Get Lights, bulbs, switches - exterior Guide for Volkswagen Amarok Truck First Generation (2010-2022)

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

94 – Lights, bulbs, switches - exterior

1

Headlights

⇒ a1.1 nd safety notes for gas discharge lamps”, page 93

⇒ o1.2 verview - headlight”, page 95

⇒ a1.3 nd installing headlight”, page 105

⇒ h1.4 eadlights”, page 110

⇒ a1.5 nd installing front turn signal bulb”, page 111

⇒ a1.6 nd installing side light bulb”, page 116

⇒ a1.7 nd installing dipped beam bulb”, page 121

⇒ a1.8 nd installing main beam bulb”, page 126

⇒ a1.9 nd installing daytime running light and main beam bulb”,

page 132

⇒ a1.10 nd installing gas discharge bulbL13/L14”, page 136

⇒ a1.11 nd installing LED module for daytime running light and

side lightL176/L177”, page 138

⇒ a1.12 nd installing control unit for daytime running light and

side lightJ860/J861”, page 138

⇒ a1.13 nd installing gas discharge bulb control unitJ343/J344”,

page 140

⇒ c1.14 onversion for left-hand/right-hand traffic”, page 141

⇒ a1.15 nd installing headlight range control motor”, page 147

1.1

Operation and safety notes for gas dis‐

charge lamps

Note

Never change bulbs if you are not familiar with the appropriate

procedures, safety precautions or tools.

1. Headlights

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WARNING

Danger to life due to high voltage.

♦ It is essential that the battery earth cable is disconnected

before any work on parts of the gas discharge headlight

is performed. The parts a marked with a yellow high

voltage symbol.

♦ Then switch dipped beam on and off again. This will

eliminate any possible residual voltage.

♦ Switch off ignition and all electrical consumers, and with‐

draw ignition key.

♦ The gas discharge lamp control unit must never be oper‐

ated without a gas discharge lamp.

♦ Due to the high voltage, the gas discharge lamp must

only be operated in the headlight housing. Voltages

above 28,000 V occur when igniting the gas discharge

lamp.

WARNING

Risk of injury due to burns, ultraviolet radiation, glare and

explosion.

♦ Due to high temperatures, the absorption of ultraviolet

radiation and risk of glare, the gas discharge lamp must

only be operated in the headlight housing.

♦ Avoid looking directly into the light beam; otherwise vi‐

sion may be impaired for a substantial time.

♦ Gas discharge lamps are under high internal pressure

and can explode while being changed.

♦ Always wear eye protection and gloves when removing

and installing gas discharge lamps!

WARNING

Risk of environmental pollution.

♦ Gas discharge lamps are classified as hazardous waste.

They contain metallic mercury (Hg) and traces of thalli‐

um.

♦ Gas discharge lamps must not be destroyed. Avoid con‐

tact with burst bulbs.

♦ Observe relevant disposal regulations.

♦ Only dispose of gas discharge lamps in containers inten‐

ded for this purpose at an authorised collection point.

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Caution

♦ Do not touch the bulb of the gas discharge lamp with

bare fingers. 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. Wear clean fabric gloves when inserting a

gas discharge lamp.

♦ A defective gas discharge lamp must always be re‐

newed with a new gas discharge lamp of the same type.

The designation appears on the base of the bulb or on

the bulb glass.

♦ Properly engage connectors during installation and the

connection is seated tightly.

1.2

Assembly overview - headlight

⇒ o1.2.1 verview - Arteb headlights with H1 bulb”, page 95

⇒ o1.2.2 verview - Valeo headlights with H1 bulb”, page 97

⇒ o1.2.3 verview - Arteb headlights with H15 bulb”, page 99

⇒ o1.2.4 verview - Valeo headlights with H15 bulb”, page 101

⇒ o1.2.5 verview - gas discharge headlight”, page 103

1.2.1

Assembly overview - Arteb headlights

with H1 bulb

Note

♦ Arteb headlights can be identified by the large cap -6- with

retaining clip on the back side.

♦ Before working on headlights, always switch off the head‐

lights and remove the ignition key.

♦ When dealing with complaints, it is absolutely essential that

the function and operation of the lighting system are first

understood.

♦ Additional information:

⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐

tions

⇒ Operating manual

Fault detection and fault display:

The onboard supply control unit has a self-diagnostic function,

which makes fault finding on headlights easier.

For fault finding, use the systems described in chapter “Vehi‐

cle diagnosis, testing and information system” in “Guided Fault

Finding” mode ⇒ page 269 .

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1 - Front left turn signal bulb

-M5- or front right turn signal

bulb -M7-

❑ Bulb 12V, PY21W

❑ Removing and instal‐

ling ⇒ page 111

2 - Bulb holder for turn signal

bulb

3 - Rubber cover cap on rear

headlight housing

4 - Left side-light bulb -M1- or

right side-light bulb -M3-

❑ Bulb 12V, W5W

❑ Removing and instal‐

ling ⇒ page 116

5 - Retaining clip for cover on

rear headlight housing

6 - Cover on rear headlight

housing

7 - Holder for bulb for side

light

8 - Retaining clip for headlight

dipped beam bulb

9 - Left headlight dipped

beam bulb -M29- or right

headlight dipped beam bulb -

M31-

❑ H7 bulb

❑ 12V, 55 W

❑ Removing and instal‐

ling ⇒ page 121

10 - Securing bolts for top of

headlight housing

❑ Specified torque: 2 Nm

11 - Headlights

❑ Removing and installing ⇒ page 105

❑ Adjusting ⇒ page 110

❑ Headlight conversion for left-hand/right-hand traffic ⇒ page 141

❑ Repairs to the headlight fastening tabs are not envisaged at the moment. In the event of damage, the

entire headlight must be renewed.

12 - Securing bolts for bottom of headlight housing

❑ Specified torque: 2 Nm

13 - Securing bolts for bottom of headlight housing

❑ Specified torque: 2 Nm

14 - Securing bolts for top of headlight housing

❑ Specified torque: 2 Nm

15 - Left headlight main beam bulb -M30- and right headlight main beam bulb -M32-

❑ H1 bulb

❑ 12 V, 55 W

❑ Removing and installing ⇒ page 126

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❑ On vehicles with “Canyon” equipment version with optional main beam headlights on the roof bar, the

front headlights are not provided with a main beam function ⇒ page 150 .

1.2.2

Assembly overview - Valeo headlights

with H1 bulb

Note

♦ On vehicles as of 07.2012, Valeo headlights with H1 bulbs

can also be installed.

♦ Valeo headlights can be identified by the 3 individual rubber

caps on the back side.

♦ Before working on headlights, always switch off the head‐

lights and remove the ignition key.

♦ When dealing with complaints, it is absolutely essential that

the function and operation of the lighting system are first

understood.

♦ Additional information:

⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐

tions

⇒ Operating manual

Fault detection and fault display:

The onboard supply control unit has a self-diagnostic function,

which makes fault finding on headlights easier.

For fault finding, use the systems described in chapter “Vehi‐

cle diagnosis, testing and information system” in “Guided Fault

Finding” mode ⇒ page 269 .

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1 - Left headlight main beam

bulb -M30- or right headlight

main beam bulb -M32-

❑ H1 bulb

❑ 12 V, 55 W

❑ Removing and instal‐

ling ⇒ page 129

❑ On vehicles with “Can‐

yon” equipment ver‐

sion with optional main

beam headlights on the

roof bar, the front head‐

lights are not provided

with a main beam func‐

tion ⇒ page 150 .

2 - Front left turn signal bulb

-M5- or front right turn signal

bulb -M7-

❑ Bulb 12V, PY21W NA

❑ Removing and instal‐

ling ⇒ page 113

3 - Bulb holder with grip ele‐

ment for turn signal bulb

4 - Rubber cap at rear of

headlight housing

5 - Rubber cap at rear of

headlight housing

6 - Rubber cap at rear of

headlight housing

7 - Bulb holder with grip ele‐

ment for side light bulb

8 - Left side-light bulb -M1- or

right side-light bulb -M3-

❑ Bulb 12V, W5W LL

❑ Removing and installing ⇒ page 118

9 - Left headlight dipped beam bulb -M29- or right headlight dipped beam bulb -M31-

❑ H7 bulb

❑ 12V, 55W LL

❑ Removing and installing ⇒ page 123

10 - Securing bolt for top of headlight housing

❑ Specified torque: 2 Nm

11 - Securing bolt for top of headlight housing

❑ Specified torque: 2 Nm

12 - Headlights

❑ Removing and installing ⇒ page 109

❑ Adjusting ⇒ page 110

❑ Headlight conversion for left-hand/right-hand traffic ⇒ page 141

❑ Repairs to the headlight fastening tabs are not envisaged at the moment. In the event of damage, the

entire headlight must be renewed.

13 - Securing bolt for bottom of headlight housing

❑ Specified torque: 2 Nm

14 - Securing bolt for bottom of headlight housing

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Electrical system - Edition 12.2020

❑ Specified torque: 2 Nm

1.2.3

Assembly overview - Arteb headlights

with H15 bulb

Note

♦ Arteb headlights can be identified by the large cap -6- with

retaining clip on the back side.

♦ Before working on headlights, always switch off the head‐

lights and remove the ignition key.

♦ When dealing with complaints, it is absolutely essential that

the function and operation of the lighting system are first

understood.

♦ Additional information:

⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐

tions

⇒ Operating manual

Fault detection and fault display:

The onboard supply control unit has a self-diagnostic function,

which makes fault finding on headlights easier.

For fault finding, use the systems described in chapter “Vehi‐

cle diagnosis, testing and information system” in “Guided Fault

Finding” mode ⇒ page 269 .

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1 - Front left turn signal bulb

-M5- or front right turn signal

bulb -M7-

❑ Bulb 12V, PY21W

❑ Removing and instal‐

ling ⇒ page 113

2 - Bulb holder for turn signal

bulb

3 - Rubber cover cap on rear

headlight housing

4 - Left side-light bulb -M1- or

right side-light bulb -M3-

❑ Bulb 12V, W5W

❑ Removing and instal‐

ling ⇒ page 118

5 - Retaining clip for cover on

rear headlight housing

6 - Cover on rear headlight

housing

7 - Holder for bulb for side

light

8 - Retaining clip for headlight

dipped beam bulb

9 - Left headlight dipped

beam bulb -M29- or right

headlight dipped beam bulb -

M31-

❑ H7 bulb

❑ 12 V, 55 W

❑ Removing and instal‐

ling ⇒ page 123

10 - Securing bolt for top of

headlight housing

❑ Specified torque: 2 Nm

11 - Headlights

❑ Removing and installing ⇒ page 109

❑ Adjusting ⇒ page 110

❑ Headlight conversion for left-hand/right-hand traffic ⇒ page 141

❑ Repairs to the headlight fastening tabs are not envisaged at the moment. In the event of damage, the

entire headlight must be renewed.

12 - Securing bolt for bottom of headlight housing

❑ Specified torque: 2 Nm

13 - Securing bolt for bottom of headlight housing

❑ Specified torque: 2 Nm

14 - Securing bolts for top of headlight housing

❑ Specified torque: 2 Nm

15 - Bulb for left main beam and daytime running light or bulb for right main beam and daytime running light

❑ H15 bulb

❑ 12 V, 15/55W

❑ Removing and installing ⇒ page 132

❑ On vehicles with “Canyon” equipment version with optional main beam headlights on the roof bar, the

front headlights are not provided with a main beam function ⇒ page 150 .

