Sunday, June 12, 2011

how to replace headlight on audi a6 and a4?

You will need a 7-point star screwdriver (6+ inches)

1) unscrew the two screws on the tabs above the headlight fixture (if one is missing its not a big deal)

2) unscrew the screw on the bottom of the light fixture. It will be on the inside bottom of the light (towards the grille).

3) For the driver side: unscrew the screw that is slightly infront of the power steering reservoir (if its stuck you may need a wrench to get some movement). This screw only needs to be loosened, don't unscrew it all the way.

For the passenger side: unhook the left part of the air filter (don't worry, it pops in and out easily) there should be a screw towards the hole for the air filter on the upper left of the light, loosen it.

4) Slide the headlight fixture out of the car and undo the little metal clips over the covers. take off which ever cover holds the old bulb and replace it witht he new one. BE CAREFUL! DON;T TOUCH THE BULB WITH YOUR FINGERS, THE OIL MAY CAUSE THEM TO EXPLODE


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Removing :--

For right headlight, remove rear part of air intake duct.
Remove cover from headlight housing.

Remove connector -2- for low beam bulb.
Remove wire clamp -1- and take bulb out of housing.
Installing

Install new bulb in housing.
CAUTION! Do not touch the glass part of the bulb with bare hands .

Secure base of bulb with wire clamp.
Reinstall connector and install cover on headlight housing.
Secure cover on housing with wire retainers.
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Here's what you'll need:

-- Extra long, flat-edged screwdriver
-- Replacement bulb (@$10-15 at an auto parts store) -- exact model number can be found in manual I believe or any self-respecting auto store will be able to look it up for you.
-- A hex (star-head shaped) screwdriver
-- bright flashlight

1. If you are changing the bulb on the passenger side, you first need to remove the air duct housing, since it gets in the way. Take out screws on top and squeeze/pull housing gently out of duct (easy to see how it fits together)
2. If changing driver's side, go to step 3
3. Remove 2 or 3 hex screws ontop of underhood lip that secures the top of the headlight assembly
4. Loosen but don't remove (2 turns at most) two screws at the base of the headlight assembly (way down inside the engine compartment) with the extra long screwdriver
5. Gently slide entire headlight assembly out so until you can reach the back of it
6. Release metal clip that holds headlight socket in place
7. Pull headlight socket free and remove bulb
8. Put in new bulb and slide socket back into assembly
9. Clip in place
10. Slide headlight assembly back into front end, making sure metal brackets are under base screws
11. Tighten base screws
12. Replace hex screws on top
13. Replace air duct housing (if you removed it)

And you're done! This takes 10 to 30 minutes, working slowly and carefully

FYI, you can buy extra bright bulbs (they come in a two-pack for about $35), so if you want more light you may want to take this opportunity to upgrade them both or you can use DRL bulbs.

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Removal & Installation



Front

Remove the front bumper as follows:

  1. On A4 models, remove the left and right lower bumper air grilles by carefully prying them out of the bumper using a suitable pry tool that will not damage the painted surface of the bumper and remove the hex socket bolt securing the cover to the front bumper shocks.
  2. Remove the fasteners that secure the inner fender lining to the front bumper.
  3. On A4 models:
    1. Grasp the end of the bumper cover firmly at the wheel well and press down while pulling the top most portion outward to release the cover from the top of the plastic holding bracket.
    2. Then while pulling out on the upper portion of the cover, lift the bottom upward to fully release the bumper from the bumper side bracket.
    3. Access the front bumper mounting fasteners through the lower air intake opening and remove the bumper-to-bumper energy absorbing strut mounting fasteners with a 6mm hex tool.

  4. On Passat models, remove the turn signal assemblies by releasing the retaining spring and remove the fender cover mounting fastener.
  5. Using both hands, hold the area of the bumper securely where the inner fender lining fasteners were removed and pull down on the bumper firmly and pull the topmost portion of the bumper outward to release the bumper from the plastic mounting saddle. Then while pulling outward on the upper portion of the bumper, lift the bumper slightly, and pull the lower portion of the bumper outward to release the bumper from the bottom of the plastic mounting saddle.
  6. Carefully pull the bumper assembly forward away from the vehicle and place on a soft surface that will not damage the painted areas.
  7. Installation is in reverse order of removal noting the following;
  8. On A4 models, after installing the bumper cover-to-bumper shock fasteners, to seat the side of the bumper cover into the side brackets;
    1. Pull outward on the upper portion of the bumper cover and lift upward while pressing on the lower side portion of the bumper cover until it is seated in the bottom jaw of the bracket.
    2. Press down far enough on the bumper cover for the upper portion of the cover to properly align itself with the lower portion of the fender and rap the upper portion of the bumper cover sharply using the palm of your hand to seat the cover into the upper jaws of the bracket.


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Hood

Alignment



Once the hood is installed, tighten the hood-to-hinge bolts just snug. Close the hood and check for perfect seam alignment. The hood seams are one of the most visible on the car; the slightest error will be plainly obvious to an observer.

Loosen the bolts and position the hood as necessary, then snug the nuts and recheck. Continue the process until the hood is properly centered, level with the fenders, and aligns evenly at all the seams.


NOTE
Do NOT adjust hood position by moving the latch, however the latch assembly may have to be moved and readjusted if the hood has been moved.

The hood bolts and the hinge mount bolts may be loosened just enough to adjust their positions. When everything aligns correctly, tighten the bolts securely.

The elevation of the hood at the latch end may be adjusted by turning the rubber stops or cushions. These bumpers have threaded bottoms and move up or down when turned. An annoying hood rattle on bumps may be caused by missing cushions, or misalignment of the hood.

