Loosen and remove the T25 screw located in the wheel well (each side), 3 screws in the wheel well (each side), and 3 flathead screws located on the underside of the bumper cover.
Step 2: Using the flathead screwdriver, gently pry the parking light away from the vehicle. Disconnect the light and remove it from the vehicle (each side).
Step 3: Remove the 2 T30 screws located on the bumper cover near the radiator.
Step 4: Remove the vehicle's grille.
There is a small release lever that allows you to remove the bumper cover. Using the flathead screwdriver, gently pry the latching mechanism and pull these levers free of the vehicle. In the center (just in front of the radiator) use a flathead screwdriver to release the vehicle's grille.
Step 5: Loosen the 4 T30 screws exposed by the grille's removal. You can now remove the front bumper cover.
Step 6: Disconnect your fog lights.
Step 7: Loosen and remove the 2 T30 screws that hold the small panel that spans the radiator area.
This gives you a bit more room to work. If you're only replacing one side, full removal isn't necessary. Instead, we are simply looking to allow for a slight "pull-back" of the panel near the headlight assemblies.
Step 8: Remove the two plastic ducts that cover the headlight assembly mounting area.
The rear panel comes off first, by simply pulling it off, and the other is removed by loosening and removing its 3 retaining screws.
Step 9: Remove the small square rubber grommet, exposing the screw beneath it. Loosen and remove the 4 screws that hold the headlight assembly in place.
Two screws are easily found on top of the headlight assembly. Another is located in the area exposed by removing the rubber grommet, and the final screw is between the duct that was just removed and the back of the headlight assembly.
Step 10: Disconnect the wiring harness on the back of the headlight assembly.
Step 11: With all of the retaining bolts removed, you can now remove the headlight assembly.
NOTE: If you ordered your replacement headlight assembly from Go-Parts, it likely includes new bulbs, as most of our models do. This saves you the installation step of removing the bulbs from the old assembly! However, in case your particular model doesn't include new bulbs, you can easily remove them from the old assembly and insert them into the new one!
Step 12: Connect the wiring harness to the new headlight assembly.
Step 13: Secure the new headlight assembly by tightening the four 10mm retaining bolts.
Step 14: Reattach the two plastic ducts by tightening the retaining screws.
Step 15: Reattach the vehicle's grille.
Step 16: Reattach the vehicle's bumper cover.
NOTE: Be sure to reconnect the fog lights' wiring harnesses before secure the bumper cover to the vehicle!
Step 17: Reattach the side marker lights to the bumper cover.
While we are more than happy to create these installation guides for your benefit, we cannot maintain any liability regarding the part, or the driving experience, once the part has been replaced/installed. We always guarantee the quality of the parts we provide, but the installation liability rests solely on the installer.
And, though we are always here to answer your questions, please note that our technicians created these guides for your convenience, and cannot provide assistance beyond this guide.
These Part Change / Installation Instructions Apply to
05 2005, 04 2004, 03 2003, 02 2002, 01 2001 Volkswagen Passat Headlight Replacement Instructions