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16 - Left headlight range control motor -V48- or right headlight range control motor -V49-

❑ The actuator cannot be renewed individually. In the event of damage, the entire headlight must be

renewed.

1.2.4

Assembly overview - Valeo headlights

with H15 bulb

Note

♦ On vehicles as of 07.2012, Valeo headlights with H15 bulbs

can also be installed.

♦ Valeo headlights can be identified by the 3 individual rubber

caps on the back side.

♦ Before working on headlights, always switch off the head‐

lights and remove the ignition key.

♦ When dealing with complaints, it is absolutely essential that

the function and operation of the lighting system are first

understood.

♦ Additional information:

⇒ Current flow diagrams, Electrical fault finding and Fitting loca‐

tions

⇒ Operating manual

Fault detection and fault display:

The onboard supply control unit has a self-diagnostic function,

which makes fault finding on headlights easier.

For fault finding, use the systems described in chapter “Vehi‐

cle diagnosis, testing and information system” in “Guided Fault

Finding” mode ⇒ page 269 .

1. Headlights

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1 - Front left turn signal bulb

-M5- or front right turn signal

bulb -M7-

❑ Bulb 12V, PY21W NA

❑ Removing and instal‐

ling ⇒ page 113

2 - Bulb holder with grip ele‐

ment for turn signal bulb

3 - Rubber cap at rear of

headlight housing

4 - Left side-light bulb -M1- or

right side-light bulb -M3-

❑ Bulb 12V, W5W LL

❑ Removing and instal‐

ling ⇒ page 119

5 - Bulb holder with grip ele‐

ment for side light bulb

6 - Rubber cap at rear of

headlight housing

7 - Rubber cap at rear of

headlight housing

8 - Left headlight dipped

beam bulb -M29- or right

headlight dipped beam bulb -

M31-

❑ H7 12V, 55W LL

❑ Removing and instal‐

ling ⇒ page 124

9 - Securing bolt for top of

headlight housing

❑ Specified torque: 2 Nm

10 - Securing bolt for top of

headlight housing

❑ Specified torque: 2 Nm

11 - Headlights

❑ Removing and installing ⇒ page 109

❑ Adjusting ⇒ page 110

❑ Headlight conversion for left-hand/right-hand traffic ⇒ page 141

❑ Repairs to the headlight fastening tabs are not envisaged at the moment. In the event of damage, the

entire headlight must be renewed.

12 - Securing bolt for bottom of headlight housing

❑ Specified torque: 2 Nm

13 - Securing bolt for bottom of headlight housing

❑ Specified torque: 2 Nm

14 - Bulb for left main beam and daytime running light or bulb for right main beam and daytime running light

❑ with grip element

❑ H15 12 V, 55/15W

❑ Removing and installing ⇒ page 134

❑ On vehicles with “Canyon” equipment version with optional main beam headlights on the roof bar, the

front headlights are not provided with a main beam function ⇒ page 150 .

15 - Left headlight range control motor -V48- or right headlight range control motor -V49-

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❑ The actuator cannot be renewed individually. In the event of damage, the entire headlight must be

renewed.

1.2.5

Assembly overview - gas discharge headlight

1. Headlights

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1 - Headlights

❑ Removing and instal‐

ling ⇒ page 109

❑ Adjusting ⇒ page 110

❑ Headlight conversion

for left-hand/right-hand

traffic ⇒ page 141

❑ Repairs to the head‐

light fastening tabs are

not envisaged at the

moment. In the event

of damage, the entire

headlight must be re‐

newed.

2 - Securing bolt

❑ Qty. 4

❑ Headlight to body

❑ Specified torque: 2 Nm

3 - Headlight range control

motor

❑ Left headlight range

control motor -V48-

❑ Right headlight range

control motor -V49-

❑ Removing and instal‐

ling ⇒ page 147

4 - Housing cover

5 - Securing bolts

❑ Qty. 5

❑ For housing cover ⇒

Item 4 (page 104)

❑ Specified torque:

1.8 Nm

6 - Gas discharge bulb

❑ With integrated starter unit

❑ D8S, 25 Watt

❑ Left gas discharge (xenon) bulb -L13-

❑ Right gas discharge (xenon) bulb -L14-

❑ Removing and installing ⇒ page 136

7 - Housing cover

❑ For front turn signal bulb ⇒ Item 8 (page 104)

8 - Front turn signal bulb

❑ With grip

❑ 12V, H21W

❑ Front left turn signal bulb -M5-

❑ Front right turn signal bulb -M7-

❑ Removing and installing ⇒ page 114

9 - LED module for daytime running light and side light

❑ Left LED module for daytime running light and side light -L176-

❑ Right LED module for daytime running light and side light -L177-

❑ Cannot be renewed individually

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10 - Control unit for daytime running light and side light

❑ Control unit for left daytime running light and side light -J860-

❑ Control unit for right daytime running light and side light -J861-

❑ Removing and installing ⇒ page 138

11 - Securing bolt

❑ Qty. 3

❑ For control unit for daytime running light and side light ⇒ Item 10 (page 104)

❑ Specified torque: 1.8 Nm

12 - Securing bolt

❑ Qty. 3

❑ For control unit for gas discharge bulb ⇒ Item 13 (page 105)

❑ Specified torque: 1.8 Nm

13 - Gas discharge bulb control unit

❑ Left gas discharge bulb control unit -J343-

❑ Right gas discharge bulb control unit -J344-

❑ Removing and installing ⇒ page 140

1.3

Removing and installing headlight

⇒ a1.3.1 nd installing headlights, Arteb headlights with H1 bulb”,

page 105

⇒ a1.3.2 nd installing headlights, Valeo headlights with H1

bulb”, page 109

⇒ a1.3.3 nd installing headlights, Arteb headlights with H15

bulb”, page 109

⇒ a1.3.4 nd installing headlights, Valeo headlights with H15

bulb”, page 109

⇒ a1.3.5 nd installing headlights, gas discharge headlights”,

page 109

1.3.1

Removing and installing headlights, Ar‐

teb headlights with H1 bulb

Note

♦ There is no requirement to disconnect the battery earth

strap.

♦ Illustrations show removal and installation of the left head‐

light. Removal and installation of the right headlight are car‐

ried out in the same way.

♦ If a headlight is removed, the alignment should always be

checked following installation ⇒ page 110 .

Special tools and workshop equipment required

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♦ Torque wrench -V.A.G 1331-

Removing

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

Caution

Risk of damage to component.

♦ Carefully pull off bumper. When doing this, ensure that

the bumper is not being deformed or torn.

♦ In order to avoid scratches on the surfaces when remov‐

ing the headlight, mask off the surrounding areas.

– Loosen front bumper cover on the respective side and care‐

fully push it until the lower bolts can be reached.

– Unscrew lower securing bolts -arrows- from headlight.

Right headlight up to model year 2017

– Remove air duct on air filter housing -arrow- ⇒ Power unit;

Rep. gr. 24; Air filter; Assembly overview - air filter housing.

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Continued for all vehicles

– Unclip overflow hose of coolant expansion tank located

above headlight, leave it connected, and lay it to one side.

– Unscrew upper securing bolts -arrows- from headlight.

– Pull headlight slightly forwards at top to gain access to con‐

nector.

Note

Depending on the equipment, the position of the connector on

the headlight may differ from the position shown in the illustra‐

tion.

– Release and disconnect connector -arrow- on headlight.

– Take headlight housing out forwards.

Installing

Install in the reverse order of removal, observing the following:

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– Insert headlight into bracket. When doing this, make sure

that the lateral guide -arrow- is correctly seated.

– Start all securing bolts.

– Use adjuster screw to align headlight -arrow- in relation to

the body.

– Tighten all securing bolts of headlight.

Note

When fitting the bumper cover, make sure that the radiator air

ducts are properly seated behind the bumper cover ⇒ General

body repairs, exterior; Rep. gr. 63; Front bumper; Assembly

overview - bumper cover.

– Check functions of headlight.

– Checking and, if necessary, adjusting headlight setting ⇒

page 110 .

Specified torques

♦ ⇒ o1.2.1 verview - Arteb headlights with H1 bulb”, page 95

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1.3.2

Removing and installing headlights,

Valeo headlights with H1 bulb

Note

♦ The procedure for removal and installation of Valeo head‐

lights with H1 bulb is identical to the procedure for Arteb

headlights with H1 bulb.

♦ Removing and installing headlights, Arteb headlights with H1

bulb ⇒ page 105 .

1.3.3

Removing and installing headlights, Ar‐

teb headlights with H15 bulb

Note

♦ The procedure for removal and installation of Arteb head‐

lights with H15 bulb is identical to the procedure for Arteb

headlights with H1 bulb.

♦ Removing and installing headlights, Arteb headlights with H1

bulb ⇒ page 105 .

1.3.4

Removing and installing headlights,

Valeo headlights with H15 bulb

Note

♦ The procedure for removal and installation of Valeo head‐

lights with H15 bulb is identical to the procedure for Arteb

headlights with H1 bulb.

♦ Removing and installing headlights, Arteb headlights with H1

bulb ⇒ page 105 .

1.3.5

Removing and installing headlights,

gas discharge headlights

WARNING

Risk of death due to high voltage! Risk of injury and environ‐

mental pollution!

♦ High voltage is supplied to the gas discharge bulbs. If

they are not handled properly they can cause serious or

fatal injuries.

♦ If work on high-voltage components is to be performed

after a headlight has been removed (e.g. change gas

discharge bulb), the battery earth strap must be discon‐

nected and the residual voltage in the headlight must be

discharged before the headlight is removed.

♦ Observe operation and safety notes for gas discharge

bulbs ⇒ page 93 .

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Note

♦ The procedure for removal and installation of gas discharge

headlights is identical to the procedure for Arteb headlights

with H1 bulb.

♦ Removing and installing headlights, Arteb headlights with H1

bulb ⇒ page 105 .

1.4

Adjusting headlights

Note

The illustrations shows the adjuster screw for adjusting the left

headlight. Adjuster screws on right headlight are in a mirror-im‐

age arrangement.

A - Screw for vertical headlight setting

B - Screw for horizontal headlight setting

Adjusting headlights ⇒ Maintenance; Booklet ; Descriptions of

work.

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1.5

Removing and installing front turn sig‐

nal bulb

⇒ a1.5.1 nd installing front turn signal bulb, Arteb headlights

with H1 bulb”, page 111

⇒ a1.5.2 nd installing front turn signal bulb, Valeo headlights

with H1 bulb”, page 113

⇒ a1.5.3 nd installing front turn signal bulb, Arteb headlights

with H15 bulb”, page 113

⇒ a1.5.4 nd installing front turn signal bulb, Valeo headlights

with H15 bulb”, page 113

⇒ a1.5.5 nd installing front turn signal bulb, gas discharge head‐

lights”, page 114

1.5.1

Removing and installing front turn sig‐

nal bulb, Arteb headlights with H1 bulb

Note

♦ Removing and installing the bulbs is possible when the

headlight is installed.

♦ The diagrams show renewal of the front left turn signal bulb

-M5-.

♦ The renewal of the front right turn signal bulb -M7- is carried

out in the same way.

♦ The bulb of the left headlight can be replaced without it

being necessary to remove any other components.

♦ For bulb replacement on the right headlight the air duct

-arrow- must be removed beforehand.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Using grip element, turn bulb holder together with front turn

signal bulb in -direction of arrow-.

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– Pull out bulb holder together with turn signal bulb in

-direction of arrow-.

– Push front turn signal bulb -2- into bulb holder -1- and turn it

in -direction of arrow-.

– Pull front turn signal bulb -2- out of bulb holder -1-.