Hood Lock Carrier Service Position



Setting The Service Position

To allow clearance for engine compartment related component removal, repairs and maintenance on all A4 and 1998-00 Passat models, the front body section of the vehicle must be moved forward. This procedure is referred to as placing the (hood) lock carrier in the service position.

To place the (hood) lock carrier in the service position requires removal of the front bumper and the upper radiator support/(hood) lock carrier assembly must be loosened and moved forward where it is held in place by reinstalling the upper mounting bolts.

To place the (hood) lock carrier in the service position:

  1. Remove the front bumper. For additional information, please refer to the following topic(s): Front Bumper, Removal and Installation.
  2. Matchmark the front bumper shock-to-body panel for reinstallation and remove the bumper shocks.
  3. Install Tool No. 3369 or place a 3 / 8 inch (9mm) inside diameter sleeve, about 4 inches (100mm) long around the 8mm front bumper mounting bolts such that 1 inch (25mm) of the threads are exposed, and thread them into the threaded hole just above the inner fasteners for the front bumper shock mounts. This is used to support the (hood) lock carrier assembly once it has been detached from the body.
  4. Disconnect the hood release cable by lifting the small retaining bracket and spreading the forked clevis to clear the pins.
  5. Detach the (hood) lock carrier from its body mounting points leaving all electrical wiring, coolant and air conditioner hoses attached.
  6. Carefully move the (hood) lock carrier forward and if necessary, secure it in place by aligning the lock carrier upper rearmost fastener holes with the forward most fastener holes of the front fenders and installing one upper fastener on both sides of the upper inner fender-to-carrier mounting point.
  7. Installation is in reverse order of removal.



Click image to see an enlarged view

Fig. Bumper mounting fastener (1), energy absorbing strut fasteners (2), strut assembly (3), saddle (4), bumper cover (5), spoiler (6) and liner fastener (7)-A4 models and 1998-00 Passat models



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Fig. Exploded view of the hood lock carrier assembly-A4 models and 1998-00 Passat models



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Fig. The hood lock carrier assembly (1) secured in the service position with the mounting fastener (2) installed



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Fig. Remove the self-tapping fasteners securing the inner fender to the front bumper cover



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Fig. Remove the fasteners securing the front bumper cover to the fender



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Fig. Remove the turn signal assembly to access and remove the upper fender cover fasteners



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Fig. Disconnect the hood safety catch release handle



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Fig. Once all of the bumper cover fasteners are removed, grasp the sides of the bumper, pull outward, then . . .



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Fig. . . . carefully pull the bumper away from the vehicle



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Fig. A frontal view of the vehicle with the front bumper cover and bumper beam removed



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Fig. Remove the fasteners along the top of the hood lock carrier



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Fig. Remove the hood lock carrier to upper fender fasteners



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Fig. Matchmark the bumper shock fasteners to ensure proper alignment during assembly



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Fig. Remove the outer support bracket fasteners, then . . .



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Fig. . . . remove the support



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Fig. Apply masking tape to the outer edges to protect the painted finish of the fender



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Fig. Install a metal sleeve around the long hex head bumper shock-to-beam mounting bolts and . . .



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Fig. . . . install the sleeved bolt into the front support bracket. The sleeved bolts are used to support the lock carrier once it is released from the front of the vehicle



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Fig. Matchmark the front bumper shock mounting area before removal for proper alignment during assembly

Removal & Installation





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Fig. Use a suitable paint marker to matchmark the installed position of the hood brackets



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Fig. Stuff a soft clean cloth between the body and the rear edge of the hood. This protects the paint on both components, and allows some support when removing the hood


NOTE
The help of an assistant is recommended when removing or installing the hood.

  1. Open and support the hood.
  2. Disconnect the negative battery cable.
  3. Protect the body with covers to prevent damage to the paint.
  4. Use a suitable marker, or scribe marks around the hinge locations for reference during installation.
  5. Unplug any electrical connections and windshield washer hoses that would interfere with hood removal.
  6. If equipped with a gas charged lifting shock, disconnect the shock from the hood.
  7. While an assistant helps secure the hood, unfasten the attaching bolts, then remove the hood from the vehicle.

To install:

  1. Place the hood into position. Install and partially tighten attaching bolts.
  2. Adjust the hood with the reference marks and tighten the attaching bolts.
  3. Check the hood for an even fit between the fenders and for flush fit with the front of the fenders. Also, check for a flush fit with the top of the cowl and fenders. If necessary, adjust the hood latch.
  4. Attach any electrical connections or windshield washer hoses that were disconnected during hood removal.

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Fenders

Removal & Installation



The front fenders are bolted onto the body shell and the hood lock carrier on A4 and Passat models and can be removed and installed with basic hand tools. The rear fenders are integral with the body shell. Replacement of the rear fenders requires the use of specialized equipment. Replacement of the rear fenders should only be performed by a certified body repair technician, who can use approved equipment in accordance with the manufacturer's instructions, standards and specifications.

  1. Remove the front bumper.
  2. Remove the inner wheel liners.
  3. Remove the turn signal assembly and disconnect the electrical connection for the side turn signal light.
  4. Apply protective tape around the surrounding body panels and exposed edges.
  5. Remove the fender mounting fasteners and remove the fender.
  6. Installation is in reverse order of removal noting the following:
  7. Tighten the fender bolt and washer assemblies to 66 inch lbs. (7.5 Nm).
  8. Tighten the Phillips screw and the bolt for the threaded rivet to 40 inch lbs. (4.5 Nm).



Click image to see an enlarged view

Fig. Front fender fastener locations

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