Note. After carrying out activities that could affect the adjustment of the headlights, the headlights should be adjusted again.
Part 1. Headlights 1. Bolt. 4.5 Nm; 2. Front turn signal lamp: front left turn signal lamp -M5-; Front right turn signal lamp -M7-. 12 V, 24 W. Yellow; 3. Housing cover for high beam and turn signal; 4. Main beam lamp: left main beam lamp -M30-; Right main beam lamp -M32-. 12 V, 55 W (H7); 5. Lamp for daytime traffic. Left lamp for daytime running light system -L174-. Right lamp for daytime running lights -L175-. 12 V, 13 W; 6. Bolt. 4.5 Nm; 7. Headlight housing bracket; 8. Bolt. 4.5 Nm; 9. The nut is self-locking. Replace; 10. Explanation of lamp symbols for daytime driving lamps; 11. Low beam headlight bulb: left low beam headlight bulb -M29-; Right low beam headlight bulb -M31-. 12 V, 55 W (H7); 12. Housing cover for low beam/daylight/parking lights; 13. Explanation of the front side marker lamp symbols; 14. Front side marker lamp (only for vehicles incl. for USA). Front left side marker lamp -MZZ-. Front right side marker light bulb -M34-. 12 V, 5 W; 15. Parking light/daylight lamp. Left parking light bulb -M1-. Right parking light bulb -MZ-. Left lamp for daytime running light system -L174-. Right lamp for daytime running lights -L175-. 12 V, 13 W; 16. Headlight housing
Part 2. Repair kits for other vehicles 1. Headlight housing; 2. Exec. electric motor for headlight range control: ex. Left headlight range control motor -V48-; executive Right headlight range control motor -V49-; 3. Seal ring. Not supplied separately as a spare part; 4. Cover of the actuator housing for adjusting the headlight angle. To replace the actuator motor, the headlight housing must be cut. A housing cover is supplied for subsequent closing of the mounting hole; 5. Bolt from the actuator motor repair kit for adjusting the headlight angle. 2 Nm
Removing the headlight housing
Turn off the ignition. Set the light switch to position "0". Remove the front bumper trim. Disconnect email plug connection -5-. Release the wiring harness -6- from the bracket by opening the crimps -arrows B- and cutting the clamps -arrows A-. If present, remove the headlight washer hose -8- from the clamps. Disconnect the front Airbag crash sensor connector. Unscrew bolts -1,3,4,7- and remove headlight bracket -2- with headlight housing. When replacing the headlight housing, the bracket mount must be removed.
Installation
Installation in reverse order: place headlight housing -3- with bracket on radiator frame and wing arch. Tighten bolts -1,2,4,5- tightly.
The guide nose -arrow B- on the bracket -1 - of the headlight housing must fit into the groove of the radiator frame -3-. The guides -2- and -4- must fit into the mountings -arrow A-. Install the front bumper trim.
Align the gaps -3- along the contours of the body. Gap size = gap uniformity. Remove the front bumper trim. Tighten bolts -1, 2,4, 5-. Install the front bumper trim. Check the clearances again and, if necessary, repeat the adjustment of the clearances as described at the beginning. Adjust the position of the headlights.
Replacing low beam headlight bulb -M29-/-M31-
Turn off the ignition. Set the light switch to position "ABOUT". To remove the spacer clips -arrows-, carefully insert the pin -1- a distance -x- into the clip until it audibly clicks into place -arrow A-. Dimension -x- = 5 mm.
Remove the unlocked clip -2- with pin. Lift the cover -3- on the radiator frame and hang it on the radiator grille. Right side of the vehicle: remove the air housing. filter: vehicles with a gasoline engine. Open the clamp -2-arrow A-. Turn housing cover -1- in direction -arrow B- and remove.
Remove bolts -2- and -4-. Loosen bolt -3- 3 turns. Press headlight housing -1- in direction -arrow- all the way forward.
Remove lamp -1. from spring clips -arrows-. Disconnect plug connection -2- from lamp.
Installation
Installation in reverse order: insert the new lamp into the housing, but do not touch the glass bulb of the lamp with your bare hands. Insert the lamp, overcoming the resistance of the clamps, into the housing and connect the connector. Close the housing cover and secure with a clamp. Right side of the vehicle: install the air housing. filter: vehicles with a gasoline engine. Install the radiator frame trim on the radiator grille.
Replacing the high beam headlight bulb -M30-/-M32-
Turn off the ignition. Set the light switch to position "0". Right side of the vehicle: remove the air housing. filter: vehicles with a gasoline engine. Open clamp -2- -arrow-. Turn the housing cover -1- to the side and remove it.
Remove bulb -2- from spring clips -arrows-. Disconnect plug connection for bulb -1.
Installation
Installation in reverse order: insert the new lamp into the housing, but do not touch the glass bulb of the lamp with your bare hands. Insert the lamp, overcoming the resistance of the clamps, into the housing and connect the connector. Close the housing cover and secure with a clamp.
Right side of the vehicle: Installing the air housing. filter: vehicles with a gasoline engine.
Replacement of parking light bulb -M1-/-MZ-, front daytime running light bulb -L174-/-L175-
Turn off the ignition. Set the light switch to position "ABOUT". To remove the spacer clips -arrows-, carefully insert the pin -1- a distance -x- into the clip until it audibly clicks into place -arrow A-. Dimension -x- = 5 mm.
