Headlight issue: 1997 1.9 TDi

[Possu]

Went to replace the dip beam bulbs on my TDI with something a bit brighter, all went well until I gently pushed the connector block on to the back of the bulb itself on the r/h headlight, the headlight reflector mounting lugs appear to have popped out of the retaining grommets? With the bulb removed, I was able to pull the refelctor back in to place but it popped back out when I trued reconnecting the electrics. The r/h beam now points downards.

How easy is it to remove the headlight lens so I can put everything together correctly?

The remote headlamp adjuster in the cabin also now appears not to be working although I was careful not to touch it - all thoughts appreciated with both issues.

[creedxup]

The electric height adjuster has a rod with a ball on the end that holds the internal reflector secure, I would think that the ball end has come out of it's slot, if you remove the electric adjuster motor, by twisting it, you will see whether you can re-fit the rod.

The headlight is removed by the two top screws (under the caps), and a screw under the indicator (remove the indicator by releasing a sprung clip), then release the top of the centre grill (3 screws) and the headlight can be removed.

The front lens is held on with spring clips and sealant and is difficult to remove.

I bought a new headlamp unit on-line for about £50

[yaman]

Try connecting the the block to the bulb before you
put the bulb into the light.

Only attempt to remove the lens if you have another
headlight on standby. I stick it in the oven (for 15minutes
at 120c) first, and then quickly (and carefully!!!) remove
the lens and sealant. But it could go wrong, you have
been warned

Regards
Jim

[Possu]

Thanks for the advice Creedxup, it went pretty well.

Removed indicators to find that the headlight mounting bolts on both sides of the car missing, I've used cable ties for the moment.

I unclipped the headlight from the housing far enough to get enough fingers inside to push the reflector back in to place once I'd pre-fitted the bulb & connector block in place. Reassembly went well although I think I may have rotated the beam height adjuster whilst the r/h headlight was disconnected which has put the headlights out of synch with each other.

I managed to remove the complete light unit without removing the centre grill.

Thanks again.