Front turn signal bulb: 12V, PY 21W NA

Installing:

Install in the reverse order of removal. When doing this, note

the following:

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Caution

When installing, make sure cover is correctly seated. The

ingress of water will cause permanent damage to the head‐

light.

Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the

bulb is switched on and cause the glass to cloud over.

– Insert new bulb with holder so that locking lugs are in re‐

cesses in headlight housing, and turn it in clockwise direc‐

tion as far as stop.

– Check function of headlight.

– Checking and, if necessary, adjusting headlight setting ⇒

page 110 .

1.5.2

Removing and installing front turn sig‐

nal bulb, Valeo headlights with H1 bulb

Note

♦ The procedure for removal and installation of the front turn

signal bulb in Valeo headlights with H1 bulb is identical to

the procedure for Arteb headlights with H1 bulb.

♦ Removing and installing front turn signal bulb ⇒ page 111 .

1.5.3

Removing and installing front turn sig‐

nal bulb, Arteb headlights with H15

bulb

Note

♦ The procedure for removal and installation of the front turn

signal bulb in Arteb headlights with H15 bulb is identical to

the procedure for Arteb headlights with H1 bulb.

♦ Removing and installing front turn signal bulb ⇒ page 111 .

1.5.4

Removing and installing front turn sig‐

nal bulb, Valeo headlights with H15

bulb

Note

♦ The procedure for removal and installation of the front turn

signal bulb in Valeo headlights with H15 bulb is identical to

the procedure for Arteb headlights with H1 bulb.

♦ Removing and installing front turn signal bulb ⇒ page 111 .

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1.5.5

Removing and installing front turn sig‐

nal bulb, gas discharge headlights

Note

♦ For reasons of clarity, the headlight is shown removed.

♦ The headlight does not need to be removed in order to in‐

stall or remove turn signal bulbs.

♦ The diagrams show renewal of the front left turn signal bulb

-M5-.

♦ The renewal of the front right turn signal bulb -M7- is carried

out in the same way.

♦ The bulb of the left headlight can be replaced without it

being necessary to remove any other components.

♦ For bulb replacement on the right headlight the air duct

-arrow- must be removed beforehand.

Removing

– Pull off housing cover -1- from headlight.

– Pull grip together with bulb holder -1- to stop in

-direction of arrow- to unlock it, and then pull it carefully out

of reflector.

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– Push turn signal bulb -1- into bulb holder on grip -2-, turn it

anti-clockwise, and pull it out of grip.

Front turn signal bulb: 12V, H21W

Installing

Installation is carried out in the reverse order. When installing

observe the following:

Caution

Risk of damage to the headlight.

♦ Do not touch the glass part of the bulb with bare fingers.

Fingers leave traces of grease on the glass bulb, which

evaporate when the bulb is switched on and cause the

glass bulb to cloud over.

♦ Wear e.g. clean fabric gloves when inserting bulbs.

♦ Make sure the housing cover is correctly seated when

installing. The ingress of water will cause permanent

damage to the headlight.

– Perform functional check.

– Check headlight setting and adjust headlight if necessary

⇒ Maintenance; Booklet 36.1; Descriptions of work

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1.6

Removing and installing side light bulb

⇒ a1.6.1 nd installing side light bulb, Arteb headlights with H1

bulb”, page 116

⇒ a1.6.2 nd installing side light bulb, Valeo headlights with H1

bulb”, page 118

⇒ a1.6.3 nd installing side light bulb, Arteb headlights with H15

bulb”, page 118

⇒ a1.6.4 nd installing side light bulb, Valeo headlights with H15

bulb”, page 119

⇒ a1.6.5 nd installing side light bulb, gas discharge headlights”,

page 121

1.6.1

Removing and installing side light bulb,

Arteb headlights with H1 bulb

Note

♦ Removing and installing the bulbs is possible when the

headlight is installed.

♦ The diagrams show renewal of the left side light bulb -M1-.

♦ The renewal of the right side light bulb -M3- is carried out in

the same way.

♦ The bulb of the left headlight can be replaced without it

being necessary to remove any other components.

♦ For bulb replacement on the right headlight the air duct

-arrow- must be removed beforehand.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Unlock retaining clip in -direction of arrow- and remove cap

-A- from headlight housing.

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– Pull side light bulb holder out of reflector in

-direction of arrow-.

– Carefully take bulb out of bulb holder.

Side light bulb: 12V, W5W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Caution

When installing, make sure cover is correctly seated. The

ingress of water will cause permanent damage to the head‐

light.

Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the

bulb is switched on and cause the glass to cloud over.

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– Insert side light bulb holder into reflector in

-direction of arrow- to stop.

– Check function of headlight.

– Checking and, if necessary, adjusting headlight setting ⇒

page 110 .

1.6.2

Removing and installing side light bulb,

Valeo headlights with H1 bulb

Note

♦ The procedure for removal and installation of the side light

bulb in Valeo headlights with H1 bulb is identical to the pro‐

cedure for Valeo headlights with H15 bulb.

♦ Removing and installing side light bulb, Valeo headlights

with H15 bulb ⇒ page 119 .

1.6.3

Removing and installing side light bulb,

Arteb headlights with H15 bulb

Note

♦ The procedure for removal and installation of the side light

bulb in Arteb headlights with H15 bulb is identical to the

procedure for Arteb headlights with H1 bulb.

♦ Removing and installing side light bulb, Arteb headlights with

H1 bulb ⇒ page 116 .

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1.6.4

Removing and installing side light bulb,

Valeo headlights with H15 bulb

Note

♦ Removing and installing the bulbs is possible when the

headlight is installed.

♦ The diagrams show renewal of the left side light bulb -M1-.

♦ The renewal of the right side light bulb -M3- is carried out in

the same way.

♦ The bulb of the left headlight can be replaced without it

being necessary to remove any other components.

♦ For bulb replacement on the right headlight the air duct

-arrow- must be removed beforehand.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Pull cap -1- off headlight housing.

– Pull side light bulb -1- in -direction of arrow- straight out of

reflector.

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– Carefully pull bulb straight out of bulb holder.

Side light bulb: 12V, W5W LL

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Caution

When installing, make sure cover is correctly seated. The

ingress of water will cause permanent damage to the head‐

light.

Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the

bulb is switched on and cause the glass to cloud over.

– Insert side light bulb holder -1- in -direction of arrow- into

reflector as far as stop.

– Check function of headlight.

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– Checking and, if necessary, adjusting headlight setting ⇒

page 110 .

1.6.5

Removing and installing side light bulb,

gas discharge headlights

Note

♦ The left LED module for daytime running light and side light

-L176-/right LED module for daytime running light and side

light -L177- are only fitted on gas discharge headlights.

♦ The daytime running light and side lights (LEDs) are integra‐

ted in the headlight. These LEDs cannot be renewed. If one

of the LEDs fails, the entire headlight needs to be renewed.

1.7

Removing and installing dipped beam

bulb

⇒ a1.7.1 nd installing dipped beam bulb, Arteb headlights with

H1 bulb”, page 121

⇒ a1.7.2 nd installing dipped beam bulb, Valeo headlights with

H1 bulb”, page 123

⇒ a1.7.3 nd installing dipped beam bulb, Arteb headlights with

H15 bulb”, page 123

⇒ a1.7.4 nd installing dipped beam bulb, Valeo headlights with

H15 bulb”, page 124

1.7.1

Removing and installing dipped beam

bulb, Arteb headlights with H1 bulb

Note

♦ Removing and installing the bulbs is possible when the

headlight is installed.

♦ The diagrams show renewal of the left headlight dipped

beam bulb -M29-.

♦ The renewal of the right headlight dipped beam bulb -M31-

is carried out in the same way.

♦ The bulb of the left headlight can be replaced without it

being necessary to remove any other components.

♦ For bulb replacement on the right headlight the air duct

-arrow- must be removed beforehand.

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Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Unlock retaining clip in -direction of arrow- and remove cap

-A- from headlight housing.

– Pull connector -arrow- off dipped beam bulb.

– To disengage clip in -direction of arrow-, first move it down

and then to left.

– Pull dipped beam bulb out of reflector in -direction of arrow-.

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Headlight dipped beam bulb: H7, 12 V, 55 W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Caution

When installing, make sure cover is correctly seated. The

ingress of water will cause permanent damage to the head‐

light.

Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the

bulb is switched on and cause the glass to cloud over.

– Insert new bulb so that the locking lugs lie in the grooves in

the reflector.

– Check function of headlight.

– Checking and, if necessary, adjusting headlight setting ⇒

page 110 .

1.7.2

Removing and installing dipped beam

bulb, Valeo headlights with H1 bulb

Note

♦ The procedure for removal and installation of the dipped

beam bulb in Valeo headlights with H1 bulb is identical to the

procedure for Valeo headlights with H15 bulb.

♦ Removing and installing dipped beam bulb, Valeo headlights

with H15 bulb ⇒ page 124 .

1.7.3

Removing and installing dipped beam

bulb, Arteb headlights with H15 bulb

Note

♦ The procedure for removal and installation of the dipped

beam bulb in Arteb headlights with H15 bulb is identical to

the procedure for Arteb headlights with H1 bulb.

♦ Removing and installing dipped beam bulb, Arteb headlights

with H1 bulb ⇒ page 121 .

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1.7.4

Removing and installing dipped beam

bulb, Valeo headlights with H15 bulb

Note

♦ Removing and installing the bulbs is possible when the

headlight is installed.

♦ The diagrams show renewal of the left headlight dipped

beam bulb -M29-.

♦ The renewal of the right headlight dipped beam bulb -M31-

is carried out in the same way.

♦ The bulb of the left headlight can be replaced without it

being necessary to remove any other components.

♦ For bulb replacement on the right headlight the air duct

-arrow- must be removed beforehand.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Pull cap -3- off headlight housing.

Note

♦ The dipped beam headlight bulb is clipped into the reflector.

♦ Initially, do not disconnect the connector when removing the

dipped beam bulb.

– Push connector -1- together with bulb holder in

-direction of arrow- until bulb feels loose.

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– Pull connector -1- together with dipped beam bulb out of

reflector, while taking into account the lengths of connected

wires.

– Pull dipped beam bulb -1- straight off connector -2-.

Headlight dipped beam bulb: H7 12V, 55W LL

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Caution

When installing, make sure cover is correctly seated. The

ingress of water will cause permanent damage to the head‐

light.

Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the

bulb is switched on and cause the glass to cloud over.

– Insert new bulb so that lug on bulb holder -1- is positioned in

recess on reflector -arrow-.

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– Then, engage bulb in reflector.

– Check function of headlight.

– Checking and, if necessary, adjusting headlight setting ⇒

page 110 .

1.8

Removing and installing main beam

bulb

⇒ a1.8.1 nd installing main beam bulb, Arteb headlights with H1

bulb”, page 126

⇒ a1.8.2 nd installing main beam bulb, Valeo headlights with H1

bulb”, page 129

1.8.1

Removing and installing main beam

bulb, Arteb headlights with H1 bulb

Note

♦ Removing and installing the bulbs is possible when the

headlight is installed.

♦ The illustrations show the renewal of the left headlight main

beam bulb -M30-.

♦ The renewal of the right headlight main beam bulb -M32- is

carried out in the same way.

♦ The bulb of the left headlight can be replaced without it

being necessary to remove any other components.

♦ For bulb replacement on the right headlight the air duct

-arrow- must be removed beforehand.

♦ On vehicles with “Canyon” equipment version with optional

main beam headlights on the roof bar, the front headlights

are not provided with a main beam function ⇒ page 150 .

