Volkswagen Touareg: Headlamps
Page 1 / 25
94 - 1
Headlamps
General information
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 89E303 "The
Touareg"
Self Study Program - Course Number 89J303 "The
Touareg Electrical System Design and Function"
Wiring Diagrams Component Locations
On Board Diagnostic (OBD), function
Headlamp functions are monitored by Vehicle Electrical
System Control Module J519 which has On Board
Diagnostic (OBD) capability. If malfunctions occur in
monitored components, Diagnostic Trouble Codes (DTC)
will be stored in memory.
Troubleshoot headlamp system malfunctions by performing
OBD program using VAS 5051/5052 Tester in operating
mode "Guided Fault Finding" .
Headlamps, assembly
Note:
„
After performing any repairs or service that could
affect headlamp aim, check/adjust aim
Repair Manual, Maintenance
.
Headlamps
- Tightening torques 94-13,
Headlamps, tightening torques
1 - Not applicable to USA/CDN models
with standard headlamp system
2 - Not applicable to USA/CDN models
with standard headlamp system
3 - Cover
4 - Left Low Beam Headlamp M29 and
Right Low Beam Headlamp M31
„
Lamp H7LL 12 V, 55 W
„
Replacing 94-1, Low Beam
Headlamp Bulbs M29 / M31,
replacing
„
Checking 97-5, Vehicle
Electrical System Control Module
J519 , Output Diagnostic Test
Page 2 / 25
Headlamps
Mode (DTM)
5 - Left High Beam Headlamp M30 and
Right High Beam Headlamp M32
„
Lamp H9 12 V, 65 W
„
Replacing 94-1, High Beam
Headlamp Bulbs M30 / M32,
replacing
„
Checking 97-5, Vehicle
Electrical System Control Module
J519 , Output Diagnostic Test
Mode (DTM)
6 - Cover
7 - Cover
8 - Turn signal bulb holder
9 - Left Parking Lamp M1 and Right
Parking Lamp M3
„
Orange tinted - Lamp 12 V, WY 5
W
„
Replacing 94-1, Parking Lamp
Bulbs M1 / M3, replacing
„
Checking 97-5, Vehicle
Electrical System Control Module
J519 , Output Diagnostic Test
Mode (DTM)
10 - Left Front Turn Signal Lamp M5
and Right Front Turn Signal Lamp M7
„
Bulb 12 V, PY 21 W Diadem
„
Replacing 94-1, Front Turn
Signal Lamp Bulbs M5 / M7,
replacing
„
Checking 97-5, Vehicle
Electrical System Control Module
J519 , Output Diagnostic Test
Mode (DTM)
11 - Headlamp housing
„
Removing and installing 94-1,
Headlamps, removing and
installing
Page 3 / 25
Headlamps
„
Correcting installation position of
headlamp 94-1, Headlamp
installation position, correcting
12 - Adjustment guide
„
Correcting installation position of
headlamp 94-1, Headlamp
installation position, correcting
13 - Screws
„
For front headlamp bracket
14 - Headlamp bracket
„
Left headlamp bracket - Vehicles
with 6-cyl. fuel injection engine,
removing and installing 94-1,
Left headlamp bracket - Vehicles
with 6-cyl. fuel injection engine,
removing and installing
„
Left headlamp bracket - Vehicles
with 10-cyl. TDI engine and 8-cyl.
fuel injection engine, removing and
installing 94-1, Left headlamp
bracket - Vehicles with 10-cyl. TDI
engine and 8-cyl. fuel injection
engine, removing and installing
„
Right headlamp bracket - Vehicles
with 6-cyl. fuel injection engine,
removing and installing 94-1,
Right headlamp bracket - Vehicles
with 6-cyl. fuel injection engine,
removing and installing
„
Right headlamp bracket - Vehicles
with 10-cyl. TDI engine and 8-cyl.
fuel injection engine, removing and
installing 94-1, Right headlamp
bracket - Vehicles with 10-cyl. TDI
Engine and 8-cyl. fuel injection
engine, removing and installing
15 - Securing clip
16 - Locking bolt
17 - Bushing
18 - Screws
„
For rear headlamp bracket
Page 4 / 25
Headlamps
Page 5 / 25
19 - Connector
20 - Securing clip
21 - Adjusting shaft for lateral high
beam adjustment
22 - Adjusting shaft for vertical
low/high beam adjustment
23 - Screws
„
For adjusting shafts
Headlamps, removing and installing
Removing:
Note:
„
It is not necessary to disconnect battery.
„
Removal of left headlamp is illustrated. Removal of
right headlamp is mirror image.
Caution!
„
Switch off all electrical consumers.
