cts4b5tt
04-10-2023, 09:53 AM
*edit 2: Pictures appear to be loading in on mobile now. Still keeping the individual links. More disclaimers.
Sup y'all,
I'd like to preface this with letting you know that I have done tons and TONS of searching and I have not been able to find a writeup or video on how to take apart an A7 headlight specifically, so I wanted to put something together that would hopefully help someone in the future. There's A6 stuff all over the place, but nothing for A7.
Also, disclaimer: part of this project happened because I totally effed up when I took the first light apart and tore the ribbon cable for the LED's. In my defense, all I did was try to bend it off to the side and it was so brittle that it snapped.
Disclaimer 2: This write-up is for HID (NON-LED) ONLY. Full LED headlights (aka the fancy schmancy ones) are PERMASEALED and you need to sell your soul to Hades if you ever want to get those apart. HID, pre-facelift headlights use butyl like a normal person and are easy to take apart. Thanks Cameron for the reminder.
Disclaimer 3: ATTEMPT AT YOUR OWN RISK. I made plenty of mistakes during this project and some things did break, I'm here to try to prevent you from doing the same but I AM NOT responsible for any damage you incur on your own property.
Disclaimer 4: I know I'll catch a full ration of poop from this by a lot of you, but I would like to point out that this didn't go as I initially intended, and also it's my car I do what I want *Cartman voice*
Now, a look at the final product:
301766
Ok, so here's how it should go down. I suggest reading through the whole post before you think you want to do this/ gain a more general understanding.
Tools needed: Copious amounts of patience. Oven. Basic german car tools (torx bits, screwdrivers, large hammers). Flashlight. Pick set.
1. Remove bumper. It's so easy, there's like 4 screws on each side fender well and 2 on the top, pops right off.
2. Remove headlights and brackets. Pop off the connector on the back, like 4 bolts on all sides. You don't have to remove the bolts all the way, just loosen them. Brackets have a plastic key you pull up on, and 2 bolts holding them on.
3. Preheat oven to 200 degrees Fahrenheit.
4. Remove all bulbs/ ballasts and clips. Not sure if this is 100% necessary, but better safe than sorry. I replaced my bulbs with LED bulbs, but if you're planning on keeping your original bulbs be very careful with them. Each ballast has 3 screws on bottom of headlight. There are about 6 metal clips securing the lens cap to the housing. Use a flathead and pop them off.
5. Place headlight in oven for 15-20 minutes.
6. CAUTION HOT. You've been warned. Use gloves and remove headlight, and quickly bring it to your work surface. Use a flathead screwdriver and gently begin to pry between the lens and housing. Mine came off very easily, with no hassle whatsoever. Easiest part of this whole nightmarish job.
Should now look something like this:
301768
7. Have some flatheads, small to medium, and some curved/right angle picks available. The first thing to take off is the gloss black piece that lines the LEDs. One tab on the side, a couple underneath. I used a pick for these because they're kind of "blocked" by a clear plastic piece and you need to get behind them.
301771301770301769
8. Next is the upper chrome strip. It has one tab on the inside of the light, and one that goes through the back. It's easier to the the back one out first. I gave mine a good tug (you heard me) and it popped out, the second light I did that on, it broke. Use caution.
301774301773301772
9, Next is the lower chrome strip. It has one tab towards the back and one screw on the inside. Screw first, tab second. Much like my friday nights.
https://i.imgur.com/0QOn3hl.jpeg
https://i.imgur.com/0QOn3hl.jpeg
10. Time to take off the led strip. There are 4 screws that line the bottom and one on the top, pictured. I circled the wrong bolt in one of them but you get the idea. Give it a solid tug after and it should pop out, and at the same time totally rip apart the $#&&^(*& ribbon cable for the LEDs.
https://i.imgur.com/cv74KGB.jpeg
https://i.imgur.com/cv74KGB.jpeg
https://i.imgur.com/rZVaNzB.jpeg
https://i.imgur.com/rZVaNzB.jpeg
https://i.imgur.com/UqHABQc.jpeg
https://i.imgur.com/UqHABQc.jpeg
https://i.imgur.com/cAvEcaK.jpeg
https://i.imgur.com/cAvEcaK.jpeg
https://i.imgur.com/r0mAKtA.jpeg
https://i.imgur.com/r0mAKtA.jpeg
It'll look something like this now:
https://i.imgur.com/99t91sd.jpeg
https://i.imgur.com/99t91sd.jpeg
11. Next is the WORST part of the whole thing. This large plastic piece that makes up the back. Have some angled picks and a few extra hands available. I tried to capture where all the tabs are and how i put the picks in. If (when) you have trouble, try using a flashlight to get a good look in there. Try to have all the tabs popped up a bit and pull pull pull. I broke the top corner of mine off trying to pry it forward with a screwdriver. Somehow overall the first headlight went better than the second. Also be mindful of a screw and tab that need to be undone underneath the projector lens.
https://i.imgur.com/osCLk4x.jpeg
https://i.imgur.com/osCLk4x.jpeg
https://i.imgur.com/g2plPAy.jpeg
https://i.imgur.com/g2plPAy.jpeg
https://i.imgur.com/aq30BUw.jpeg
https://i.imgur.com/aq30BUw.jpeg
https://i.imgur.com/OMN6GiK.jpeg
https://i.imgur.com/OMN6GiK.jpeg
https://i.imgur.com/umukyLa.jpeg
https://i.imgur.com/umukyLa.jpeg
After the top strip of this piece is loose, you can bend it down a little and get to this screw that is holding it and the signal lens in.