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Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove cap -arrow- from headlight housing.

– Pull connector -arrow- off main beam bulb.

– To disengage clip in -direction of arrow-, first move it down

and then to left.

– Pull main beam bulb out of reflector in -direction of arrow-.

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Headlight main beam bulb: H1, 12 V, 55 W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Caution

When installing, make sure cover is correctly seated. The

ingress of water will cause permanent damage to the head‐

light.

Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the

bulb is switched on and cause the glass to cloud over.

– Insert new bulb so that the locking lugs lie in the grooves in

the reflector.

– Check function of headlight.

– Checking and, if necessary, adjusting headlight setting ⇒

page 110 .

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1.8.2

Removing and installing main beam

bulb, Valeo headlights with H1 bulb

Note

♦ Removing and installing the bulbs is possible when the

headlight is installed.

♦ The illustrations show the renewal of the left headlight main

beam bulb -M30-.

♦ The renewal of the right headlight main beam bulb -M32- is

carried out in the same way.

♦ The bulb of the left headlight can be replaced without it

being necessary to remove any other components.

♦ For bulb replacement on the right headlight the air duct

-arrow- must be removed beforehand.

♦ On vehicles with “Canyon” equipment version with optional

main beam headlights on the roof bar, the front headlights

are not provided with a main beam function ⇒ page 150 .

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove cap -3- from headlight housing.

Note

♦ The headlight main beam bulb is clipped into the reflector.

♦ Initially, do not disconnect the connector when removing the

main beam bulb.

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– Push connector -1- in -direction of arrow- until bulb feels

loose.

– Grasp on connector and pull main beam bulb out of reflector,

while taking into account the lengths of connected wires.

– Pull main beam bulb -1- in -direction of arrow- straight off

connector -2-.

Headlight main beam bulb: H1, 12 V, 55 W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Caution

When installing, make sure cover is correctly seated. The

ingress of water will cause permanent damage to the head‐

light.

Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the

bulb is switched on and cause the glass to cloud over.

– Insert new bulb so that lug on bulb holder -1- is positioned in

recess on reflector.

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– Then, engage bulb in reflector.

– Check function of headlight.

– Checking and, if necessary, adjusting headlight setting ⇒

page 110 .

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1.9

Removing and installing daytime run‐

ning light and main beam bulb

⇒ a1.9.1 nd installing daytime running light and main beam

bulb, Arteb headlights with H15 bulb”, page 132

⇒ a1.9.2 nd installing daytime running light and main beam

bulb, Valeo headlights with H15 bulb”, page 134

1.9.1

Removing and installing daytime run‐

ning light and main beam bulb, Arteb

headlights with H15 bulb

Note

♦ Removing and installing the bulbs is possible when the

headlight is installed.

♦ The illustrations show the renewal of the right daytime run‐

ning light and main beam bulb.

♦ The renewal of the left daytime running light and main beam

bulb is carried out in the same way.

♦ The bulb of the left headlight can be replaced without it

being necessary to remove any other components.

♦ For bulb replacement on the right headlight, the air duct

-arrow- may have to be removed beforehand.

♦ On vehicles with “Canyon” equipment version with optional

main beam headlights on the roof bar, the front headlights

are not provided with a main beam function ⇒ page 150 .

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove cap -arrow- from headlight housing.

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– Turn bulb for main beam and daytime running light approx.

90° anti-clockwise in -direction of arrow-.

– Pull bulb for main beam and daytime running light out of

reflector in -direction of arrow-.

Daytime running light and main beam bulb: H15 12V, 15/55W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Caution

When installing, make sure cover is correctly seated. The

ingress of water will cause permanent damage to the head‐

light.

Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the

bulb is switched on and cause the glass to cloud over.

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– Turn bulb for main beam and daytime running light -1- in

-direction of arrow- until contacts in connection housing -2-

have engaged.

– Check function of headlight.

– Checking and, if necessary, adjusting headlight setting ⇒

page 110 .

1.9.2

Removing and installing daytime run‐

ning light and main beam bulb, Valeo

headlights with H15 bulb

Note

♦ Removing and installing the bulbs is possible when the

headlight is installed.

♦ The illustrations show the renewal of the left daytime running

light and main beam bulb.

♦ The renewal of the right daytime running light and main

beam bulb is carried out in the same way.

♦ The bulb of the left headlight can be replaced without it

being necessary to remove any other components.

♦ For bulb replacement on the right headlight the air duct

-arrow- must be removed beforehand.

♦ On vehicles with “Canyon” equipment version with optional

main beam headlights on the roof bar, the front headlights

are not provided with a main beam function ⇒ page 150 .

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

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– Pull cap -2- off headlight housing.

– Turn daytime running light and main beam bulb -1- anti-

clockwise by 90° in -direction of arrow-.

– Pull daytime running light and main beam bulb -1- in

-direction of arrow- out of reflector.

Note

The daytime running light and main beam bulb and the grip

element form one part and cannot be disassembled.

Daytime running light and main beam bulb: H15 12V, 55/15W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

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Caution

When installing, make sure cover is correctly seated. The

ingress of water will cause permanent damage to the head‐

light.

Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the

bulb is switched on and cause the glass to cloud over.

– Insert daytime running light and main beam bulb -1- in re‐

flector, and turn it in -direction of arrow- until contacts in

connection housing have engaged.

– Check function of headlight.

– Checking and, if necessary, adjusting headlight setting ⇒

page 110 .

1.10

Removing and installing gas discharge

bulb -L13-/-L14-

WARNING

Risk of death due to high voltage! Risk of injury and environ‐

mental pollution!

♦ High voltage is supplied to the gas discharge bulbs. If

they are not handled properly they can cause serious or

fatal injuries.

♦ If work on high-voltage components is to be performed

after a headlight has been removed (e.g. change gas

discharge bulb), the battery earth strap must be discon‐

nected and the residual voltage in the headlight must be

discharged before the headlight is removed.

♦ Observe operation and safety notes for gas discharge

bulbs ⇒ page 93 .

Note

Removal and installation are described for the left side. The

removal and installation procedure for the right-hand side is

basically the same.

Removing

– Remove headlight ⇒ page 109 .

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– Unscrew securing bolts -arrows- of housing cover -1-.

– Remove housing cover -1-.

– Press securing tab -arrow-, and disconnect connector -2-.

– Turn locking element -1- to stop in -direction of arrow-.

– Carefully remove gas discharge bulb -3- in a straight line

towards rear from reflector.

Installing

Installation is carried out in the reverse order. When installing

observe the following:

Caution

Risk of damage to the headlight.

♦ Do not touch the glass part of the bulb with bare fingers.

Fingers leave traces of grease on the glass bulb, which

evaporate when the bulb is switched on and cause the

glass bulb to cloud over.

♦ Wear e.g. clean fabric gloves when inserting bulbs.

♦ Make sure the housing cover is correctly seated when

installing. The ingress of water will cause permanent

damage to the headlight.

Note

Installation position: connector faces downwards.

– Perform functional check.

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– Check headlight setting and adjust headlight if necessary

⇒ Maintenance; Booklet 36.1; Descriptions of work

Specified torques

♦ ⇒ o1.2.5 verview - gas discharge headlight”, page 103

1.11

Removing and installing LED module

for daytime running light and side light

-L176-/-L177-

Note

♦ The left LED module for daytime running light and side light

-L176-/right LED module for daytime running light and side

light -L177- are only fitted on gas discharge headlights.

♦ The daytime running light and side lights (LEDs) are integra‐

ted in the headlight. These LEDs cannot be renewed. If one

of the LEDs fails, the entire headlight needs to be renewed.

1.12

Removing and installing control unit for

daytime running light and side light -

J860-/-J861-

WARNING

Risk of death due to high voltage! Risk of injury and environ‐

mental pollution!

♦ Observe operation and safety notes for gas discharge

bulbs ⇒ page 93 .

♦ It is essential that the battery earth cable is disconnected

before any work on parts of the gas discharge headlight

is performed. The parts a marked with a yellow high

voltage symbol.

Note

♦ The control unit for left daytime running light and side light

-J860-/control unit for right daytime running light and side

light -J861- are only fitted on gas discharge headlights.

♦ Removal and installation are described for the left side. The

removal and installation procedure for the right-hand side is

basically the same.

Removing

– Remove headlight ⇒ page 109 .

– Remove bolts -arrows-.

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– Pull control unit for left daytime running light and side light

-J860- -1- off headlight.

– Release and disconnect connector -arrow-.

– Remove control unit for left daytime running light and side

light -J860- -1-.

Installing

Installation is carried out in the reverse order. When installing

observe the following:

Caution

Make sure seal is correctly seated when installing the gas

discharge bulb control unit. The ingress of water will cause

permanent damage to the headlight.

– Connect connector and engage it.

– Check seal between control unit and headlight for damage.

Specified torques

♦ ⇒ o1.2.5 verview - gas discharge headlight”, page 103

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1.13

Removing and installing gas discharge

bulb control unit -J343-/-J344-

WARNING

Risk of death due to high voltage! Risk of injury and environ‐

mental pollution!

♦ Observe operation and safety notes for gas discharge

bulbs ⇒ page 93 .

♦ It is essential that the battery earth cable is disconnected

before any work on parts of the gas discharge headlight

is performed. The parts a marked with a yellow high

voltage symbol.

Note

Removal and installation are described for the left side. The

removal and installation procedure for the right-hand side is

basically the same.

Removing

– Remove headlight ⇒ page 109 .

– Remove bolts -arrows-.

– Remove left gas discharge bulb control unit -J343- -1- from

headlight.

– Release and disconnect connectors -arrows-.

– Remove left gas discharge bulb control unit -J343- -1-.

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Installing

Installation is carried out in the reverse order. When installing

observe the following:

Caution

Make sure seal is correctly seated when installing the gas

discharge bulb control unit. The ingress of water will cause

permanent damage to the headlight.

– Connect connectors and engage them.

– Check seal between control unit and headlight for damage.

Specified torques

♦ ⇒ o1.2.5 verview - gas discharge headlight”, page 103

1.14

Headlight conversion for left-hand/

right-hand traffic

Note

♦ The procedure for the headlight conversion for left-hand/

right-hand traffic applies only for vehicles without gas dis‐

charge bulbs.

♦ Vehicles with gas discharge bulbs and D8S light with 25 watt

meet the requirements for use in left-hand/right-hand traffic

without being converted.

Note

♦ To avoid dazzling oncoming traffic with the asymmetrical

lights, both headlights should be converted relevant to the

country (driving on the left or right) in which the vehicle is

being driven.

♦ The corresponding headlight conversion set consists of 2

sections of film.

♦ The conversion of the headlights is not designed as a per‐

manent conversion for other countries. It is only suitable as a

travel mode for a short stay abroad.

♦ Both headlights of a vehicle must always be converted.

♦ The details “right” and “left” on the masking film always refer

to the direction of travel when looking forwards from inside

the vehicle.

♦ Please note the different part numbers for the headlight con‐

version sets from right to left-hand traffic and from left to

right-hand traffic.

♦ Turn light switch to zero position.

Films for conversion

1. Headlights

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1 - Application film with pre-

punched masking film

❑ Conversion from driving

on right to driving on

left

❑ For left headlight

2 - Application film with pre-

punched masking film

❑ Conversion from driving

on left to driving on

right

❑ For left headlight

3 - Application film with pre-

punched masking film

❑ Conversion from driving

on left to driving on

right

❑ For right headlight

4 - Application film with pre-

punched masking film

❑ Conversion from driving

on right to driving on

left

❑ For right headlight

Conversion from driving on right to driving on left:

»Left headlight:«

– Clean headlight lens.