„
Switch off ignition and remove ignition key.
- Press lightly against headlamp before releasing it.
- Turn locking bolt - arrow - in direction of "OPEN" arrow
(sticker) until resistance is felt (the headlamp housing will
slide forward while doing this).
Caution!
Headlamps
Do not continue to turn with force. Damage to release
mechanism will result.
- Pull headlamp out of opening in fender until resistance is
felt.
- Hold locking clip - 1 - depressed - arrow - and remove
headlamp from opening.
Installing:
Note:
„
Guides - arrows - must be free from dirt.
- Check connector - 1 - in headlamp bracket for proper
fitting before inserting headlamp into guides.
- Set headlamp into guides - arrows - .
- Slide headlamp into opening.
Note:
„
A clear "click" must be audible when the retainer
engages.
Page 6 / 25
Headlamps
- Turn locking bolt - arrow - in direction of "CLOSE" arrow
(sticker) until resistance is felt.
- Press lightly against headlamp and turn further in
direction of "OPEN" arrow until audibly heard to engage.
Caution!
Do not continue to turn with force. Damage to release
mechanism will result.
- Check headlamp installation position for even gaps.
If gaps between headlamp and body are uneven, correct
installation position 94-1, Headlamp installation position,
correcting .
- Perform functional check of headlamp.
- Check headlamp aim and adjustment if necessary
Repair Manual, Maintenance
.
Headlamp bracket, removing and installing
Left headlamp bracket - Vehicles with 6-cyl. fuel injection
engine, removing and installing 94-1, Left headlamp
bracket - Vehicles with 6-cyl. fuel injection engine,
removing and installing
Left headlamp bracket - Vehicles with 10-cyl. TDI engine
and 8-cyl. fuel injection engine, removing and installing
94-1, Left headlamp bracket - Vehicles with 10-cyl. TDI
engine and 8-cyl. fuel injection engine, removing and
installing
Right headlamp bracket - Vehicles with 6-cyl. fuel injection
engine, removing and installing 94-1, Right headlamp
bracket - Vehicles with 6-cyl. fuel injection engine,
removing and installing
Page 7 / 25
Headlamps
Page 8 / 25
Right headlamp bracket - Vehicles with 10-cyl. TDI engine
and 8-cyl. fuel injection engine, removing and installing
94-1, Right headlamp bracket - Vehicles with 10-cyl. TDI
Engine and 8-cyl. fuel injection engine, removing and
installing
Left headlamp bracket - Vehicles with 6-cyl. fuel injection
engine, removing and installing
Special tools, testers and auxiliary items required
„
Torque Wrench 5-50Nm VAG1331 (or 5 - 50 Nm
equivalent)
Removing:
Caution!
„
Switch off all electrical consumers.
„
Switch off ignition and remove ignition key.
- Remove headlamp
installing .
94-1, Headlamps, removing and
- Bring lock carrier into service position
Repair Manual, Body Exterior, Repair Group 50, Lock
carrier service position
.
Headlamps
- Remove front bracket screws - arrows - .
- Disconnect electrical connection - arrow - , at rear side
of headlamp bracket.
- Separate cable harness - 1 - from harness guides arrows - and press downward.
Page 9 / 25
Headlamps
- Remove rear bracket screws - arrows - .
- Remove headlamp bracket.
Installing:
Install in reverse order of removal, noting the following:
- Torque front bracket screws - arrows - according to
value in table 94-13, Headlamps, tightening torques .
- Torque rear bracket screws - arrows - according to
value in table 94-13, Headlamps, tightening torques .
- Check headlamp installation position for even gaps.
If gaps between headlamp and body are uneven, correct
Page 10 / 25
Headlamps
Page 11 / 25
installation position
correcting .
94-1, Headlamp installation position,
- Perform functional check of headlamp.
- Check and adjust headlamp aim
Repair Manual, Maintenance
.
Left headlamp bracket - Vehicles with 10-cyl. TDI engine and 8cyl. fuel injection engine, removing and installing
Special tools, testers and auxiliary items required
„
Torque Wrench 5-50Nm VAG1331 (or 5 - 50 Nm
equivalent)
Removing:
Caution!
„
Switch off all electrical consumers.
„
Switch off ignition and remove ignition key.
- Remove headlamp
installing .
94-1, Headlamps, removing and
- Bring lock carrier into service position
Repair Manual, Body Exterior, Repair Group 50, Lock
carrier service position
.
Headlamps
- Remove front bracket screws - arrows - .
Vehicles with 10-cyl. TDI engine:
- Remove left air filter housing
Repair Manual, 5.0 Liter V10 2V TDI PD Engine
Mechanical, Fuel Injection Glow Plug, Engine Code(s)
BKW, BLE, Repair Group 23, Diesel Direct Injection, air
filter, assembly
.
