Volkswagen Golf Variant / Jetta. Manual - part 697

Headlights with gas discharge bulbs

(up to MY2009)

Note

♦

Before working on headlights with gas discharge bulbs, al‐

ways switch off headlights and remove ignition key.

♦

The automatic headlight range control on headlights with gas

discharge bulbs is equipped with self-diagnosis.

♦

When dealing with complaints, it is absolutely necessary to

understand the functions and the operation of the lighting sys‐

tem ⇒  Operating instructions .

♦

Additional information ⇒ Current flow diagrams, Electrical fault

finding and Fitting locations.

Fault detection and fault display
Automatic headlight range control and onboard supply control unit

-J519- are equipped with self-diagnosis.
For fault finding, use vehicle diagnosis, testing and information

system -VAS 5051B- in „Guided fault finding“ mode.

3.1

Operation and safety notes for gas dis‐

charge bulbs

WARNING

♦ Never change bulbs if you are not familiar with the appro‐

priate procedures, safety precautions and tools.

– If repairs are to be made to the headlights with gas discharge

bulbs, observe the following:

♦ Notes on dangerous high voltage/currents 

⇒ page 258

♦ Notes on pressure/temperature/radiation/arcs 

⇒ page 259

♦ Assembly notes for gas discharge bulbs 

⇒ page 260

♦ Disposal regulations for gas discharge bulbs 

⇒ page 260

Special tools and workshop equipment required
♦ Safety goggles
♦ Gloves
Notes on dangerous high voltage/currents

WARNING

Control units for light systems, connectors and components

pertaining to bulb holders conduct lethally high voltage.
Operating the control unit and the starter unit is permitted only

with the bulb fitted.

258

• Switch off ignition and all electrical consumers and re‐

move ignition key.

• When working on headlight system, ensure that there is

no voltage in any components, including the dissipation of

residual voltage after the headlights are switched off.

• Residual voltage can be dissipated by turning the dipped

beams on and then off again after withdrawing the ignition

key.

• When working on the headlight system, ensure that the

lights cannot be switched on.

Notes on pressure/temperature/radiation/arcs

WARNING

♦ Within the glass envelope of a gas discharge bulb, pres‐

sure can range from between 7 bar (cold) and 100 bar

(hot). Temperatures can reach up to 700 degrees Celsius

on the glass bulb.

♦ Should the glass envelope explode, there is a risk of injury

from burning.

♦ Always wear safety goggles and gloves when removing

and installing gas discharge bulbs!

WARNING

• The bulbs may be operated in the headlight housing only

(protection against contact due to very hot bulbs, absorp‐

tion of UV radiation, avoidance of dazzling light, protection

against explosion).

• The glass envelope of the bulbs can be very hot - danger

of burns!

• Avoid looking directly into the beam, as the UV rays from

the gas discharge bulb are about 2.5 times greater than

normal halogen bulbs.

• Avoid looking into the light beam (danger of glare); vision

may be impaired for a substantial time.

WARNING

• Avoid contact with burst glass envelopes.
• H7 bulbs and gas discharge bulbs (xenon and bi-xenon)

are under pressure and can explode while being changed

- danger of injury.

• Always wear safety goggles and gloves when removing

and installing gas discharge bulbs!

3. Headlights with gas discharge bulbs (up to MY2009)    

259

Caution

♦ Before renewing a bulb, always switch off the concerned

electrical consumer.

♦ Switch off ignition and all electrical consumers and re‐

move ignition key.

♦ Do not touch the glass envelope with bare fingers; use a

clean cloth glove. When the light bulb is switched on, the

heat would vaporise the oil of the finger prints which would

then settle on the reflector, impairing the brightness of the

headlight.

♦ A light bulb must always be renewed with a bulb of the

same sort. The designation appears on the base of the

bulb or on the glass envelope.

♦ Properly engage connector during installation and ensure

tight seating of the connection.

Disposal regulations for gas discharge bulbs

WARNING

• Gas discharge bulbs must be disposed of as hazardous

waste; never dispose of gas discharge bulbs via house‐

hold waste system.

• Gas discharge bulbs contain metallic mercury (Hg) and

traces of thallium; never destroy these bulbs.

• These components must be recycled in the correct man‐

ner according to national law.

• Only dispose of in containers intended for this purpose at

an authorised collection point.

260

Assembly overview

Note

After any measures which could affect the headlight setting, the headlight setting must be checked and the

headlights adjusted ⇒ Maintenance ; Booklet  20.1 ; Descriptions of work .

1 - Vent hose

❑ On headlight

2 - Left headlight range control

motor -V48- / right headlight

range control motor -V49-

❑ Manufacturer AL (Auto‐

motive Lighting)

3 - Bolt

❑ 2 Nm

4 - Cover cap
5 - Starter unit for gas dis‐

charge bulbs -N195-
6 - Bulb retainer
7 - Left gas discharge (xenon)

bulb -L13- / right gas discharge

(xenon) bulb -L14-

❑ Type: D2S 35 W
❑ Notes on safety

⇒ page 258

❑ Renewing 

⇒ page 262

8 - Bolt

❑ 4 Nm

9 - Headlight

❑ Removing and installing

⇒ page 215

❑ Adjusting headlight in‐

stallation position

⇒ page 217

❑ Repairing headlight se‐

curing tabs

⇒ page 276

❑ Converting for driving on left/right 

⇒ page 277

10 - Control unit for headlight range control -J431-

❑ Removing and installing 

⇒ page 272

❑ Coding 

⇒ page 274

11 - Front left vehicle level sender -G78-

❑ Removing and installing 

⇒ page 275

❑ Checking 

⇒ page 275

12 - Rear left vehicle level sender -G76-

❑ Removing and installing 

⇒ page 275

❑ Checking 

⇒ page 275

13 - Adjustment bush

❑ Adjusting headlight installation position 

⇒ page 217

3. Headlights with gas discharge bulbs (up to MY2009)    

261