– Pull release paper off masking film.

– Align application film such that lower edge of application film

-1- is flush with lower edge of headlight -arrows-.

– Carefully pull application film -2- in -direction of arrow- off

headlight. The masking film -1- remains on the lens.

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The illustration shows the headlight with masking film -1- after

conversion.

Note

♦ Remove any remaining adhesive using alcohol-based or al‐

cohol and water-based cleaning fluid. For example a cloth

soaked with isopropyl alcohol.

♦ Customers should be informed of how to remove residual

adhesive after pulling off the masking section.

»Right headlight:«

– Clean headlight lens.

– Pull release paper off masking film.

– Align application film such that lower edge of application film

-1- is flush with lower edge of headlight -arrows-.

– Carefully pull application film -2- in -direction of arrow- off

headlight. The masking film -1- remains on the lens.

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The illustration shows the headlight with masking film -1- after

conversion.

Note

♦ Remove any remaining adhesive using alcohol-based or al‐

cohol and water-based cleaning fluid. For example a cloth

soaked with isopropyl alcohol.

♦ Customers should be informed of how to remove residual

adhesive after pulling off the masking section.

Conversion from driving on left to driving on right:

»Left headlight:«

– Clean headlight lens.

– Pull release paper off masking film.

– Align application film such that lower edge of application film

-1- is flush with lower edge of headlight -arrows-.

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– Carefully pull application film -2- in -direction of arrow- off

headlight. The masking film -1- remains on the lens.

The illustration shows the headlight with masking film -1- after

conversion.

Note

♦ Remove any remaining adhesive using alcohol-based or al‐

cohol and water-based cleaning fluid. For example a cloth

soaked with isopropyl alcohol.

♦ Customers should be informed of how to remove residual

adhesive after pulling off the masking section.

»Right headlight:«

– Clean headlight lens.

– Pull release paper off masking film.

– Align application film such that lower edge of application film

-1- is flush with lower edge of headlight -arrows-.

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– Carefully pull application film -2- in -direction of arrow- off

headlight. The masking film -1- remains on the lens.

The illustration shows the headlight with masking film -1- after

conversion.

Note

♦ Remove any remaining adhesive using alcohol-based or al‐

cohol and water-based cleaning fluid. For example a cloth

soaked with isopropyl alcohol.

♦ Customers should be informed of how to remove residual

adhesive after pulling off the masking section.

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1.15

Removing and installing headlight

range control motor

⇒ a1.15.1 nd installing headlight range control motor, Arteb

headlights with H15 bulb”, page 147

⇒ a1.15.2 nd installing headlight range control motor, Valeo

headlights with H15 bulb”, page 147

⇒ a1.15.3 nd installing headlight range control motor V48/V49,

gas discharge headlights”, page 147

1.15.1

Removing and installing headlight

range control motor, Arteb headlights

with H15 bulb

Note

♦ The left headlight range control motor -V48- or right head‐

light range control motor -V49- cannot be renewed individu‐

ally.

♦ In the event of repair, the entire headlight must be renewed

⇒ page 109 .

1.15.2

Removing and installing headlight

range control motor, Valeo headlights

with H15 bulb

Note

♦ The left headlight range control motor -V48- or right head‐

light range control motor -V49- cannot be renewed individu‐

ally.

♦ In the event of repair, the entire headlight must be renewed

⇒ page 109 .

1.15.3

Removing and installing headlight

range control motor -V48-/-V49-, gas

discharge headlights

Note

Removal and installation are described for the left side. The

removal and installation procedure for the right-hand side is

basically the same.

Removing

– Remove headlight ⇒ page 109 .

– Unscrew bolt -3-, and remove cover of headlight range ad‐

juster -1-.

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– Pull gear rack of headlight range adjuster -2- upwards out of

headlight housing.

– Unscrew the 5 securing bolts -arrows- on housing cover -1-.

– Remove housing cover -1-.

– Turn left headlight range control motor -V48- -1- to stop in

-direction of arrow- to release it.

– Swing left headlight range control motor -V48- -2- out of ball

head mounting on reflector -1-, and remove it from mounting

in headlight.

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– Disconnect connector -3-, and remove left headlight range

control motor -V48- -2-.

Installing

Installation is carried out in the reverse order. When installing

observe the following:

Caution

Risk of damage to the headlight.

♦ Make sure the housing cover is correctly seated when

installing. The ingress of water will cause permanent

damage to the headlight.

– Insert left headlight range control motor -V48- -2- into mount‐

ing in headlight, and connect connector -3-.

– Pull reflector towards rear, and insert ball head of left head‐

light range control motor -V48- -2- into ball head mounting

on reflector -1-.

– Turn left headlight range control motor -V48- -2- clockwise to

stop to lock it.

– Install gear rack and cover of headlight range adjuster.

– Turn headlight range adjuster. The reflector must move.

– Check function of headlights.

– Check headlight setting and adjust headlight if necessary

⇒ Maintenance; Booklet 36.1; Descriptions of work

Specified torques

♦ ⇒ o1.2.5 verview - gas discharge headlight”, page 103

1. Headlights

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2

Main beam headlights on roof

⇒ a2.1 nd installing main beam headlights on roof”, page 150

⇒ a2.2 nd installing bulb for main beam headlights on roof”,

page 153

⇒ m2.3 ain beam headlights on roof”, page 155

2.1

Removing and installing main beam

headlights on roof

⇒ a2.1.1 nd installing main beam headlights on roof, halogen

headlights”, page 150

⇒ a2.1.2 nd installing main beam headlights on roof, LED head‐

lights”, page 152

2.1.1

Removing and installing main beam

headlights on roof, halogen headlights

Note

♦ A roof bar with 4 main beam headlights is optionally availa‐

ble.

♦ If the vehicle is equipped with the roof bar and 4 main beam

headlights, the main beam function is only provided by the 4

main beam headlights on the roof.

♦ In this case, the front headlights are not provided with a

main beam function.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove bulb for main beam headlight on roof ⇒ page 153 .

Removing headlight housing:

– Remove securing bolts -3-.

– Carefully remove headlight housing -2- and guide out wires

-1- through passage in housing.

Removing headlight holder:

– Remove securing bolt -5-.

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– Carefully remove headlight holder -3- together with rubber

seal -2- from roof bar. Guide out wires -1- towards bottom

while doing so.

Note

When removing headlight holder from roof bar, take care not to

lose seal -4-.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Installing headlight holder:

– Guide wires -1- through headlight holder -3- and rubber seal

-2-.

– Insert seal -4- between roof bar and headlight holder -3-.

– Screw in securing bolt -5-, and tighten it to 20 Nm.

Installing headlight housing:

– Guide wires -1- through passage in headlight housing to‐

wards the inside.

2. Main beam headlights on roof

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– Fit headlight housing, screw in securing bolts -3-, and tighten

them to 20 Nm.

– Install bulb for main beam headlight on roof ⇒ page 153 .

– Perform functional check of main beam headlights on roof.

– Adjust main beam headlights on roof ⇒ page 155 .

2.1.2

Removing and installing main beam

headlights on roof, LED headlights

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Lower moulded headliner ⇒ General body repairs, interior;

Rep. gr. 70; Roof trims; Removing and installing moulded

headliner in double cab.

– Release end cap -2- from carrier -1- on left and right sides in

-direction of arrow-.

– Separate electrical connector under roof.

– Guide electrical wiring -4- out of roof.

– Remove securing bolts -2-.

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– Carefully remove headlight -1- and, when doing so, guide

both connecting wires outwards out of carrier -3-.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Perform functional check of main beam headlights on roof.

– Adjust main beam headlights on roof ⇒ page 155 .

2.2

Removing and installing bulb for main

beam headlights on roof

⇒ a2.2.1 nd installing bulb for main beam headlights on roof,

Halogen headlights”, page 153

⇒ a2.2.2 nd installing headlight main beam bulb on roof, LED

headlights”, page 154

2.2.1

Removing and installing bulb for main

beam headlights on roof, Halogen

headlights

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Unscrew the 4 securing bolts -1-.

– Remove headlight ring -2-, and carefully pull reflector -3-

slightly out of headlight housing -5-.

– Disconnect connectors -6- and -7-, and remove reflector.

– Pull bulb -4- out of reflector.

Bulb for main beam headlights on roof: H1 12V, 55W

2. Main beam headlights on roof

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Installing:

Install in the reverse order of removal. When doing this, note

the following:

Caution

Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the

bulb is switched on and cause the glass to cloud over.

– Connect connectors -6- and -7- to bulb -4- and reflector -3-.

– Insert reflector -3- with “TOP” marking facing upwards in

headlight housing -5-.

– Fit headlight ring -2- such that water drain aperture -arrow-

faces downwards.

– Screw in and tighten the 4 securing bolts -1-.

– Perform functional check of main beam headlights on roof.

2.2.2

Removing and installing headlight main

beam bulb on roof, LED headlights

Note

The headlight main beam bulbs are integrated in the headlight

as LEDs. These LEDs cannot be renewed. The headlight can

be renewed only as a complete unit.

– Removing and installing main beam headlights on roof ⇒

page 150

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2.3

Adjusting main beam headlights on

roof

⇒ m2.3.1 ain beam headlights on roof, halogen headlights”,

page 155

⇒ m2.3.2 ain beam headlights on roof, LED headlights”, page

156

2.3.1

Adjusting main beam headlights on

roof, halogen headlights

Note

♦ After removing and installing the main beam headlights on

the roof or after any other work which may influence the

headlight setting, check the setting of the headlights, and

adjust them if necessary.

♦ The relevant country's guidelines and legal regulations must

be observed on checking and adjusting.

Conditions for testing and adjustment:

♦ Tyre pressure OK.

♦ Lenses must not be damaged or dirty.

♦ Reflectors and bulbs OK.

♦ The vehicle must not be loaded (no load, no passengers).

Checking headlight settings:

– Place vehicle on a level surface facing a wall. Ensure that

the vehicle front is in parallel with the wall.

– Ensure dimension -a- between front bumper cover and wall

is 12 metres.

– The focal points of the 4 main beam headlights on the roof

must be positioned relative to centre line -1- as follows:

2. Main beam headlights on roof

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♦ a = 1,550 mm

♦ b = 600 mm

♦ c= 1250 mm

Adjusting headlights:

If the focal points are not in accordance with the specification,

the headlights must be adjusted.

– Loosen securing bolts -3- and align headlight housing -2-

according to the specification.

– Upon completion of the adjustment procedure, tighten secur‐

ing bolts -3- to 20 Nm.

– Adjust the other main beam headlights on the roof in the

same way.

2.3.2

Adjusting main beam headlights on

roof, LED headlights

Note

♦ After removing and installing the main beam headlights on

the roof or after any other work which may influence the

headlight setting, check the setting of the headlights, and

adjust them if necessary.

♦ The relevant country's guidelines and legal regulations must

be observed on checking and adjusting.

Conditions for testing and adjustment:

♦ Tyre pressure OK.

♦ Lenses must not be damaged or dirty.

♦ Reflectors and bulbs OK.

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♦ The vehicle must not be loaded (no load, no passengers).

Checking headlight settings:

– Place vehicle on a level surface facing a wall. Ensure that

the vehicle front is in parallel with the wall.

– Ensure dimension -a- between front bumper cover and wall

is 12 metres.

– The focal points of the 2 main beam headlights on the roof

must be positioned relative to vehicle centre line -1- as fol‐

lows:

♦ a = 1,550 mm

♦ b = 750 mm

Adjusting headlights:

If the focal points are not in accordance with the specification,

the headlights must be adjusted.

