Volkswagen Passat B6 2005 - Headlamps
. 1 34
94 - 1
Headlamps
General information
Headlamps from two different manufacturers may be
installed:
Hella
Valeo
With the exception of the various bulb mountings,
assembly and disassembly of headlamps and their
attachments is identical.
Before troubleshooting or servicing, technicians must be
familiar with the functions and operation specifics of the
standard or optional headlamp or lighting system. Always
read the owners manual and review applicable system
functions.
Note:
Additional information:
Owners Manual
Self Study Program - Course Number 891503 "The
2006 Passat Introduction"
Self Study Program - Course Number 871503 "The
2006 Passat Electrical Systems Design and Function"
Electrical Wiring Diagrams, Troubleshooting and
Component Locations binder
CAN-Bus wire repairs
97-8, Repairing CAN-Bus wires
On Board Diagnostic (OBD), function
Vehicle electrical system control is equipped with On Board
Diagnostics (OBD) capabilities which assists in
troubleshooting headlamps.
For troubleshooting, use Vehicle Diagnostic, Testing and
Information System VAS 5051/5052 in operating mode
"Guided Fault Finding" .
Headlamps, assembly
Headlamps
. 2 34
Note:
After performing any repairs or service that could
affect headlamp aim, check/adjust aim
Tightening torques
torques
Not applicable to USA/CDN
models with standard headlamp
system
Not applicable to USA/CDN
models with standard headlamp
system
Not applicable to USA/CDN
models with standard headlamp
system
Not applicable to USA/CDN
94-12, Headlamps, tightening
Headlamps
. 3 34
models with standard headlamp
system
Body cross section
Cover
Left High Beam Headlamp M30
and Right High Beam Headlamp
M32
Bulb H7 12 V, 55 W
Replacing, manufacturer:
Hella 94-1, High Beam
Headlamp Bulbs M30 / M32,
replacing
Replacing, manufacturer:
Valeo 94-1, High Beam
Headlamp Bulbs M30 / M32,
replacing
Screws
Screws
8 Nm
Adjustment bushings
2 Nm
Correcting installation
position of headlamp 941, Headlamp installation
position, correcting
Headlamp housing
Removing and installing
94-1, Headlamps, removing
and installing
Headlamp installation
position, correcting 94-1,
Headlamp installation
position, correcting
Headlamp securing lugs,
servicing 94-1, Headlamp
securing lugs, servicing
Headlamps
. 4 34
Left Parking Light M1 and Right
Parking Light M3
Bulb: 12 V, WY 5 W
Replacing, manufacturer:
Hella 94-1, Parking Lamp
Bulbs M1 / M3, replacing
Replacing, manufacturer:
Valeo 94-1, Parking Lamp
Bulbs M1 / M3, replacing
Cover
Left Low Beam headlamp M29
and Right Low Beam headlamp
M31
Bulb H7 12 V, 55 W
Replacing, manufacturer:
Hella 94-1, Low Beam
Headlamp Bulbs M29 / M31,
replacing
Replacing, manufacturer:
Valeo 94-1, Low Beam
Headlamp Bulbs M29 / M31,
replacing
Cover
Headlamps, removing and installing
Headlamps, removing
Note:
Removal and installation of standard headlamps and
headlamps with High Intensity Gas Discharge (HID)
lamps is the same as described below. In the event
an HID headlamp requires removal, read,
understand and observe all safety precautions for
servicing HID lamps 94-2, General information
It is not necessary to disconnect battery.
The following illustrations depict removal and
installation of left headlamp. Procedure for right
Headlamps
. 5 34
headlamp is the same.
If one headlamp is removed, it must always be
adjusted after installation
Repair Manual, Maintenance, Repair Group 00,
.
Should an HID headlamp be removed, perform basic
setting after installation
Repair Manual, Maintenance, Repair Group 00,
.
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Leave remote control ignition key in passenger
compartment in order to prevent accidental door
locking and automatic headlamp "Coming
home/leaving home" activation.
- Release and disconnect electrical connection - arrow .
- Remove radiator grille
Headlamps
Repair Manual, Body Exterior, Repair Group 66, Strips
and panels; removing and installing radiator grille
.
- Remove front bumper cover
Repair Manual, Body Exterior, Repair Group 63, Front
bumper
.
- Remove screws - arrows - and remove retainer bracket
- 1- .
