrical connector has been disconnected, squeeze the ends of the retaining bracket inward, then pivot the retainer away from the rear of the headlight assembly.
  6.  
  7. Grasp the bulb securely and remove, noting the location of the alignment tabs for installation. Allow the bulb to cool before removing it from the headlight assembly.
  8.  

To install:


NOTE
Do NOT touch the glass portion of the new bulb. This will shorten the life of the bulb.

  1. Install the new bulb into the headlight housing and squeeze the ends of the retaining bracket inward while pivoting the retainer toward the rear of the headlight assembly. Release the retaining bracket making sure it is fully seated in its retainer.
  2.  
  3. The balance of assembly is in reverse order of removal.
  4.  



Click image to see an enlarged view

Fig. On some models, a rubber cover is removed to access the bulb-1.8L Passat model shown



Click image to see an enlarged view

Fig. Once the cover is removed the wiring can be accessed and disconnected-1.8L Passat model shown



Click image to see an enlarged view

Fig. The bulb is retained by metal bracket. The ends are squeezed toward one another to release them from their retainers-1.8L Passat shown

AIMING

The following items should be considered before aiming the headlights:



Check and set tire pressures to specification
 
Vehicle's fuel tank full or an appropriate load in the trunk
 
Have a load equivalent to the driver's weight on the driver's seat
 
On vehicles with Xenon® headlamps, wait 30 seconds after switching them on
 

  1. Park the vehicle on level ground, so it is perpendicular to and, facing a flat wall about 25 ft. (7.6m) away.
  2.  
  3. Remove any stone shields, if equipped, and switch ON the lights.
  4.  
  5. Using a Phillips-head screwdriver or suitable hex tool, aim them as follows:
  6.  
    1. The horizontal distance between the center of the light beams on the wall should be the same as between the lights themselves.
    2.  
    3. For fog lights, the vertical height of the light beams above the ground should be 4 in. (10cm) less than the distance between the ground and the center of the lamp lenses.
    4.  
    5. For driving lights, the vertical height should be even with the distance between the ground and the center of the lamp.
    6.  

  7. Test to make sure the lights work correctly, and the light pattern is even.
  8.  



Click image to see an enlarged view

Fig. The head light alignment adjusters are located on the back of the assembly. Access holes are provided as necessary-2.0L Passat GLS model shown

 
label.common.footer.alt.autozoneLogo