– Affix protective film beneath headlights.

– Loosen securing bolts -2- and -3- on both sides and align to

specified measuring points by moving headlight housing -1-.

2. Main beam headlights on roof

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– When adjustment is complete, tighten securing bolts -3- to

8 Nm and -2- to 2.5 Nm.

– Adjust the other main beam headlight on the roof in the

same way.

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3

Fog lights

⇒ o3.1 verview - fog lights”, page 159

⇒ a3.2 nd installing fog light”, page 160

⇒ a3.3 nd installing fog light bulb”, page 162

⇒ f3.4 og lights”, page 162

3.1

Assembly overview - fog lights

Assembly overview - fog lights as of model year 2017

1 - Fog lights

❑ Removing and instal‐

ling ⇒ page 160

2 - Seal

3 - Front fog light bulb

❑ Removing and instal‐

ling ⇒ page 162

4 - Electrical connector

5 - Bolt

❑ 1.5 Nm

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3.2

Removing and installing fog light

⇒ a3.2.1 nd installing fog lights up to model year 2017”, page

160

⇒ a3.2.2 nd installing fog lights as of model year 2017”, page

161

3.2.1

Removing and installing fog lights up to

model year 2017

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Unclip bumper trim at catches -arrows-.

– Remove bolts -arrows-.

– Pull fog light housing out of bumper.

– Release and disconnect connector -arrow-.

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Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Tighten bolts securing fog light to bumper cover to 1.5 Nm.

– Check functioning of fog light.

– Checking fog light settings and, if necessary, adjusting ⇒

page 162 .

3.2.2

Removing and installing fog lights as of

model year 2017

Special tools and workshop equipment required

♦ Torque screwdriver -V.A.G 1624-

Removing

– Switch off ignition.

– Turn light switch to zero position.

– Remove fog light trim ⇒ General body repairs, exterior; Rep.

gr. 63; Front bumper; Removing and installing bumper cov‐

er.

– Unscrew bolt -3-.

– Pull fog light -2- out of bumper cover.

– Disconnect electrical connector -1-.

Installing

Install in the reverse order of removal, observing the following:

– Make sure that fog light is properly seated in its mountings.

– Perform functional check.

– Check adjustment, and adjust fog light if necessary ⇒ Main‐

tenance; Booklet 11; Descriptions of work.

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3.3

Removing and installing fog light bulb

Note

Depending on vehicle equipment, the fog light bulb is also used

as static cornering light.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove fog light ⇒ page 160 .

– Turn bulb holder in -direction of arrow-, and remove it from

fog light.

Fog light bulb: H11 12V 55 W

Note

The left fog light bulb -L22- or right fog light bulb -L23- is

permanently fixed in the bulb holder and cannot be renewed

individually.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Caution

Do not touch bulb glass when installing a bulb. Fingers leave

traces of grease on the glass, which evaporate when the

bulb is switched on and cause the glass to cloud over.

– Check functions of fog light.

– Checking fog light settings and, if necessary, adjusting ⇒

page 162 .

3.4

Adjusting fog lights

Adjusting fog light ⇒ Maintenance; Booklet 11; Work descrip‐

tions.

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4

Side turn signals

⇒ a4.1 nd installing turn signal repeater”, page 163

⇒ t4.2 urn signal repeater bulb”, page 164

4.1

Removing and installing turn signal re‐

peater

Note

♦ The illustrations show removal and installation of the left turn

signal repeater.

♦ Removal and installation of the right turn signal light are

analogous.

Caution

Risk of damage when turn signal repeater is being removed!

♦ It is only possible to remove turn signal repeater in one

direction, therefore great care must be taken during re‐

moval.

♦ Attempting to lever out the light on the spring clip side by

force runs the risk of damaging the turn signal repeater

or the vehicle paintwork.

♦ When seen from outside in installed condition, it is not

possible to tell on which side of the turn signal repeater

the bearing point is located and on which side the spring

clip is located.

♦ Locate spring clip by carefully pushing turn signal re‐

peater sideways.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

Note

If the respective vehicle equipment allows for reaching the rear

of the turn signal repeater on the inside of the wing with the

hand, the turn signal repeater can also be pushed against the

spring clip and pushed out accordingly from behind.

– Mask off the painted area on both sides of the turn signal.

– Carefully press the turn signal light in the direction of the

spring clip -arrow- and, starting with the fixed anchor point,

pull it out of the body.

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– Pull holder -1- together with glass-base bulb -2- off bulb

housing -3-, and remove bulb housing.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Insert bulb housing into body, starting with the spring clip,

press in direction of spring clip, and secure it in body with

fixed anchor point.

– Perform functional check of turn signal repeater.

4.2

Removing turn signal repeater bulb

Note

♦ The illustrations show removal and installation of the left turn

signal repeater bulb -M18-.

♦ Removal and installation of bulb for right turn signal -M19-

are analogous.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove turn signal light ⇒ page 163 .

– Pull glass-base bulb -2- in a straight line out of bulb holder

-1-.

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Turn signal repeater bulb: glass-base bulb 12V, 5W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Fit rubber holder with glass-base bulb onto bulb housing.

– Install turn signal repeater ⇒ page 163 .

– Perform functional check of turn signal repeater.

4. Side turn signals

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5

Tail lights

⇒ o5.1 verview - tail light”, page 166

⇒ a5.2 nd installing tail light cluster”, page 167

⇒ a5.3 nd installing tail light bulb”, page 168

⇒ a5.4 nd installing brake light bulb”, page 169

⇒ a5.5 nd installing rear fog light bulb”, page 170

⇒ a5.6 nd installing reversing light bulb”, page 171

⇒ a5.7 nd installing turn signal bulb”, page 172

5.1

Assembly overview - tail light

1 - Ball head

2 - Tail light

❑ Removing and instal‐

ling ⇒ page 167

3 - Left tail light bulb -M4- or

right tail light bulb -M2-

❑ 12V, 5W/21W

❑ 21 W wire not present

❑ Removing and instal‐

ling ⇒ page 168

4 - Left brake light bulb -M21-

or right brake light bulb -M22-

❑ 12 V, 21W

❑ Removing and instal‐

ling ⇒ page 169

5 - Securing bolts of bulb car‐

rier

6 - Bulb carrier

7 - Left rear fog light bulb -

L46-

❑ Only installed on left

❑ 12V, 21W halogen

❑ Removing and instal‐

ling ⇒ page 170

8 - Right reversing light bulb

-M17-

❑ 12 V, 21W

❑ Only installed on right

❑ Removing and instal‐

ling ⇒ page 171

9 - Rear left turn signal bulb

-M6- or rear right turn signal bulb -M8-

❑ 12V, PY21W

❑ Removing and installing ⇒ page 172

10 - Securing bolts of tail light

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5.2

Removing and installing tail light clus‐

ter

Note

♦ The illustrations show the removal and installation for the

right tail light.

♦ The removal and installation of the left tail light are carried

out in the same way.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Open rear lid.

– Unscrew securing bolts -arrows- from tail light.

– Guide tail light sideways out of ball head in

-direction of arrow-.

– Release and disconnect connector -arrow- of tail light.

5. Tail lights

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– Remove tail light.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Connect connector and engage it.

– Insert tail light in body aperture, and fit fixtures onto ball

heads.

– Align tail light with body.

– Screw in securing bolts, and tighten them to 4 Nm.

5.3

Removing and installing tail light bulb

Note

♦ The illustrations show the removal and installation of the left

tail light bulb -M4-.

♦ The removal and installation of the right tail light bulb -M2-

are carried out in the same way.

♦ The 21 W glow coil will not be activated.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove tail light ⇒ page 167 .

– Unscrew securing bolts -arrows- on bulb holder.

– Push tail light bulb -3- into bulb holder, turn it in anti-clock‐

wise direction, and pull it out.

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Tail light bulb: 12V, 5W/21W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Perform functional check of tail lights.

5.4

Removing and installing brake light

bulb

Note

♦ The illustrations show the removal and installation of the left

brake light bulb -M21-.

♦ The removal and installation of the right brake light bulb

-M22- are carried out in the same way.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove tail light ⇒ page 167 .

– Unscrew securing bolts -arrows- on bulb holder.

– Push brake light bulb -4- into bulb holder, turn it in anti-clock‐

wise direction, and pull it out.

5. Tail lights

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Brake light bulb: 12 V, 21 W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Perform functional check of tail lights.

5.5

Removing and installing rear fog light

bulb

Note

The rear fog light bulb -L46- is only installed in left tail light.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove tail light ⇒ page 167 .

– Unscrew securing bolts -arrows- on bulb holder.

– Pull out rear left fog light bulb -L46- -1-.

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Rear left fog light bulb -L46-: 12V, 21W halogen

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Perform functional check of tail lights.

5.6

Removing and installing reversing light

bulb

Note

The reversing light bulb -M17- is only installed in right tail light.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove tail light ⇒ page 167 .

– Unscrew securing bolts -arrows- on bulb holder.

– Push right reversing light bulb -M17- -1- into bulb holder,

turn it in anti-clockwise direction, and pull it out.

5. Tail lights

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Right reversing light bulb -M17-: 12V, 21W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Perform functional check of tail lights.

5.7

Removing and installing turn signal

bulb

Note

♦ The illustrations show the removal and installation of the rear

left turn signal bulb -M6-.

♦ Removal and installation of rear right turn signal bulb -M8-

are carried out in the same way.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove tail light ⇒ page 167 .

– Unscrew securing bolts -arrows- on bulb holder.

– Push rear turn signal bulb -2- into bulb holder, turn it in

anti-clockwise direction, and pull it out.

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Rear turn signal bulb: 12V, PY21W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Perform functional check of tail lights.

5. Tail lights

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6

High-level brake light

⇒ a6.1 nd installing high-level brake light”, page 174

⇒ a6.2 nd installing high-level brake light”, page 177

6.1

Removing and installing high-level

brake light

⇒ a6.1.1 nd installing high-level brake light to model year 2017”,

page 174

⇒ a6.1.2 nd installing high-level brake light from model year

2017”, page 175

⇒ a6.1.3 nd installing high-level brake light CANYON”, page

175

6.1.1

Removing and installing high-level

brake light to model year 2017

Removing

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Push entire light a little in -direction of arrow- and remove

light.

– Release and disconnect connector -arrow-.

– Remove high-level brake light.

Installing

Install in the reverse order of removal. When doing this, note

the following:

– Insert light in body aperture at position -1-, and then engage

it at position -2-.

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– Perform functional check of additional brake light.

6.1.2

Removing and installing high-level

brake light from model year 2017

Removing

– Push high-level brake light -1- in -direction of arrow A-, then

swing out high-level brake light -1- in -direction of arrow B-.

– Disconnect electrical connector -2-.

– Detach high-level brake light -1-.

Installing

Install in reverse order of removal.

6.1.3

Removing and installing high-level

brake light “CANYON”

Special tools and workshop equipment required

6. High-level brake light

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♦ Torque screwdriver -VAS 6494-

♦ Wax spray ⇒ Electronic parts catalogue (ETKA)

Removing

– Unscrew bolts -1-.

– Pull off high-level brake light -2-.

– Disconnect electrical connector -2-.

– Detach high-level brake light -1-.

Installing

Install in the reverse order of removal, observing the following:

– Seal bolt heads with wax spray.

Specified torques

Component

Bolts

Specified torque

1.3 Nm

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6.2

Removing and installing high-level

brake light

Note

If the event of a defective LED, the entire additional brake light

needs to be renewed. It is not possible to repair light-emitting

diodes in interior.