Vehicles with 8-cyl. fuel injection engine:
- Remove air filter housing
Repair Manual, 4.2 Liter V8 5V Engine Mechanical, Fuel
Injection Ignition, Engine Code(s): AXQ, BHX, Repair
Group 24, Fuel Injection system, air filter, assembly
.
Continued for all vehicles:
Page 12 / 25
Headlamps
- Disconnect electrical connection - arrow - , at rear side
of headlamp bracket.
- Separate cable harness - 1 - from harness guides arrows - and press downward.
- Remove rear bracket screws - arrows - .
- Remove headlamp bracket.
Installing:
Install in reverse order of removal, noting the following:
- Torque front bracket screws - arrows - according to
value in table 94-13, Headlamps, tightening torques .
Page 13 / 25
Headlamps
- Torque rear bracket screws - arrows - according to
value in table 94-13, Headlamps, tightening torques .
- Check headlamp installation position for even gaps.
If gaps between headlamp and body are uneven, correct
installation position 94-1, Headlamp installation position,
correcting .
- Perform functional check of headlamp.
- Check and adjust headlamp aim
Repair Manual, Maintenance
.
Right headlamp bracket - Vehicles with 6-cyl. fuel injection
engine, removing and installing
Right headlamp bracket and ancillaries are a mirror image
of left side.
Procedure for removal and installation of right headlamp
bracket for vehicles with 6-cyl. fuel injection engine is the
same as the left side, noting the following:
Removing:
- Remove air filter housing
Repair Manual, 3.2 Liter V6 4V Engine Mechanical, Fuel
Injection Ignition, Engine Code(s): BAA, BMX, Repair
Group 24, Fuel Injection system, air filter, assembly
.
Left headlamp bracket - Vehicles with 6-cyl. engine,
removing and installing 94-1, Left headlamp bracket Vehicles with 6-cyl. fuel injection engine, removing and
installing
Page 14 / 25
Headlamps
Page 15 / 25
Right headlamp bracket - Vehicles with 10-cyl. TDI Engine and
8-cyl. fuel injection engine, removing and installing
Right headlamp bracket and ancillaries are a mirror image
of left side.
Procedure for removal and installation of right headlamp
bracket for vehicles with 10-cyl. TDI and 8-cyl. fuel injection
engines is the same as the left side 94-1, Left headlamp
bracket - Vehicles with 10-cyl. TDI engine and 8-cyl. fuel
injection engine, removing and installing .
Headlamp installation position, correcting
If during the check of the final installation position it is
established that headlight gaps are uneven with the body,
correct installation position as follows:
Special tools, testers and auxiliary items required
„
Torque Wrench 5-50Nm VAG1331 (or 5 - 50 Nm
equivalent)
Note:
„
It is not necessary to disconnect battery.
„
Position of left headlamp is illustrated. Position of
right headlamp is mirror image.
Caution!
„
Switch off all electrical consumers.
„
Switch off ignition and remove ignition key.
- Remove front bumper cover
Headlamps
Repair Manual, Body Exterior, Repair Group 63, Front
bumper; Bumper cover, removing and installing
.
- Remove screw - arrows - for bumper guide - 1 - .
- Remove bumper guide - 1 - .
- Loosen screws - arrows - until headlamp bracket can be
moved back and forth easily in the adjustment guides.
- Even out gaps by screwing adjustment guide - arrow - in
or out.
Page 16 / 25
Headlamps
Page 17 / 25
- Torque screws according to value in table
Headlamps, tightening torques .
94-13,
- Recheck headlight installation position for even gaps and
correct if necessary.
- Install bumper guide.
- Install front bumper cover
Repair Manual, Body Exterior, Repair Group 63, Front
bumper; removing and installing bumper cover
.
- Perform functional check of headlamp.
- Check and adjust headlamp aim
Repair Manual, Maintenance
.
Headlamp 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
Front turn signal lamp bulbs M5 / M7, replacing
Front Turn Signal Lamp Bulbs M5 / M7, replacing
94-1,
Low Beam Headlamp Bulbs M29 / M31, replacing
Note:
„
Low beam headlamp bulb function can be checked
using Vehicle Electrical System Control Module
J519 On Board Diagnostic function "Output
Diagnostic Test Mode (DTM)" 97-5, Vehicle
Electrical System Control Module J519 , Output
Diagnostic Test Mode (DTM) .
„
Illustrations depict replacement of left low beam
headlamp bulb.
Headlamps
„
Page 18 / 25
Procedure to replace left or right bulbs is the same.