Remove the unlocked clip -2- with pin. Lift the cover -3- on the radiator frame and hang it on the radiator grille. Right side of the vehicle: remove the air housing. filter: vehicles with a gasoline engine. Open clamp -2- -arrow A-. Turn housing cover -1- in direction -arrow B- and remove.
Remove bolts -2- and -4-. Loosen bolt -3- 3 turns. Press headlight housing -1- in direction -arrow- all the way forward.
Turn the bulb -1- counterclockwise -arrow- and remove it from the housing. Unlock the spring latch -4- and disconnect the connector -3- from the lamp -2-.
Installation
Installation in reverse order: insert the new lamp into the headlight, but do not touch the glass bulb of the lamp with your bare hands. Close the housing cover and secure with a clamp. Right side of the vehicle: install the air housing. filter: vehicles with a gasoline engine. Install the radiator frame trim on the radiator grille.
Replacing daytime running light bulb -L174-/-L175-
Turn off the ignition. Set the light switch to position "0". To remove the spacer clips -arrows-, carefully insert the pin -1- a distance -x- into the clip until it audibly clicks into place -arrow A-. Dimension -x- = 5 mm. Remove the unlocked clip -2- with pin. Lift the cover -3- on the radiator frame and hang it on the radiator grille. Right side of the vehicle: remove the air housing. filter: vehicles with a gasoline engine. Open the clamp -2-arrow A-. Turn the housing cover -1 - towards -arrow B- and remove it. Remove bolts -2- and -4-. Loosen bolt -3- 3 turns. Press headlight housing -1 - in direction -arrow- forward until it stops. Turn the bulb key -1- counterclockwise -arrow- and remove it from the housing. Unlock the spring latch -4- and disconnect the connector from the lamp -2-.
The key -5- cannot be removed from the connector -3-.
Installation
Installation in reverse order: insert the new lamp into the headlight, but do not touch the glass bulb of the lamp with your bare hands. Close the housing cover and secure with a clamp. Right side of the vehicle: install the air housing. filter: vehicles with a gasoline engine. Install the radiator frame trim on the radiator grille.
Replacing front side marker lamp -M33-/-M34-
Turn off the ignition. Set the light switch to position "0". To remove the spacer clips -arrows-, carefully insert the pin -1- a distance -x- into the clip until it audibly clicks into place -arrow A-. Dimension -x- = 5 mm. Remove the unlocked clip -2- with pin. Lift the cover -3- on the radiator frame and hang it on the radiator grille. Right side of the vehicle: remove the air housing. filter. Open clamp -2- -arrow A-. Turn the housing cover -1 - towards -arrow B- and remove it. Remove bolts -2- and -4-. Loosen bolt -3- 3 turns. Press headlight housing -1- in direction -arrow- all the way forward. Remove the key -1 - for the lamp from the housing -arrow-. Remove the bulb -2- from the socket -3-.
Installation
Installation in reverse order: insert the new lamp into the headlight, but do not touch the glass bulb of the lamp with your bare hands. Close the housing cover and secure with a clamp. Right side of the vehicle: install the air housing. filter. Install the radiator frame trim on the radiator grille.
Replacing the front turn signal lamp -M5-/-M7-
Turn off the ignition. Set the light switch to position "0". Right side of the vehicle: remove the air housing. filter: vehicles with a gasoline engine.
Open clamp -2- -arrow-. Turn the housing cover -1 - to the side and remove it.
Turn the bulb -1- counterclockwise -arrow- and remove it from the housing. Unlock the spring latch -4- and disconnect the connector -3- from the lamp -2-.
Installation
Installation in reverse order: insert the new lamp into the headlight, but do not touch the glass bulb of the lamp with your bare hands. Close the housing cover and secure with a clamp.
Right side of the vehicle: Installing the air housing. filter: vehicles with a gasoline engine.
Removing headlight range control motor -V48-/-V49-
To replace the actuator motor for headlight angle correction, the headlight housing must be cut with a sharp carpet knife in the place provided for this purpose. A housing cover is supplied for subsequent closing of the mounting hole. Remove the headlight housing. Cut out the plug -5- from the headlight housing with a sharp carpet knife. Open the clamp -2-. Turn the housing cover -1- to the side and remove it. Turn the headlight adjustment motor -4-: left headlight counterclockwise; right headlight clockwise.
Move the ball head of the adjusting rod by turning the motor upwards from the ball head mount. Remove the motor. Disconnect email plug connection -3-.
Installation
Installation in reverse order: connect the connector when inserting. First, insert the ball head of the adjusting axis from below into the mount of the ball head of the reflector; to do this, pull the reflector back. Install and close the bayonet connection of the headlight adjustment motor on the headlight housing. Left headlight clockwise. Right headlight counterclockwise. Close the hole in the headlight with housing cover -1 - from the spare parts kit. Tighten bolts -arrows-.
Install the headlight housing.
Installing the headlight housing repair kit
If the headlight mounting plates are damaged, the vehicle's headlights must be completely replaced by March 22, 2009. Damaged headlight mounting plates can be replaced as of March 23, 2009 by installing a repair kit. Thanks to this, a complete replacement of the headlight is not required. Remove the headlight with the damaged mounting plate. Remove the remainder of the damaged mounting plate on the headlight housing. Install the mounting plate -2- from the repair kit onto the headlight housing -3- and screw it in with bolts -1-.
Mounting plate to headlight housing: 6 Nm.
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