- Remove screws - arrow - at top of headlamp.
. 6 34
Headlamps
. 7 34
- Remove screws - arrow - at bottom of headlamp.
- Remove headlamp from body opening.
Headlamp, installing
Special tools, testers and auxiliary items required
Torque wrench VAG 1410 (or 4 - 20 Nm
equivalent)
Install in reverse order of removal, noting the following:
- Torque all fasteners according to value in table
Headlamps, tightening torques .
94-12,
- Check the installed position of the headlamp for uniform
gap dimensions.
If the gaps are uneven in relation to the body, the installed
position of the headlamp must be corrected
94-1,
Headlamp installation position, correcting .
- Check headlamp function.
Note:
If one headlamp is removed, it must always be
Headlamps
adjusted after installation.
Should an HID headlamp be removed, perform basic
setting after installation
Repair Manual, Maintenance, Repair Group 00,
.
- Check and adjust headlamp aim if necessary
Repair Manual, Maintenance, Repair Group 00,
.
Headlamp installation position, correcting
Special tools, testers and auxiliary items required
Torque wrench VAG 1410 (or 4 - 20 Nm
equivalent)
Note:
The following illustrations depict the left headlamp.
Installation position for right and left headlamps is
the same.
If during the check of the final installation position it is
established that headlamp gaps are uneven with the body,
correct installation position as follows:
. 8 34
Headlamps
. 9 34
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
- Remove radiator grille
Repair Manual, Body Exterior, Repair Group 66, Strips
and panels; removing and installing radiator grille
.
- Remove front bumper cover
Repair Manual, Body Exterior, Repair Group 63, Front
bumper
.
- Loosen screws - arrow - at top of headlamp.
- Loosen screws - arrow - at bottom of headlamp.
Headlamps
. 10 34
- Adapt surface alignment to body by screwing in or
screwing out adjustment bushing - arrow - at lower left of
headlamp or at lower right of headlamp.
- Torque all fasteners according to value in table
Headlamps, tightening torques .
94-12,
- Check and if necessary correct installation position of
headlamp again for uniform gap dimension.
- Install front bumper cover
Repair Manual, Body Exterior, Repair Group 63, Front
bumper
.
- Install radiator grille
Repair Manual, Body Exterior, Repair Group 66, Strips
and panels; removing and installing radiator grille
.
- Check headlamp function.
Note:
If a headlamp is removed or adapted to the body, it
must always be adjusted after installing or after
adapting.
- Check and adjust headlamp aim if necessary
Repair Manual, Maintenance, Repair Group 00,
Headlamps
. 11 34
.
Hella headlamps - bulbs, replacing
Low beam headlamp bulbs M29 / M31, replacing
1, Low Beam Headlamp Bulbs M29 / M31, replacing
94-
High beam headlamp bulbs M30 / M32, replacing
1, High Beam Headlamp Bulbs M30 / M32, replacing
94-
Parking lamp bulbs M1 / M3, replacing
Lamp Bulbs M1 / M3, replacing
94-1, Parking
Low Beam Headlamp Bulbs M29 / M31, replacing
Note:
Left Low Beam Headlamp M29 and Right Low Beam
Headlamp M31 function can be checked using
Vehicle Electrical System Control Module J519 On
Board Diagnostic (OBD) function "Output Diagnostic
Test Mode (DTM)" .
Removing:
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Leave remote control ignition key in passenger
compartment in order to prevent accidental door
locking and automatic headlamp "Coming
home/leaving home" activation.
Note:
The following illustrations depict replacement of right
low beam headlamp bulb.
Procedure to replace Left Low Beam Headlamp M29
and Right Low Beam Headlamp M31 is the same.
Headlamps
. 12 34
- Remove cap - 1 - .
- Turn low beam bulb socket - 1 - in direction of - arrow and remove from headlamp housing, and pull out as far as
wiring harness allows.
- Remove bulb - 2 - in direction of - arrow - from bulb
socket - 1 - .
Installing:
Caution!
Do not touch glass portion of bulb with bare
hands. Even the smallest amount of moisture
and/or contaminants from fingers that
Headlamps
. 13 34
evaporates on the bulb during operation can
cause the glass to cloud over.
When installing cap, ensure proper seating.
Water intrusion will damage headlamp.
- Insert bulb in socket so that the bulb tab - 1 - aligns with
the bulb socket guide - 2 - .