6. High-level brake light

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7

Number plate light

⇒ a7.1 nd installing number plate light”, page 178

⇒ a7.2 nd installing bulb for number plate light”, page 179

7.1

Removing and installing number plate

light

Note

♦ When removing and installing components that are in view

(switches, covers, trim and so on), mask off areas in which

tools (assembly wedge -T10039/1-, screwdriver) are used

to lever out those components using commercially available

masking tape.

♦ The removal and installation procedure for both number

plate lights is carried out in the same way and is only descri‐

bed for one light.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Using a screwdriver, lever number plate light out of bumper

cover -arrow-.

– Release and disconnect connector -arrow-.

– Remove number plate light.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

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– Insert connector end of number plate light in bumper cover,

and firmly engage opposing side of number plate light.

– Check function of number plate light.

7.2

Removing and installing bulb for num‐

ber plate light

Note

On LED number plate lights, the entire light must be renewed if

an LED is faulty.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove number plate light ⇒ page 178 .

– Pull holder -3- together with bulb -2- out of number plate light

-1-.

– Pull bulb for number plate light -2- out of bulb holder -3-.

Bulb for number plate light: glass-base bulb 12V, 5W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Check function of number plate light.

7. Number plate light

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8

Load area light

⇒ a8.1 nd installing load area light”, page 180

⇒ a8.2 nd installing bulb for load area light”, page 182

8.1

Removing and installing load area light

⇒ a8.1.1 nd installing load area light”, page 180

⇒ a8.1.2 nd installing load area light CANYON”, page 181

8.1.1

Removing and installing load area light

The illustrations show the removal and installation for the right

load area light -B-.

The removal and installation of the left load area light -A- are

carried out in the same way.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Unclip light cover in -direction of arrow- and pull off to the

rear.

– Press locking lug -A- in -direction of arrow- -B-.

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– Lift load area light upwards in -direction of arrow C-, and

remove it from mounting -D-.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Perform functional check of load area light.

8.1.2

Removing and installing load area light

“CANYON”

Special tools and workshop equipment required

♦ Torque screwdriver -VAS 6494-

Removing

– Unscrew bolts -1-.

– Remove load area light -2-.

– Disconnect electrical connector.

Installing

Install in the reverse order of removal, observing the following:

8. Load area light

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Specified torques

Component

Bolts

Specified torque

1.3 Nm

8.2

Removing and installing bulb for load

area light

Note

♦ The illustrations show the removal and installation for the

right bulb for load area light -M53- -B-.

♦ The removal and installation of the left bulb for load area

light -M53- -A- are carried out in the same way.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove load area light ⇒ page 180 .

– Press spring clip -B- in direction of arrow -C- and remove

bulb for load area light -A-.

Bulb for load area light -M53-: festoon bulb 12V, 10W

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Perform functional check of load area light.

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9

Steering column switch module

⇒ a9.1 nd installing steering column switch module”, page 183

⇒ a9.2 nd installing ignition/starter switch”, page 186

⇒ a9.3 nd installing lock cylinder”, page 188

⇒ a9.4 nd installing steering lock housing”, page 190

9.1

Removing and installing steering col‐

umn switch module

Caution

To disconnect and reconnect the battery, the procedure de‐

scribed in the workshop manual should be strictly adhered to

⇒ page 11 .

The following equipment-specific components are integrated in‐

to the steering column switch module:

♦ Turn signal switch -E2-

♦ Headlight dipper and flasher switch -E4-

♦ Parking light switch -E19-

♦ Intermittent wiper regulator -E38-

♦ Intermittent wiper switch -E22-

♦ Multifunction display call-up button -E86-

♦ Multifunction display memory switch -E109-

♦ Cruise control system switch -E45-

♦ Button for CCS set -E227-

Special tools and workshop equipment required

♦ Torque wrench (5 - 50 Nm) -V.A.G 1331-

Note

♦ For removal and installation of the airbag coil connector and

return ring with slip ring -F138- or the steering column switch

module, the steering wheel must be in the “centre position”

(wheels in “straight ahead position”).

♦ The airbag coil connector and return ring with slip ring

-F138- is not to be moved out of position.

9. Steering column switch module

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Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Disconnect battery ⇒ page 11 .

– Remove steering wheel ⇒ General body repairs, interior;

Rep. gr. 69; Airbag; Removing and installing steering wheel.

– Release and disconnect connector -arrow-.

– Unclip fabric trim on top of steering column -arrows-, and

remove it.

– Remove upper part of steering column trim.

– Unscrew securing bolts -arrows- on inner side of trim.

– Remove lower part of steering column trim.

– Unscrew clamping bolt -arrow- on steering column switch

module.

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– Pull locking lever of connector on steering column switch

module upwards in -direction of arrow-.

– Pull steering column switch module out of contact connector

housings, and remove it.

Note

The connector catch on the steering column switch module runs

in a quadrant in the housing. When pulling out the switch mod‐

ule, it might be necessary to pull the locking lever up again to

enable the connector to easily slide out of the curved track.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Note

When assembling the steering column switch module, do not

push it completely onto the steering column to avoid cracking

sounds when steering.

– Tighten bolts -arrows- inside the trim to a torque of 1.5 Nm.

9. Steering column switch module

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9.2

Removing and installing ignition/starter

switch

Caution

To disconnect and reconnect the battery, the procedure de‐

scribed in the workshop manual should be strictly adhered to

⇒ page 11 .

Removing:

– Switch off ignition and all electrical consumers.

– Disconnect battery ⇒ page 11 .

– Remove steering column trim ⇒ General body repairs, interi‐

or; Rep. gr. 68; Compartments/covers; Steering column trim.

Note

♦ The illustrations below are only schematic illustrations and

specific details may vary.

♦ For reasons of clarity, the ignition/starter switch is shown

without steering wheel and steering column switch module in

the illustrations below.

– Pull out primary locking element -1- of connector in

-direction of arrow A-.

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– Press primary locking element -1- and pull connector -2- in

-direction of arrow B- off ignition/starter switch -D- -3-.

– Remove anti-tamper paint from securing screws -A-.

– Loosen securing bolts -A- slightly, and pull ignition/starter

switch -D- -1- in -direction of arrow- out of steering lock

housing.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Caution

When installing the ignition/starter switch, ensure that the

ignition/starter switch and the lock cylinder are in the same

position, e.g. “ignition on”.

– Turn ignition key in lock cylinder to “Ignition ON” position.

– Push ignition/starter switch into steering lock housing to

stop.

– Tighten securing screws and reinstate anti-tamper paint

coating.

– Push connector onto ignition/starter switch and push in pri‐

mary locking element.

9. Steering column switch module

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– Install steering column trim ⇒ General body repairs, interior;

Rep. gr. 68; Compartments/covers; Steering column trim.

9.3

Removing and installing lock cylinder

Caution

♦ The steering lock could be destroyed.

♦ If the steering lock is actuated without lock cylinder, it

will block and must be renewed.

♦ The steering lock must not be actuated without lock cyl‐

inder.

Removing

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove steering column trim ⇒ General body repairs, interi‐

or; Rep. gr. 68; Compartments/covers; Steering column trim.

– Release connector -arrow- of immobiliser reader coil on lock

cylinder and carefully pull it off.

Note

The immobiliser reading coil is secured to the lock cylinder and

cannot be renewed individually.

– Insert ignition key in lock cylinder and turn to position

“Drive”.

Positions for key in lock cylinder:

1 - Position “Stop”

2 - Position “Drive”

3 - Position “Start”

– Insert a piece of steel wire (approx. 1.2 mm in diameter) in

drilling next to ignition key -arrow-.

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Note

♦ In order to insert the steel wire straight into the hole, it may

be necessary to dismantle the ignition key and insert the key

into the lock cylinder without the key head.

♦ If possible, use the so-called “workshop key”. This has a

smaller head and there is no requirement for it to be disman‐

tled.

– Dismantling ignition key ⇒ General body repairs, exterior;

Rep. gr. 57; Front door.

– Release lock cylinder securing lever using steel wire -arrow-

and remove lock cylinder from steering lock housing.

1 - Lock cylinder

2 - Steel wire (approx. 1.2 mm diameter)

3 - Securing lever

9. Steering column switch module

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Installing

Install in the reverse order of removal. When doing this, note

the following:

– Insert ignition key in lock cylinder and turn to position

“Drive”.

– Release securing lever using a piece of steel wire (approx.

1.2 mm in diameter), and insert lock cylinder in steering lock

housing.

Note

When installing lock cylinder, ensure that connection for immo‐

biliser reader coil is in guide of steering lock housing.

– Pull piece of steel wire out of lock cylinder and check that

lock cylinder is sitting properly in steering lock housing.

– Connect immobiliser reader coil connector -arrow- to lock

cylinder and engage it.

– Install steering column trim ⇒ General body repairs, interior;

Rep. gr. 68; Compartments/covers; Steering column trim.

Note

In the event of complaints regarding the lock cylinder or the

steering lock, it is imperative that the corresponding key is also

provided if a warranty or goodwill claim is made. Without the

key, no analysis can be carried out for the steering lock or lock

cylinder by the manufacturer/supplier and the invoice will not be

covered by the warranty. In the event of non-compliance, the

warranty reserves the right to cancel the request. The purchase

costs for the new key can be submitted with the request.

9.4

Removing and installing steering lock

housing

Caution

To disconnect and reconnect the battery, the procedure de‐

scribed in the workshop manual should be strictly adhered to

⇒ page 11 .

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Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Disconnect battery ⇒ page 11 .

– Remove steering column switch module ⇒ page 183 .

Only vehicles with automatic gearbox

– Unclip clip -arrow-, and disconnect locking cable.

Continued for all vehicles:

WARNING

Danger of eye injury from drilling swarf.

When drilling out, swarf may fly off and cause eye injury.

Wear safety goggles.

– Drill out shear-head bolts -arrows-.

– Remove steering lock housing.

If steering lock housing is to be renewed, further steps may be

necessary:

– Remove lock cylinder ⇒ page 188 .

– Remove ignition/starter switch ⇒ page 186 .

Installing:

Install in the reverse order of removal. When doing this, note

the following:

9. Steering column switch module

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Caution

Steering lock will be damaged if improperly fitted!

Failure to follow instructions will result in damage to the

steering lock when the shear-head bolts are tightened.

Before fitting the steering lock housing to the steering col‐

umn, the ignition key must be turned in the lock cylinder to

the “Ignition ON” position.

Fit steering lock housing with new shear-head bolts -arrows- to

steering column.

– Tighten shear-head bolts until the heads shear off.

– Install steering column switch module ⇒ page 183 .

If the steering lock housing has been renewed:

– Install lock cylinder ⇒ page 188 .

– Install ignition/starter switch ⇒ page 186 .

Note

In the event of complaints regarding the lock cylinder or the

steering lock, it is imperative that the corresponding key is also

provided if a warranty or goodwill claim is made. Without the

key, no analysis can be carried out for the steering lock or lock

cylinder by the manufacturer/supplier and the invoice will not be

covered by the warranty. In the event of non-compliance, the

warranty reserves the right to cancel the request. The purchase

costs for the new key can be submitted with the request.

