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Jake
Jake, Technician
Category: Audi
Satisfied Customers: 2399
Experience:  Over 30 years experience, 17 years with Audi, Factory trained
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how do I remove the headlight assembly on my 2006 AudiTT C

Customer Question

how do I remove the headlight assembly on my 2006 AudiTT Coupe????
Submitted: 5 years ago.
Category: Audi
Expert:  Jake replied 5 years ago.

Hello,

 

Thank You for choosing Just Answer for your query. Yes, I can help you.

 

Headlight Housing, Removing And Installing

Note: Removal and installation procedure is identical for headlight housings with normal (halogen) and High Intensity Gas Discharge (HID) lamps.

CAUTION: Before beginning repairs on the electrical system:

  • Obtain the anti-theft radio security code.
  • Switch the ignition off.
  • Disconnect the battery Ground (GND) strap.
  • After reconnecting battery, re-code and check operation of anti-theft radio. Also check operation of clock and power windows according to Owner's Manual.

WARNING:

  • HIGH VOLTAGE!
  • Always disconnect battery Ground (GND) strap prior to servicing any parts of the HID lamp system marked with the yellow "HIGH VOLTAGE!"symbol.
  • After disconnecting battery, briefly turn headlights on and off in order discharge any residual voltage.

Removing:

  • Remove front bumper
  • Remove engine compartment trim,right/left.
  • Remove cover for headlight, left or right (press locking pin at the relevant spring clip, but not all the way through, and remove spring clip upward).

 

graphic

 

  • Unscrew 3 combi bolts -1- (tightening torque: 6 Nm ).
  • The headlight is just a press fit in retainer -3-. Retainer -3- is secured with combi bolt -2- (tightening torque: 6 Nm ).
  • Pivot headlight outward and pull out from retainer -3-.
  • Disconnect electrical connectors on headlight and remove headlight housing from opening.

Installing

 

graphic

 

Install in reverse order of removal, noting the following:

  • After installation, the headlight must be aligned flush with the contours of the bumper and body.
  • The adjuster screw provided for this purpose (dotted circle) is accessible from the front through the radiator grille.
  • Using a suitable tool -5-, loosen securing bolt -4-
  • Using a Phillips-head screwdriver -6-, turn adjuster screw -3- so that headlight lens -1- is flush with bumper -2-.
  • Tighten securing bolt -4- again.
  • Check/adjust headlights after installing.

 

 

I hope that I have answered your questions and addressed your concerns. Should you have any further questions for me, please do not hesitate to ask. I want you to be 100% satisfied with my answer.

 

Positive feedback and bonuses are always appreciated! If you accept my answer please click on the "ACCEPT" button by THIS answer.

 

Thank You!

Jake "THE AUDI DOCTOR"

Expert:  Jake replied 5 years ago.

Front Bumper, Removing, Installing And Assembly Overview

 

graphic

 

1-Trim

Removing:

  • Open engine hood.
  • Detach front part of wheel housing liner.
  • Remove screws - 3 - and take off securing strip - 2 -.
  • Remove screws - 14 - and - 16 -, then detach wheel spoiler - 15 -.
  • Release quick-release fasteners on wheel housing liners and noise insulation Fig. 2.
  • Remove screws - 17 - at bottom of trim from noise insulation.
  • Unscrew nuts - 11 - from inner side of wheel housing.
  • Loosen screws - 10 - and press guide profile - 12 - slightly downward.

graphic

 

CAUTION: If guide profile is not loosened, trim cannot disengage from retainers, and paintwork may be damaged.

  • Detach hose at connecting piece on vehicles with headlight washers.
  • Detach trim toward the front.

2-Securing strip
3-Combi screw

  • 6 Nm

4-Combi bolt

  • 35 Nm

5-Securing nut

  • Hold nut with open-ended spanner when tightening combi bolt - 4 -.

6-Cross-head bolt

  • For pre-assembly
  • Unscrew when removing bracket - 8 -.

7-Hexagon bolt

  • 35 Nm

8-Bracket

  • Trim - 1 - and bumper - 5 - removed
  • To remove, unscrew bolts - 7 - and pull bracket out of longitudinal member

9-Bumper

  • Trim - 1 - removed
  • To remove, unscrew combi bolt - 4 - and detach bumper

NOTE: Clips must be pressed into fender before installing bumper Fig. 1.

 

10-Screws

  • 1.5 Nm
  • Before detaching trim - 1 -, loosen screws so that retainers on guide profile - 13 - disengage from trim.

11-Hexagon nut with collar

  • 6 Nm
  • Only accessible after removal of wheel housing liner

12-Guide profile

  • Trim - 1 - engages in side of guide profile
  • To enable trim - 1 - to engage upon installation, press guide profile upward as far as it will go and tighten screws - 10 -.

13-Expanding clip

  • Expanding clips must be pressed into fender before installing trim - 1 - Fig. 1

14-Self-tapping screw

  • 1.5 Nm

15-Wheel spoiler

  • Detach before removing trim - 1 -

16-Self-tapping screw

  • 1.5 Nm

17-Combi bolt

  • 2.5 Nm

graphic

 

Fig. 1 Pressing in expanding clips

  • Before installing trim - 4 -, it is necessary to press clips - 2 - into fender - 3 -.
  • Tighten hexagon collar nut - 1 - to 6 Nm

graphic

 

Fig. 2 Detaching wheel spoiler

  • Unscrew Torx screws - arrow A - and 2 screws from underside.
  • To detach wheel housing liner, release quick-release fasteners - arrow B -.

Thank You!

Jake

 

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