- Insert socket with bulb - 1 - in headlamp housing and
secure by turning in direction of - arrow - .
- Install cap.
- Check headlamp function.
- Check and adjust headlamp aim if necessary
Repair Manual, Maintenance, Repair Group 00,
.
High Beam Headlamp Bulbs M30 / M32, replacing
Headlamps
. 14 34
Note:
Left High Beam Headlamp M30 and Right High
Beam Headlamp M32 function can be checked
using Vehicle Electrical System Control Module
J519 On Board Diagnostic (OBD) function "Output
Diagnostic Test Mode (DTM)" .
Removing:
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Leave remote control ignition key in passenger
compartment in order to prevent accidental door
locking and automatic headlamp "Coming
home/leaving home" activation.
Note:
The following illustrations depict replacement of right
high beam headlamp bulb.
Procedure to replace Left High Beam Headlamp
M30 and Right High Beam Headlamp M32 is the
same.
- Remove cap - 1 - .
Headlamps
. 15 34
- Turn high beam bulb socket - 1 - in direction of - arrow and remove from headlamp housing, and pull out as far as
wiring harness allows.
- Remove bulb - 2 - in direction of - arrow - from bulb
socket - 1 - .
Installing:
Caution!
Do not touch glass portion of bulb with bare
hands. Even the smallest amount of moisture
and/or contaminants from fingers that
evaporates on the bulb during operation can
cause the glass to cloud over.
When installing cap, ensure proper seating.
Water intrusion will damage headlamp.
Headlamps
- Insert bulb in socket so that the bulb tab - 1 - aligns with
the bulb socket guide - 2 - .
- Insert socket with bulb - 1 - in headlamp housing and
secure by turning in direction of - arrow - .
- Install cap.
- Check headlamp function.
- Check and adjust headlamp aim if necessary
Repair Manual, Maintenance, Repair Group 00,
.
Parking Lamp Bulbs M1 / M3, replacing
Note:
Left Parking Lamp M1 and Right Parking Lamp M3
function can be checked using Vehicle Electrical
System Control Module J519 On Board Diagnostic
(OBD) program function "Output Diagnostic Test
Mode (DTM)" .
. 16 34
Headlamps
. 17 34
Removing:
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Leave remote control ignition key in passenger
compartment in order to prevent accidental door
locking and automatic headlamp "Coming
home/leaving home" activation.
Note:
The following illustrations depict replacement of right
parking lamp bulb.
Procedure to replace Left Parking Lamp M1 and
Right Parking Lamp M3 is the same.
- Remove cap - 1 - .
- Pull socket - 1 - with bulb out of reflector, and pull out as
Headlamps
. 18 34
far as wiring harness allows.
- Remove bulb - 2 - in direction of - arrow - from bulb
socket - 1 - .
Installing:
Install in reverse order of removal, noting the following:
Caution!
Do not touch glass portion of bulb with bare
hands. Even the smallest amount of moisture
and/or contaminants from fingers that
evaporates on the bulb during operation can
cause the glass to cloud over.
When installing cap, ensure proper seating.
Water intrusion will damage headlamp.
- Check headlamp function.
- Check and adjust headlamp aim if necessary
Repair Manual, Maintenance, Repair Group 00,
.
Valeo headlamps - bulbs, replacing
Low beam headlamp bulbs M29 / M31, replacing
1, Low Beam Headlamp Bulbs M29 / M31, replacing
94-
High beam headlamp bulbs M30 / M32, replacing
1, High Beam Headlamp Bulbs M30 / M32, replacing
94-
Parking lamp bulbs M1 / M3, replacing
Lamp Bulbs M1 / M3, replacing
94-1, Parking
Headlamps
. 19 34
Low Beam Headlamp Bulbs M29 / M31, replacing
Note:
Left Low Beam Headlamp M29 and Right Low Beam
Headlamp M31 function can be checked using
Vehicle Electrical System Control Module J519 On
Board Diagnostic (OBD) function "Output Diagnostic
Test Mode (DTM)" .
Removing:
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Leave remote control ignition key in passenger
compartment in order to prevent accidental door
locking and automatic headlamp "Coming
home/leaving home" activation.
Note:
The following illustrations depict replacement of right
low beam headlamp bulb.
Procedure to replace Left Low Beam Headlamp M29
and Right Low Beam Headlamp M31 is the same.