Removing:
Caution!
„
Switch off all electrical consumers.
„
Switch off ignition and remove ignition key.
- Remove headlamp
installing .
94-1, Headlamps, removing and
- Unclip retainer - 1 - in direction of - arrow - and remove
cap - 2 - .
- Disconnect electrical connection - arrow - .
Headlamps
Page 19 / 25
- Compress and release spring clip - arrow - .
- Carefully pull out bulb from headlamp housing.
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.
- Insert new bulb so that locking lugs align with groove in
reflector.
- Install headlamp
installing
94-1, Headlamps, removing and
- Perform functional check of headlamp.
- Check and adjust headlamp aim
Repair Manual, Maintenance
.
High Beam Headlamp Bulbs M30 / M32, replacing
Note:
„
High beam headlamp bulb function can be checked
using Vehicle Electrical System Control Module
J519 On Board Diagnostic function "Output
Diagnostic Test Mode (DTM)" 97-5, Vehicle
Headlamps
Page 20 / 25
Electrical System Control Module J519 , Output
Diagnostic Test Mode (DTM) .
„
Illustrations depict replacement of left high beam
headlamp bulb.
„
Procedure to replace left or right bulbs is the same.
Removing:
Caution!
„
Switch off all electrical consumers.
„
Switch off ignition and remove ignition key.
- Remove headlamp
installing .
94-1, Headlamps, removing and
- Remove cap - arrow - at headlamp housing.
- Press locking lug in direction of - arrow - and disconnect
electrical connection - 1 - .
Headlamps
Page 21 / 25
- Turn bulb holder in - direction of arrow - and remove
from headlamp housing.
Note:
„
High beam bulb is permanently attached to the bulb
holder and cannot be replaced separately.
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.
- Perform functional check of headlamp.
- Check and adjust headlamp aim
Repair Manual, Maintenance
.
Parking Lamp Bulbs M1 / M3, replacing
Note:
„
Parking lamp bulb function can be checked using
Vehicle Electrical System Control Module J519 On
Board Diagnostic function "Output Diagnostic Test
Mode (DTM)" 97-5, Vehicle Electrical System
Control Module J519 , Output Diagnostic Test Mode
Headlamps
Page 22 / 25
(DTM) .
„
Illustrations depict replacement of left parking lamp.
„
Procedure to replace left and right bulbs is the
same.
Removing:
Caution!
„
Switch off all electrical consumers.
„
Switch off ignition and remove ignition key.
- Remove headlamp
installing .
94-1, Headlamps, removing and
- Remove cap - arrow - at headlamp housing.
- Press the 2 locking lugs inward - arrows - and remove
bulb holder with bulb.
- Remove bulb from bulb holder.
Headlamps
Page 23 / 25
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.
- Perform functional check of headlamp.
- Check and adjust headlamp aim
Repair Manual, Maintenance
.
Front Turn Signal Lamp Bulbs M5 / M7, replacing
Note:
„
Turn signal lamp bulb function can be checked using
Vehicle Electrical System Control Module J519 On
Board Diagnostic function "Output Diagnostic Test
Mode (DTM)" 97-5, Vehicle Electrical System
Control Module J519 , Output Diagnostic Test Mode
(DTM) .
„
Turn signal lamp function can be checked using
Output Diagnostic Test Mode (DTM) of Vehicle
Electrical System Control Module J519
97-5,
Vehicle Electrical System Control Module J519 ,
Output Diagnostic Test Mode (DTM) .
„
Illustrations depict replacement of left front turn
signal lamp bulb.
„
Procedure to replace left and right bulbs is the
same.
Removing:
Caution!
Headlamps
Page 24 / 25
„
Switch off all electrical consumers.
„
Switch off ignition and remove ignition key.
- Remove headlamp
installing .
94-1, Headlamps, removing and
- Remove cap - arrow - at headlamp housing.
- Disconnect electrical connection - arrows - from bulb
holder.
- Turn bulb holder in direction of - arrow - .
Headlamps
Page 25 / 25
- Remove bulb holder with bulb from reflector.
- Press bulb into bulb holder and turn to left.
- Remove bulb from bulb holder.
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.
- Perform functional check of headlamp.
- Check and adjust headlamp aim
Repair Manual, Maintenance
.
Headlamps, adjusting
Special tools, testers and auxiliary items required
„
Optical Headlight Aimer VAS5107
„
Vehicle Diagnostic Testing and Information System
VAS 5051 or Vehicle Testing and Service System
VAS 5052
Note:
„
Always adjust headlights with optical headlight aimer
VAS 5107 using detailed aiming procedure and
specifications
Repair Manual, Maintenance