B5 A4/S4: One Piece Headlights, Clear Corner
Things You Will Need: Power drill and 5/64” drill bit (Dremel can be used), Needle nose plies, wire cutters, Ratchet with T30 Torx bit and 4” extension, Silicon, Silver spray paint (if wanted), Compressed Air.
Mod Time: 2.5 hours
Difficulty (1 to 5, 5 being the most difficult): 3 - Relatively easy, all it takes is some basic tools, a lot of patience and getting over the fear of drilling into your headlights.
Step 1 – Removing the Headlight
Since you will be removing the headlight, it is worth marking off the beam pattern so your lights are properly aimed when reinstalled. You can then proceed to remove the assembly.
Three torx screws hold the headlight in place.
Remove the first two, they are the obvious ones on the top of the headlight.
The third is located 4 to 5 inches below the white lamp adjustment screw. Be careful when loosening not to lose this screw.
Once all are unscrewed, carefully remove the light from the car.
Place the headlight on a table, protected by a soft towel.
Remove all the bulbs (and wiring harnesses to be extra careful) because you will be moving and shaking the headlight.
Step 2 – Removing the Insert
There are three orange tabs holding the insert in place. You must drill out the top and bottom one in order to free it from the assembly.
Drill two holes through the black backing of the assembly.
Slowly drill the top and bottom tabs out, slowly eating away at them. Be careful not to drill into the lens. This requires patience, its better to work slowly at drilling the tabs out.
Once both tabs have been drilled out you can slide the insert free.
It’s important to be gentle when dealing with the insert, it can easily scrape the chrome housing.
Using the needle nose pliers through the hold from the turn signal, slide the insert away from its original position.
Maneuver the insert into the turn signal area, allowing you to hold it with the needle nose plies. With your wire cutters, start cutting it, breaking it to pieces that fall through the hole. I found it easier to hold it at the same time as cutting, this helped me keep it away from the chrome housing.
Once the insert has been removed, you will need to clean the housing out. There will be small orange pieces and black plastic which can be blown through the holes using compressed air. I actually used an air compressor and vacuum to create an airflow through the assembly to get all the bits out.
Take your time cleaning the housing, you don’t want to see all sorts of bits inside your headlight once you have them back on the car.
Step 3 – Completing the Look
Now you have a nice clean looking assembly, its time to plug the holes you drilled.
Apply the silicon over the two holes. Be thorough, and check over again once dry to make sure they are completely sealed.
If you want your turn signals to blend in, now is the time to cover up the amber bulbs. With a few light coats of silver spray paint, the bulbs will look silver but blink amber.
Replace the bulbs (and wiring harness if removed) and remount the lamp.
The third screw is very tricky. Either use a magnet or use masking tape to hold the screw onto the bit.
Tighten down the assembly and readjust for proper aiming against your marked off beam pattern.
Now step back and enjoy the new look of your lights.
***Pictures Needed. Please Contact Us If You Have Photos of the Above Procedure. Thanks***
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