- Remove cap - 1 - .
Note:
Headlamps
. 20 34
Low beam bulb - 2 - is clipped into reflector - 1 - .
When removing low beam bulb - 2 - , connection 3 - remains connected.
- Press socket/connection in direction of - arrow - until
bulb is loosened.
- Remove socket/connection with bulb - 3 - from
reflector.
- Guide bulb with socket/connection out of headlamp
housing.
- Remove bulb - 2 - from socket/connection - 1 - .
Installing:
Install in reverse order of removal, noting the following:
Caution!
Do not touch glass portion of bulb with bare
hands. Even the smallest amount of moisture
and/or contaminants from fingers that
evaporates on the bulb during operation can
cause the glass to cloud over.
Headlamps
. 21 34
When installing cap, ensure proper seating.
Water intrusion will damage headlamp.
- Guide bulb into headlamp housing.
- Press bulb into reflector as illustrated.
Note:
Bulb must felt and heard to engage.
- Connect socket/connection - 1 - to bulb - 2 - .
- Check headlamp function.
- Check and adjust headlamp aim if necessary
Repair Manual, Maintenance, Repair Group 00,
.
High Beam Headlamp Bulbs M30 / M32, replacing
Headlamps
. 22 34
Note:
Left High Beam Headlamp M30 and Right High
Beam Headlamp M32 function can be checked
using Vehicle Electrical System Control Module
J519 On Board Diagnostic (OBD) function "Output
Diagnostic Test Mode (DTM)" .
Removing:
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Leave remote control ignition key in passenger
compartment in order to prevent accidental door
locking and automatic headlamp "Coming
home/leaving home" activation.
Note:
The following illustrations depict replacement of right
high beam headlamp bulb.
Procedure to replace Left High Beam Headlamp
M30 and Right High Beam Headlamp M32 is the
same.
- Remove cap - 1 - .
Note:
Headlamps
. 23 34
High beam bulb - 2 - is clipped into reflector - 1 - .
When removing high beam bulb - 2 - , connection 3 - remains connected.
- Press socket/connection in direction of - arrow - until
bulb is loosened.
- Remove socket/connection with bulb - 3 - from
reflector.
- Guide bulb with socket/connection out of headlamp
housing.
- Remove bulb - 2 - from socket/connection - 1 - .
Installing:
Install in reverse order of removal, noting the following:
Caution!
Do not touch glass portion of bulb with bare
hands. Even the smallest amount of moisture
and/or contaminants from fingers that
evaporates on the bulb during operation can
cause the glass to cloud over.
Headlamps
. 24 34
When installing cap, ensure proper seating.
Water intrusion will damage headlamp.
- Guide bulb into headlamp housing.
- Press bulb into reflector as illustrated.
Note:
Bulb must felt and heard to engage.
- Connect socket/connection - 1 - to bulb - 2 - .
- Check headlamp function.
- Check and adjust headlamp aim if necessary
Repair Manual, Maintenance, Repair Group 00,
.
Parking Lamp Bulbs M1 / M3, replacing
Headlamps
. 25 34
Note:
Left Parking Lamp M1 and Right Parking Lamp M3
function can be checked using Vehicle Electrical
System Control Module J519 On Board Diagnostic
(OBD) program function "Output Diagnostic Test
Mode (DTM)" .
Removing:
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Leave remote control ignition key in passenger
compartment in order to prevent accidental door
locking and automatic headlamp "Coming
home/leaving home" activation.
Note:
The following illustrations depict replacement of right
parking lamp bulb.
Procedure to replace Left Parking Lamp M1 and
Right Parking Lamp M3 is the same.
- Remove cap - 1 - .
Headlamps
. 26 34
- Pull socket - 1 - with bulb out of reflector, and pull out as
far as wiring harness allows.
- Remove bulb - 2 - in direction of - arrow - from bulb
socket - 1 - .
Installing:
Install in reverse order of removal, noting the following:
Caution!
Do not touch glass portion of bulb with bare
hands. Even the smallest amount of moisture
and/or contaminants from fingers that
evaporates on the bulb during operation can
cause the glass to cloud over.
When installing cap, ensure proper seating.
Water intrusion will damage headlamp.
- Check headlamp function.
- Check and adjust headlamp aim if necessary
Headlamps
Repair Manual, Maintenance, Repair Group 00,
.
