Campaign - Replace Headlight Reflectors: Overview
April 2005Subject: 2003-2004 Audi A4 Cabriolet and 2004 Audi S4 Cabriolet Vehicles
Equipped with Xenon Headlights
Replace Left and Right Xenon Headlight Reflectors
This is to inform you of the initiation of a safety recall campaign involving some 2003-2004 model year Audi A4 Cabriolet vehicles and some 2004 model year S4 Cabriolet vehicles equipped with xenon headlights.
Campaign Work Procedure
Parts:
Reflector Kit, part number 8H0 998 998 A contains:
- 1 - pr. gloves
- 1 - left headlight reflector
- 1 - right headlight reflector
Special Tools and Equipment:
- VAS 5051 or VAS 5052
- VAS 6017B K-wire adapter
- Hella Universal Beamsetter IV VAS 5107
Work Sequence
- Obtain anti-theft radio security code
- Switch ignition off
WARNING:
- Caution high voltage. Make sure to disconnect battery Ground (GND) strap before performing work on parts of high intensity gas discharge Headlights (xenon) marked with yellow high voltage symbol
- Headlights may be hot
- Open hood and slide battery cover to the right and remove
- Disconnect battery ground (GND) cable
Section A - Headlight Removal
Left headlight
- Remove cover -1- in engine compartment (left side), if present
Right headlight
- Remove cover -1- in engine compartment (right side), if present
- Remove bolts -arrows-
- Detach Evaporative Emission (EVAP) Canister Purge Regulator Valve -N80- -1- at air guide
- Remove air guide -2-
Both sides
- Apply adhesive tape below headlights to protect paint
- Remove bolts -1- and -4-
- Loosen bolt -2- several turns but do not remove
- Cut cable tie, if present
- Disconnect electrical harness connector -3-
- Swing headlight in direction of fender
- Remove headlight from body by pulling outward
Section B - Reflector Replacement
- Remove housing cover from headlight housing
- Disconnect connector -arrow- from headlight adjusting motor
- Disconnect ground cable -arrow- for gas discharge bulb from headlight beam screen
- Push harness connector for gas discharge bulb down slightly while turning counterclockwise -curved arrow-, then pull connector from gas discharge bulb
- Pull harness for gas discharge bulb from both mounting tabs -Pos. 2-
- Use Torx T20 to remove screws -arrows A, B and C-, holding gas discharge reflector in place
- Loosen screws -arrows 1 and 2- for headlight adjusting motor, but do not remove them
- Tilt headlight adjusting motor slightly, making sure connecting rod does not become disengaged from reflector assembly
- Put on gloves supplied in reflector kit to avoid damaging bulb and reflector
- Remove reflector
- If necessary, push cable to side and pull reflector out diagonally -arrow-
NOTE:
Glass portion of bulb must not be handled without gloves under any circumstances
- Remove Torx T10 screws -arrows- then remove retaining ring
- Pull gas discharge bulb out by base and lay carefully to the side
- Locate mark on new reflector -arrow- that indicates on which side of vehicle to install reflector (It is next to tab sticking out on edge of reflector)
- R - right headlight reflector
- L - left headlight reflector
- Install gas discharge bulb in new reflector, careful to only touch bulb base
- Pay attention to locating tabs -arrows-
- Set retaining ring on and install Torx T10 screws
- Examine position of headlight beam screen in headlight. Make sure it is properly located on guide pins -arrows-
NOTE:
Left and right side reflectors are different, pay attention to location
- Install new reflector in headlight housing
- Align reflector with headlight beam screen over guide pins -arrows-
- Using Torx T20 install screws -arrows A, B and C- for reflector
- Tighten two screws -arrows 1 and 2- for adjusting motor
- Connect ground cable on terminal at bottom of headlight beam screen
- Connect connector to headlight adjusting motor -arrow A-
- Install harness connector for gas discharge bulb -arrow B- by pushing it down slightly while turning clockwise
- Clip harness connector for gas discharge bulb in both places -arrows-
- Install headlight cover
- Repeat procedure for opposite headlight
Section C - Headlight Installation
- Install headlights in reverse of removal, making sure to:
- Push headlight horizontally up to stop on bottom headlight mount
- Align headlight to contours of body (gap widths)
- Install bolts -1-, -2- and -4- and torque to 6 Nm (53 in. lbs.)
- Connect electrical harness connector -3-
- Reconnect battery ground (GND) cable and tighten to 6 Nm (53 in. lbs.)
- Reinstall battery cover
- Set anti-theft radio code and check operation
- Set clock and power window pinch protection
- Set power seat memory initialization, if present
- Adjust headlights using VAS 5051 or VAS 5052 with VAS 6017B and VAS 5107 Hella Universal Beamsetter IV
- Replace air guide and engine covers
- Close hood
- Destroy and properly dispose of removed part(s)