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Headlight Assembly Replacement
 
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Pelican Technical Article:

Headlight Assembly Replacement

Jared Fenton

Time:

2 hours2 hrs

Tab:

$150 to $1,200

Talent:

***

Tools:

10mm thin wall driver, magnet, small standard screwdriver

Applicable Models:

Audi A6 (1997-04)
Audi A6 Quattro (1997-04)
Audi S6 (2002-03)

Parts Required:

Headlight Assembly

Hot Tip:

Put a magnet on the driver to remove the inner 10mm bolt

Performance Gain:

Better lighting at night

Complementary Modification:

Install HID lighting

The headlight assemblies on the C5 Audi A6 are subject to constant abuse from the elements. Over the years, hazed over or cracked headlight lenses are very common on these cars. The good news is that they are easily replaced.

Note that the headlight assemblies must be removed in order to replace the headlight bulbs. See our article on Replacing Light Bulbs on the C5 Audi A6 for more information.

You'll need to have a thin wall 10mm driver and extension to remove the inner mounting bolt. It makes the job much easier. The procedure for removing the headlight assemblies is the same for both sides.

Shown here is a new headlight assembly for the C5 Audi A6 available from Pelican Parts.
Figure 1

Shown here is a new headlight assembly for the C5 Audi A6 available from Pelican Parts. Replacing a headlight assembly is an easy way to improve your lighting at night or the overall appearance or the car. It is also helpful to try to restore a hazed over lens. See our article on Headlight Refinishing for more information

Left and Right Sides of car: Loosen and remove the two 10mm bolts (green arrows) securing the top of the headlight assembly to the car.
Figure 2

Left and Right Sides of car: Loosen and remove the two 10mm bolts (green arrows) securing the top of the headlight assembly to the car. You'll need a thin wall 10mm socket on an extension to access the inner mounting bolt through the access hole (purple arrow). It helps to have a magnetic socket or place a magnet on the tool to keep from losing the screw. See Picture 6 for further clarification.

Left and Right Sides of car: Loosen and remove the 10mm mounting bolt (green arrow) holding the headlight to the mount near the radiator.
Figure 3

Left and Right Sides of car: Loosen and remove the 10mm mounting bolt (green arrow) holding the headlight to the mount near the radiator. It is difficult to show the bolt head in this picture, but you will be able to see it.

Left and Right Sides of car: Carefully pull the headlight out as shown here from near the radiator and angle it slightly downward.
Figure 4

Left and Right Sides of car: Carefully pull the headlight out as shown here from near the radiator and angle it slightly downward. It takes a little effort to remove it because of the electrical connections on the underside, just maneuver the headlight until it can be removed.

Left and Right Sides of car: Press the tabs on the main electrical connector (green arrow) and pull it off of the bottom of the headlight assembly.
Figure 5

Left and Right Sides of car: Press the tabs on the main electrical connector (green arrow) and pull it off of the bottom of the headlight assembly. Carefully pull the tabs on both sides of the ballast electrical connector (purple arrow). Pull the connector off the ballast.

Left and Right Sides of car: Shown here is the location of the inner mounting bolt on the chassis (green arrow).
Figure 6

Left and Right Sides of car: Shown here is the location of the inner mounting bolt on the chassis (green arrow). As you can see, it's a bit challenging to access it. Use a long, thin wall 10mm driver with a magnet to locate the bolt through the upper access hole (purple arrow), securing the headlight assembly in place. Once located, install the rest of the mounting bolts.

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