Hi,

I have a 2001 Passat, manual transmission. I've had some trouble with the drivers side headlight and discovered that the connector the headlamp plugs into has melted. I tried finding a replacement connector but they are not available, as far as I can tell. So I broke down and bought a new wiring harness but I now see that it is internal to the headlight assembly.

Now I'm trying to figure out how to remove the headlight assembly so I can get inside and replace the harness. I found three screws on the top that I removed and that made the assembly loose but I couldn't get it out of the car. It moved around more than half an inch but that was it. Any suggestions? Does anyone have a picture of the assembly details for that part of the car?

Thanks in advance,
Linn

You need to remove the front bumper assembly.

1- remove bellt pan.
2- remove 3 flathead screws on lower bumper assembly
3- remove air grilles in lower bumper and remove t30 bolts behind them (1 on each side)
4- remove the center grille ( unclip the sides andpull out and up, also to remove the latch release rod stick a screwdriver in and twist. It might break but there only about 10.00 from the dealer for a new one and its thicker.
5- take out all the t30 bolts that hold the cover on under the gril you just took out.
6- remove all t20 torx screws from front side of wheel housing liners (there should be 4 i believe and 1 that goes up and down to hold bumper cover to fender (its hidden kinda in the middle)
7- you should be able to just pull the front bumper cover assembly off the front and you will see the other 2 screws that hold the lights on.

You need to remove the front bumper assembly.

1- remove bellt pan.
2- remove 3 flathead screws on lower bumper assembly
3- remove air grilles in lower bumper and remove t30 bolts behind them (1 on each side)
4- remove the center grille ( unclip the sides andpull out and up, also to remove the latch release rod stick a screwdriver in and twist. It might break but there only about 10.00 from the dealer for a new one and its thicker.
5- take out all the t30 bolts that hold the cover on under the gril you just took out.
6- remove all t20 torx screws from front side of wheel housing liners (there should be 4 i believe and 1 that goes up and down to hold bumper cover to fender (its hidden kinda in the middle)
7- you should be able to just pull the front bumper cover assembly off the front and you will see the other 2 screws that hold the lights on.
Wow, that's pretty involved looking but nice step-by-step instructions. I'm not sure exactly what the "belt pan" is though, might you have a picture of it?

Thanks much,
Linn