Headlamp securing lugs, servicing
Should one or more headlamp securing lugs be damaged
or broken, they can be replaced by installing the repair set.
It is not necessary to replace the entire headlamp.
Top outer securing lug
Top inner securing lug
Side securing lug
Lower securing lug
Note:
Check whether there is no other damage on the
headlamp that would render the installation of the
repair set unnecessary.
Two different repair sets are available, one for the
left and one for the right headlamp ETKA
(Electronic Parts Catalog) .
The same repair sets are used for both Hella and
Valeo manufacturers.
Each repair set contains the corresponding top, side
and lower headlamp securing lugs, four mounting
bolts and two banjo fittings.
The following illustrations depict replacement of right
headlamp securing lugs.
Replacement of securing lugs on left headlamp and
on right headlamp are performed analogously.
. 27 34
Headlamps
. 28 34
- Repairing top outer securing lug
outer securing lug .
94-1, Repairing top
- Repairing top inner securing lug
inner securing lug .
94-1, Repairing top
- Repairing side securing lug
securing lug .
- Repairing lower securing lug
securing lug .
94-1, Repairing side
94-1, Repairing lower
Repairing top outer securing lug
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Leave remote control ignition key in passenger
compartment in order to prevent accidental door
locking and automatic headlamp "Coming
home/leaving home" activation.
- Remove headlamp
94-1, Headlamps, removing .
- Remove remaining part of headlamp securing lug - 1 as shown.
Headlamps
. 29 34
- Insert new securing lug - 2 - form-fitting into mount - 3 on headlamp and secure the securing lug with mounting
bolt - 1 - .
- Install headlamp
94-1, Headlamp, installing .
Note:
If one headlamp is removed, it must always be
adjusted after installation.
- Check and adjust headlamp aim if necessary
Repair Manual, Maintenance
.
Repairing top inner securing lug
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Leave remote control ignition key in passenger
compartment in order to prevent accidental door
locking and automatic headlamp "Coming
home/leaving home" activation.
- Remove headlamp
94-1, Headlamps, removing .
Headlamps
. 30 34
- Remove remaining part of headlamp securing lug - 1 as shown.
- Insert new securing lug - 2 - form-fitting into mount - 3 on headlamp and secure the securing lug with mounting
bolt - 1 - .
- Install headlamp
94-1, Headlamp, installing .
Note:
If one headlamp is removed, it must always be
adjusted after installation.
- Check and adjust headlamp aim if necessary
Repair Manual, Maintenance
.
Repairing side securing lug
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Headlamps
. 31 34
Leave remote control ignition key in passenger
compartment in order to prevent accidental door
locking and automatic headlamp "Coming
home/leaving home" activation.
- Remove headlamp
94-1, Headlamps, removing .
- Remove remaining part of headlamp securing lug - 1 as shown.
- Insert new securing lug - 2 - form-fitting into mount - 1 on headlamp and secure the securing lug with mounting
bolt - 3 - .
- Thread banjo fitting - 1 - into securing lug - 2 - .
Headlamps
. 32 34
- Install headlamp
94-1, Headlamp, installing .
Note:
If one headlamp is removed, it must always be
adjusted after installation.
- Check and adjust headlamp aim if necessary
Repair Manual, Maintenance
.
Repairing lower securing lug
Caution!
Switch off all electrical consumers.
Switch ignition off and remove ignition key.
Leave remote control ignition key in passenger
compartment in order to prevent accidental door
locking and automatic headlamp "Coming
home/leaving home" activation.
- Remove headlamp
94-1, Headlamps, removing .
- Remove remaining part of headlamp securing lug - 1 as shown.
Headlamps
. 33 34
- Insert new securing lug - 2 - form-fitting into mount - 3 on headlamp and secure the securing lug with mounting
bolt - 1 - .
- Thread banjo fitting - 2 - into securing lug - 1 - .
- Install headlamp
94-1, Headlamp, installing .
Note:
If one headlamp is removed, it must always be
adjusted after installation.
- Check and adjust headlamp aim if necessary
Repair Manual, Maintenance
.
Headlamps, adjusting
Special tools, testers and auxiliary items required
Optical Headlight Aimer VAS 5107
Always adjust headlamps with optical headlamp aimer VAS
5107 using detailed aiming procedure and specifications
Headlamps
Repair Manual, Maintenance, Repair Group 00,
.
. 34 34