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10

Parking aid

⇒ o10.1 verview – parking aid”, page 193

⇒ a10.2 nd installing parking aid control unit”, page 195

⇒ r10.3 ear parking aid control unit”, page 196

⇒ a10.4 nd installing rear parking aid warning buzzer”, page

197

⇒ a10.5 nd installing front parking aid warning buzzer”, page

198

⇒ a10.6 nd installing rear parking aid senders”, page 200

⇒ a10.7 nd installing front parking aid senders”, page 202

10.1

Assembly overview – parking aid

Assembly overview - parking aid up to model year 2017 ⇒ page

193

Assembly overview - parking aid from model year 2017 ⇒ page

194

Assembly overview - parking aid up to model year 2017

10. Parking aid

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1 - Front parking aid warning

buzzer -H22-

❑ Installed behind light

switch in dash panel

❑ Removing and instal‐

ling ⇒ page 198

❑ Specified torque: 2 Nm

2 - Parking aid button -E266-

❑ Installed in switch unit

in upper section of

dash panel

❑ Removing and instal‐

ling ⇒ page 212

3 - Front right parking aid

sender -G252-, front centre

right parking aid sender -

G253-, front centre left park‐

ing aid sender -G254- and

front left parking aid sender -

G255-

❑ Installed in front bump‐

er.

❑ Removing and instal‐

ling ⇒ page 202

4 - Parking aid control unit -

J446-

❑ Installed behind right A-

pillar trim

❑ Removing and instal‐

ling ⇒ page 195

❑ Specified torque: 2 Nm

❑ Adapting rear parking

aid control unit ⇒ page

196

5 - Rear parking aid warning buzzer -H15-

❑ Installed behind upper right C-pillar trim

❑ Removing and installing ⇒ page 197

❑ Specified torque: 2 Nm

❑ Adjusting volume of rear warning buzzer ⇒ page 196

6 - Rear left parking aid sender -G203-, rear centre left parking aid sender -G204-, rear centre right parking

aid sender -G205- and rear right parking aid sender -G206-

❑ Installed in rear bumper.

❑ Removing and installing ⇒ page 200

Assembly overview - parking aid from model year 2017

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1 - Front parking aid warning

buzzer -H22-

❑ Installed behind light

switch in dash panel

❑ Removing and instal‐

ling ⇒ page 198

❑ Specified torque: 2 Nm

2 - Parking aid button -E266-

❑ Removing and instal‐

ling ⇒ page 212

3 - Front parking aid senders

❑ Front right parking aid

sender -G252-

❑ Front centre right park‐

ing aid sender -G253-

❑ Front centre left parking

aid sender -G254-

❑ Front left parking aid

sender -G255-

❑ Removing and instal‐

ling ⇒ page 202

4 - Parking aid control unit -

J446-

❑ Installed behind right A-

pillar trim

❑ Removing and instal‐

ling ⇒ page 195

❑ Specified torque: 2 Nm

5 - Rear parking aid warning

buzzer -H15-

❑ Installed behind upper

right C-pillar trim

❑ Removing and instal‐

ling ⇒ page 197

❑ Specified torque: 2 Nm

6 - Rear parking aid senders

❑ Rear left parking aid sender -G203-

❑ Rear left centre parking aid sender -G204-

❑ Rear right centre parking aid sender -G205-

❑ Rear right parking aid sender -G206-

❑ Removing and installing ⇒ page 200

10.2

Removing and installing parking aid

control unit

Note

The parking aid control unit -J446- is installed behind the right

A-pillar trim.

Special tools and workshop equipment required

10. Parking aid

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♦ Torque wrench -V.A.G 1783-

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove lower right A-pillar trim ⇒ General body repairs, in‐

terior; Rep. gr. 70; Pillar trims; Removing and installing lower

A-pillar trim.

– Remove plastic nuts -1-.

Note

The upper plastic nut can be reached easily using an offset ring

spanner. It becomes visible after the right dash panel trim is

unclipped.

– Release and disconnect connectors on control unit.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Tighten plastic nuts to 2 Nm.

10.3

Adapting rear parking aid control unit

This adaptation adapts the volume of the rear parking aid warn‐

ing buzzer -H15-.

– Connect vehicle diagnostic tester ⇒ Electrical system, Gen‐

eral information; Rep. gr. 97; Vehicle diagnosis, testing and

information systems; Connecting vehicle diagnostic tester.

– Select operating mode “Guided Fault Finding” in vehicle di‐

agnosis tester.

– Using “GoTo” button, select “Functions/component” and then

the following menu options in succession:

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♦ Body

♦ General body repairs

♦ 01 – Self-diagnosis compatible systems

♦ Parking aid

♦ Parking aid functions

♦ Parking aid adaption

10.4

Removing and installing rear parking

aid warning buzzer

Note

The rear parking aid warning buzzer -H15- is installed behind

the upper right C-pillar trim.

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1783-

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove upper right C-pillar trim ⇒ General body repairs,

interior; Rep. gr. 70; Pillar trims; Removing and installing

C-pillar trims

– Unscrew plastic screws -1-.

– Release and disconnect electrical connector -1-.

10. Parking aid

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Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Tighten plastic bolts to 2 Nm.

10.5

Removing and installing front parking

aid warning buzzer

Note

The front parking aid warning buzzer -H22- is installed in the

dash panel behind the light switch.

Special tools and workshop equipment required

♦ Torque wrench -V.A.G 1783-

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove left dash panel trim ⇒ General body repairs, interi‐

or; Rep. gr. 68; Compartments, covers and trims; Removing

and installing dash panel trim on left side.

– To gain access to the warning buzzer pull both red levers

-arrows-, and swing fuse holder downwards.

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– Unscrew the two plastic bolts -1- on the warning buzzer, and

remove warning buzzer.

– Release and disconnect electrical connector -1-.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

– Tighten plastic bolts to 2 Nm.

10. Parking aid

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10.6

Removing and installing rear parking

aid senders

Note

♦ The rear parking aid senders -G203, G204, G205 and G206-

are installed in the rear bumper cover.

♦ The senders cannot be removed without removing the rear

bumper cover.

♦ The removal of the four rear parking aid senders is carried

out in the same way and is only described for one sender in

the following.

♦ If the bumper is replaced with a new bumper which does not

have holes for the parking aid senders, the fasteners and

holes for the parking aid senders can be added later in some

cases. See the latest information in the workshop manual

⇒ General body repairs, exterior; Rep. gr. 63; Rear bumper

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove rear bumper cover ⇒ General body repairs, exteri‐

or; Rep. gr. 63; Rear bumper cover.

– Release and disconnect wiring harness connector for park‐

ing aid system -1- below vehicle.

Caution

To avoid damaging the sensor surface or the paintwork, do

not use any tools when removing.

When pressing the locking lugs, carefully push sensor out of

bracket using your finger.

– Push both locking lugs on bracket to one side in

-direction of arrow- and press parking aid sender inwards

from the outside.

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Rep. gr.94 - Lights, bulbs, switches - exterior

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

Caution

♦ The order for removing the senders must be adhered to

under all circumstances.

♦ The sender may otherwise be damaged. Fractures may

occur if too much pressure is applied to the sender, and

this may cause the sender to fail.

♦ First remove the sender from the retainer and then re‐

lease and disconnect the sender's connector.

– Release and disconnect connector -2- and remove sender

-1-.

Note

♦ When removing the sender, ensure the isolation ring (black

silicone ring) remains on the sender head and does not re‐

main stuck in the bracket or become lost.

♦ Expanding the isolation ring must be avoided under all cir‐

cumstances.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

10. Parking aid

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Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

Note

♦ When installing the sender, ensure that the isolation ring is

correctly mounted on the sender head and does not ride or

roll up on insertion into the sender retainer.

♦ Both locking lugs of sender bracket must audibly engage

when installing the sender.

– After installing the sender, check that the sender is correctly

seated in the bracket. Visible on the outer side of the bump‐

er, dimension -a- of the ring gap between the sender head

and bumper cover must be even all around.

10.7

Removing and installing front parking

aid senders

Note

♦ The front parking aid senders -G252, G253, G254 and

G255- are installed in the front bumper cover.

♦ The senders cannot be removed without removing the rear

bumper cover.

♦ Removal of the four front parking aid senders is carried out

in the same way and is only described as follows for one

sender.

♦ If the bumper is replaced with a new bumper which does not

have holes for the parking aid senders, the fasteners and

holes for the parking aid senders can be added later in some

cases. See the latest information in the workshop manual

⇒ General body repairs, exterior; Rep. gr. 63; Rear bumper

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Remove front bumper cover ⇒ General body repairs, exteri‐

or; Rep. gr. 63; Front bumper cover

Note

♦ Before removing bumper cover, separate hose connection

from headlight washer system pump -V11-.

♦ Collect leaking fluid in accordance with regulations.

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Rep. gr.94 - Lights, bulbs, switches - exterior

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

Caution

To avoid damaging the sensor surface or the paintwork, do

not use any tools when removing.

When pressing the locking lugs, carefully push sensor out of

bracket using your finger.

– Push both locking lugs on bracket to one side in

-direction of arrow- and press parking aid sender inwards

from the outside.

Caution

♦ The order for removing the senders must be adhered to

under all circumstances.

♦ The sender may otherwise be damaged. Fractures may

occur if too much pressure is applied to the sender, and

this may cause the sender to fail.

♦ First remove the sender from the retainer and then re‐

lease and disconnect the sender's connector.

– Slide locking element in -direction of arrow A-, then push it in

-direction of arrow B- and pull off connector.

10. Parking aid

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Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

Note

♦ When removing the sender, ensure the isolation ring (black

silicone ring) remains on the sender head and does not re‐

main stuck in the bracket or become lost.

♦ Expanding the isolation ring must be avoided under all cir‐

cumstances.

Installing:

Install in the reverse order of removal. When doing this, note

the following:

Note

♦ When installing the sender, ensure that the isolation ring is

correctly mounted on the sender head and does not ride or

roll up on insertion into the sender retainer.

♦ Both locking lugs of sender bracket must audibly engage

when installing the sender.

– After installing the sender, check that the sender is correctly

seated in the bracket. Visible on the outer side of the bump‐

er, dimension -a- of the ring gap between the sender head

and bumper cover must be even all around.

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Rep. gr.94 - Lights, bulbs, switches - exterior

Amarok 2011 ➤, Amarok 2017 ➤

Electrical system - Edition 12.2020

11

Towing bracket

⇒ a11.1 nd installing trailer detector control unit”, page 205

⇒ p11.2 in assignment for trailer socket”, page 206

11.1

Removing and installing trailer detector

control unit

Note

♦ Trailer detector control unit -J345- is installed beneath dash

panel.

♦ In towing mode, the start/stop system is switched off.

Removing:

– Switch off ignition and all electrical consumers, and withdraw

ignition key.

– Unclip dash panel trim below steering column.

– Remove securing bolts -1-.

– Guide trailer detector control unit -1- out of bracket.

– Release and disconnect connectors on control unit.

Installing:

Installation is carried out in the reverse sequence of removal.

11. Towing bracket

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Electrical system - Edition 12.2020

11.2

Connector pin assignment for trailer

socket

Note

In towing mode, the start/stop system is switched off.

1 - Terminal BLL (left turn signal)

2 - Terminal NSL (rear fog lamp)

3 - Terminal 31 (earth)

4 - Terminal BRR (right turn signal)

5 - Terminal 58 R (right tail light)

6 - Terminal 54 (brake light)

7 - Terminal 58 L (left tail light)

8 - Terminal RF (reversing light)

9 - Terminal 30 (battery “+”)

10 - Not assigned

11 - Not assigned

12 - Not assigned

13 - Terminal 31 (earth)

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Rep. gr.94 - Lights, bulbs, switches - exterior

Lights, bulbs, switches - exterior for Your Volkswagen Amarok Truck First Generation (2010-2022)

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