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Audi A4 Headlight Assembly and Bulb Replacement
 
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Pelican Technical Article:

Audi A4 Headlight Assembly and Bulb Replacement

Steve Vernon

Time:

1 hour1 hr

Tab:

$7 to $600

Talent:

**

Tools:

T30 Torx, Philips head screwdriver

Applicable Models:

Audi A4 (2002-05)
Audi A4 Cabriolet (2003-06)

Parts Required:

New assembly or bulbs

Hot Tip:

Do not touch the bulbs with bare skin

Performance Gain:

See better at night

Complementary Modification:

Polish headlight lens

Headlight assemblies on Audi A4's can vary depending on the model. Some A4s are equipped with Bi-Zenon headlamps. Our project car came with standard Halogen bulbs. This article will show you how to remove the headlight assembly and replace the Halogen bulbs. Unlike many other vehicles, the headlight assembly must be removed from the vehicle to change the bulbs.

When changing bulbs always make sure not to touch the bulbs with your bare hands or anything with dirt, grease or oil on it. If you touch the bulb with your bare hands the natural oils in your skin can cause a "hot spot" on the bulb and can result in diminished life of the bulb.

Adjustment- There is a single T30 Torx bolt located on the upper section of the headlight assembly between the two mounting brackets (red arrow).
Figure 1

Adjustment- There is a single T30 Torx bolt located on the upper section of the headlight assembly between the two mounting brackets (red arrow). The bolt can be used to make adjustments on the fit of the assembly so it fits flush to the bodywork of the car. The headlight assembly also includes two adjustment devices for aiming the lights while mounted in the car. There are two plastic adjusters that you can turn with a Philips head screwdriver to assist in the vertical and horizontal adjustments (yellow arrows, one shown).

Adjustment- To make adjustments to the horizontal and vertical plane of the lights remove the plastic protective caps and insert a Philips head screwdriver into the adjustment mechanisms (red arrow).
Figure 2

Adjustment- To make adjustments to the horizontal and vertical plane of the lights remove the plastic protective caps and insert a Philips head screwdriver into the adjustment mechanisms (red arrow).

You will need to remove the headlight assemblies from the vehicle to change the bulbs.
Figure 3

You will need to remove the headlight assemblies from the vehicle to change the bulbs. Removing the assemblies is easy but there are a few simple things you will need to do first. Most people take a moment and put some tape around the bumper and fenders to avoid scratching the paint (green arrow). On the right side of the vehicle you will need to remove the air intake (yellow arrow), remove the two fasteners (red arrows) and remove the intake. If your car is so equipped remove the power steering cover on the left side.

To remove the assembly use a T30 Torx and remove the two Torx bolts connecting the top of the assembly to the upper cross member (red arrows).
Figure 4

To remove the assembly use a T30 Torx and remove the two Torx bolts connecting the top of the assembly to the upper cross member (red arrows).

There are two T30 screws that are located behind the assembly.
Figure 5

There are two T30 screws that are located behind the assembly. One is between the power steering reservoir. Use a T30 Torx and loosen the bolts two turns but do not remove it (red arrow).

The second is located between the upper radiator hose and the assembly; again use a T30 Torx and just loosen the bolt a few turns (red arrow).
Figure 6

The second is located between the upper radiator hose and the assembly; again use a T30 Torx and just loosen the bolt a few turns (red arrow).

Slide the headlight assembly forward out from the front of the vehicle and separate the wiring connection from the back (red arrow).
Figure 7

Slide the headlight assembly forward out from the front of the vehicle and separate the wiring connection from the back (red arrow). If you have smaller hands you can do this while the unit is in the vehicle but there is enough play in the wiring to allow you to separate it by gently pulling it forward.

With the unit out of the vehicle you can see the access points for the turn signal/ parking light (red arrow), the main headlight (yellow arrow) and the high beam (green arrow).
Figure 8

With the unit out of the vehicle you can see the access points for the turn signal/ parking light (red arrow), the main headlight (yellow arrow) and the high beam (green arrow).

To replace the turn signal bulb grasp the plastic knob and turn it counter clockwise (red arrow).
Figure 9

To replace the turn signal bulb grasp the plastic knob and turn it counter clockwise (red arrow). The piece along with the bulb will pull out from the unit. There is a gasket on the rear of the piece (red arrow) that you need to make sure makes a good seal when reinstalling. The bulb is a simple pull out press in fitting. As always do not touch the bulb with your bare hands or anything with dirt, grease or oil on it.

To change the headlight bulb release the wire clip (red arrow) and pull the cover off the back of the unit.
Figure 10

To change the headlight bulb release the wire clip (red arrow) and pull the cover off the back of the unit.

With the cover open reach in and release the wire clip (red arrow) that holds the bulb in the reflector.
Figure 11

With the cover open reach in and release the wire clip (red arrow) that holds the bulb in the reflector.

Pull the bulb and wiring out from the reflector mount (red arrow) and change the bulb.
Figure 12

Pull the bulb and wiring out from the reflector mount (red arrow) and change the bulb. It simply pulls out and is pushed in (yellow arrow). As always do not touch the bulb with your bare hands or anything with dirt, grease or oil on it.

To change the high beam bulb release the wire clip (red arrow) and pull the cover off the back of the unit.
Figure 13

To change the high beam bulb release the wire clip (red arrow) and pull the cover off the back of the unit.

With the cover open reach in and release the wire clip (red arrow) that holds the bulb in the reflector.
Figure 14

With the cover open reach in and release the wire clip (red arrow) that holds the bulb in the reflector.

Pull the bulb and wiring out from the reflector mount and change the bulb.
Figure 15

Pull the bulb and wiring out from the reflector mount and change the bulb. It simply pulls out and is pushed in (yellow arrow). As always do not touch the bulb with your bare hands or anything with dirt, grease or oil on it. Installation of the assembly is the reverse of removal.

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