How to put the headlight back perfectly?

[loveyobi]

Hello All,

I am new to here. I own a 2004 New Beetle Hard Top. Today my coworker helped me to change the Headlight Low Beam on the driver's side since the bulb burnt. We managed to take out the headlight, change the bulb. But when we put the whole piece back, we are stuck. We tried almost like 1 hour to try to figure out how to put it in perfectly,but we didn't make it. The result is it has a small tilt on the bottom,the light is not touching the body perfectly. The top of the light is good and touching the body. We feel there is something inside blocking us to put the headlight completely in.

We decided to let it go like this,at least it won't drop on the road when I drive. But I am still not happy with the result.My coworker said we can try again tomorrow if I want.

Anybody had the successful experience that can share? I would always appreciate a lot!!!

[Bluebugster]

i replaced the headlight bulb myself with my best friend maria. First you have to release a clamp and the pull a leaver up which withh release the headlight and then you pull it out. To place it back in you have to slide it in on two tracks. Theres one on the left and theres one also on the right side. It should easily slide in, even though ours was alittle difficult. I hope that was helpful!! Goodluck!

[loveyobi]

We noticed the tricks when we put the light in.And we do slided on the tracks.However, we couldn't make the bottom sit perfectly.

How to post the picture here? I just took a picture of the headlight.

[Bluebugster]

you click on post reply and below where you reply to the thread there is a area for attached files and you click on manage attachments and you should be able to post up the picture

[Photobug]

Hi

A bit late to asnwer but I had that issue. I got the instruction here on the forum on how to replace the built in the headlight assembly. Putting it back in was not the easiest thing.

It is only after understanding how the mechanism works that I was able to snap it in. there is a ring inside the housing that caches the head light assembly. Even if it's made of plastic - dirt gets into it and it as to move freely inside to catch the assembly. There are 3 screws that hold that mechanism in place. Cleaning and lubricating this rind did it for me. When you push in the assembly the 3 prong get catch by the ring and induce a rotation and the ring locks holding the housing in place.

Mine is a 2003 NB convertible. I hope my experience can help someone

Happy motoring

ML

[IndyTom]

You don't have it properly aligned. There are 3 tracks that you have to be perfectly aligned in order to slide back in.
A lot of people think they are lined up with the track but most of them only get two out of the three.
Pull the headlight back out then look very carefully and slowly put it back in making sure all three of the tabs slide into the tracks. If you are just off by a tiny bit it will not go in all the way. And YES, the headlight could fall out if you hit a bump or a chuck hole if it isn't locked in all the way. Good Luck!

[IndyTom]

This PDF might help. One of the pictures does show the inside of the headlight housing. One large track on the side, a medium size track on the bottom and a small track on opposite side

[VWBubba]

BE CAREFUL !! If the headlight is stuck it can be difficult to get it out again. As Indytom suggested you may have missed a track which is very easy to do.

Problem now is getting the unit out again, DO NOT pull on the headlight lens as they are only glued on. The lens may come off or you break the seal and the headlight gets water in and fogs up.

My advice is to push it from the back after making sure the release clip is open. I use a piece of wood with a cloth on the end so not to damage anything. You will have read by now that when the light is out, make sure the tracks and the locking ring is clean and moves freely. The locking ring is designed to pull in the the light the last mm or so when locked and secured.

Have fun :-)