Question about 2006 Volkswagen New Beetle

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Headlight installation 2006 Beetle TDI

Trying to install a headlight (pax side) on 2006 VW Beetle tdi.

I have had 3 headlights replaced @ $89.00 each over the last 2 years on 06 Beetle. Now it has gone out again and I am trying to replace myself. I thought I was a pretty good mechanic but I can't find the lever that everyone gkeeps talking about. Do you have a picture

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  • Anonymous Apr 20, 2009

    its a pain to get the headlight out on the 2006 beetle because there isnt enough room.

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For the 2006 Beetles
FYI - The bulb for the 2006 is DIFFERENT than the 98-05 beetles
GE - H7 55w
I will start with the tools I used:
(Locking mechanism)
1/4” drive ratchet with a 10” extension and a 5mm socket.
(secondary locking mechanism)
wooden paint stir stick (freebie from your local hardware or paint store) or some long thin stick like a wooden dowel.
Passenger’s Side
This is the easiest of the two as there is not as much in your way of both locking mechanisms. If you shine a light towards the front of the bottom of the light housing inside the engine compartment you will see a small silver pin with a 5mm head that has instructions on how to lock/unlock the primary locking mechanism printed on the black plastic above the pin. Using your 5mm socket and long extension. turn the pin ONLY 1/2 a turn and take care as the pin should turn VERY EASILY. Note that the direction to turn this pin is opposite for the passenger and driver's sides. Now the light housing should be able to move slightly out of it’s seat, but it will not come more than about 1” out of the front of the car. You may have to push on the back of the light housing, as VW puts some sticky sealer around the edge of the light housing in the front. A secondary locking mechanism still holds it in place. If you look a little further back, about 3” - 4”, from the primary locking pin; behind a wrapped wire, a/c line, and the power steering resevoir; you will see a horizontal silver lever, about 3” - 4” in length, pointing towards the front of the car. Using your wooden stick, simply hold this lever down about 1” to 2” and pull out the light housing at the same time. The entire housing should freely and easily come completely out of the front of the car. Take care removing it as there are no wires connected to it and it will fall to the floor if you are not holding on to it. Just open the back of the housing and replace the bulb that is out.
Driver’s Side
This is the most difficult one. The battery location is your enemy. In front of the battery, if you look with a flashlight, you will see the primary locking mechanism. It is the only silver looking pin there with a 5mm head. It looks like the headlamp adjusters on other cars. There are instructions printed on the black plastic above it. You should ONLY turn this 1/2 a turn, and you will NOT need to put much effort into turning it as it should turn very easily. You are not done yet. The entire headlamp assembly should be able to pull out of the fender about 1” now, then it will stop as if something else is holding it. You may have to push on the back of the light housing, as VW puts some sticky sealer around the edge of the light housing in the front. There is a secondary locking mechanism that is just a simple metal lever. If you look on the back of the battery, between the air filter housing and the battery, you should see the end of the small shiny silver lever. Using your wooden stick, simply hold this lever down about 1” to 2” and pull out the light housing at the same time. The entire housing should freely and easily come completely out of the front of the car. Take care removing it as there are no wires connected to it and it will fall to the floor if you are not holding on to it. Just open the back of the housing and replace the bulb that is out.

Posted on Dec 06, 2008

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Http://tech.bentleypublishers.com/servlet/JiveServlet/download/38-33028-364054-6889/Headlamp05to08.pdf
Try this link. It is the VW manual for the new headlight assembly removal procedure.

Posted on Oct 31, 2008

There is a silver looking lever right under the passanger side headlight inside the engine bay

Posted on Nov 02, 2008

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