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Pelican Technical Article:

Headlight Assembly Replacement

Jared Fenton

Time:

2 hours2 hrs

Tab:

$150 to $300

Talent:

*****

Tools:

T20 Torx Driver

Applicable Models:

VW Jetta GL (1999-05)
VW Jetta GLS (1999-05)
VW Jetta Wolfsburg (1999)

Parts Required:

Headlight assembly

Hot Tip:

Remove the front bumper cover to gain access

Performance Gain:

Better lighting at night

Complementary Modification:

Install HID lighting

The headlight assemblies on the Mk4 Jetta 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.

You'll need to remove both the front grille and also the front bumper cover to access the headlight assemblies. See our articles on Front Grille Removal and Front Bumper Cover Removal for more information.

Left and Right Sides of car: Shown here is one of the headlight assemblies on our project car.
Figure 1

Left and Right Sides of car: Shown here is one of the headlight assemblies on our project car. Notice the hazed over appearance of the headlight lens. Sometimes, these lenses can be polished with good results. Other times, they simply need to be replaced. You'll need to remove both the front grille and the bumper cover to access the headlight assembly mounting screws. See our articles on Front Grille Removal and Front Bumper Cover Removal for more information.

Left and Right Sides of car: From inside the engine compartment, press the tab on the electrical connector (green arrow) leading to the headlight assembly and pull it off.
Figure 2

Left and Right Sides of car: From inside the engine compartment, press the tab on the electrical connector (green arrow) leading to the headlight assembly and pull it off. Access to the right side headlight is much easier with the battery and battery box removed. See our articles on Battery Replacement and Battery Box Removal for more information.

Left and Right Sides of car: Loosen and remove the two upper T20 Torx screws (green arrows) securing the headlight assembly to the radiator support.
Figure 3

Left and Right Sides of car: Loosen and remove the two upper T20 Torx screws (green arrows) securing the headlight assembly to the radiator support.

Left and Right Sides of car - Loosen and remove the two lower T20 Torx screws (green arrows) securing the headlight assembly to the radiator support.
Figure 4

Left and Right Sides of car - Loosen and remove the two lower T20 Torx screws (green arrows) securing the headlight assembly to the radiator support. At this point, you can pull the old headlight assembly out and replace it with the new one. Installing the new headlight assembly is the reverse order of removal.



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Page last updated: Mon 12/5/2016 02:53:14 AM