https://i.imgur.com/2PkJMTL.jpeg
https://i.imgur.com/2PkJMTL.jpeg
I'm done numbering steps now. Too much work. Plus now I can say "in just 11 easy* steps!". Anyway here's the whole thing removed finally and a couple scrapes later.
https://i.imgur.com/nlS6khA.jpeg
https://i.imgur.com/nlS6khA.jpeg
Now to the high beam (unused) housing. This one is easy, it's just held in by some tight fit clip thingies. I used a large screwdriver to pop it off from the front and the back. I circled all 3 of the thingies. They are tight, force is not only necessary, but encouraged.
https://i.imgur.com/ioo8Xbv.jpeg
https://i.imgur.com/ioo8Xbv.jpeg
https://i.imgur.com/sU0bDFA.jpeg
https://i.imgur.com/sU0bDFA.jpeg
https://i.imgur.com/dfnIRg4.jpeg
https://i.imgur.com/dfnIRg4.jpeg
For the signal housing, you already removed one screw, there's a second behind the high beam housing.
https://i.imgur.com/0PatELZ.jpeg
https://i.imgur.com/0PatELZ.jpeg
Here's where things get pretty optional. Also if you like me so far, I would stop reading now so as to leave our delicate relationship intact.
I'm serious.
Taking apart the LED strip very straightforward, same tabs as the gloss black piece, just more of them.
https://i.imgur.com/yYopqQm.jpeg
https://i.imgur.com/yYopqQm.jpeg
So because I royally effed the ribbon cable, through no fault of my own, I was forced to order some pretty cool LED strips from Amazon, one so I could get them immediately, two because they have a cool sequential turn signal. Judge away. The best option i could think of was to hot glue these bad boys into the original LED channel, using the raised sides of the individual bulbs as a gluing point.
https://i.imgur.com/12yuvvM.jpeg
https://i.imgur.com/12yuvvM.jpeg
The new LEDs need somewhere to exit, so take your best pair of dikes and cut open a slot at the end of the strip, and at the same spot in the housing. I used hot glue as a buffer so it won't rub on any sharp edges.
https://i.imgur.com/0EM8t13.jpeg
https://i.imgur.com/0EM8t13.jpeg
https://i.imgur.com/CXuHQqZ.jpeg
https://i.imgur.com/CXuHQqZ.jpeg
Since the LED lens is fairly clear and the new LED's are a little rough and slightly embarrassing, i used some sandpaper to give it an opaque look, so you can't see directly in. These new bulbs are quite bright, so don't worry about visibility going out. I think I used 320.
https://i.imgur.com/XmWF9Tz.jpeg
https://i.imgur.com/XmWF9Tz.jpeg
I took all the chrome pieces and painted them black, which was kind of the original point of all this. That and my lens caps were garbage. I used Krylon Fusion All-in-one Satin Black because it's good for plastic and adheres well. I made sure to very thoroughly wipe down all surfaces with alcohol. I did NOT sand, because that would just create extra dust that could ruin the paint job.
Assembly is reverse of removal, boys! All painted up, I'll let the pictures do the talking:
https://i.imgur.com/zRrG2XX.jpeg
https://i.imgur.com/zRrG2XX.jpeg
https://i.imgur.com/hcQcBCo.jpeg
https://i.imgur.com/hcQcBCo.jpeg
https://i.imgur.com/uvoM8yS.jpeg
https://i.imgur.com/uvoM8yS.jpeg
https://i.imgur.com/IRD3tnW.jpeg
https://i.imgur.com/IRD3tnW.jpeg
https://i.imgur.com/RqRBvTq.jpeg
https://i.imgur.com/RqRBvTq.jpeg
https://i.imgur.com/7010DGH.jpeg
https://i.imgur.com/7010DGH.jpeg
They look lovely. For the new lens caps, I bought some Butyl headlamp sealer. Since there's a good amount still stuck in the housing, I took strips of the sealer and rolled them thinner like one does with playdough and laid it in the channel. Oh also, where the new LED harness comes through, i put a very thin layer of sealer underneath the cable, and then put the normal amount of sealer on top of the cable, between it and the lens. Squeeze the lens on and pop the clips back on, and I threw mine back in the 200 degree even for like 10 minutes. Not sure if this is the proper way or not, idk, google it.
After everything is together, we probably want to hook up the new DRLs and turn signals, right? Right??? Well I wish i took some pictures. What I can tell you, is that these new LEDs have 3 wires (drl, signal, ground). You just have to splice them into existing wires on the headlight connector. I used a PowerProbe to find the correct wires. Ground should be obvious, it's a giant brown wire. DRL power I BELIEVE was a blue/red wire on pin 12, and signal was a blue/brown wire on pin 10. Those may be reversed, i suggest you check your wires before you go a-splicin' all willy nilly. But anyway After I spliced in the wires and verified the lights were working as intended, I used weatherstripping adhesive to seal all the connections up to protect them from the elements. I also proved my own personal theory correct, in that even though the connection to the original LEDs was severed, the car takes resistance readings to see if bulbs are out. The new LED strip provides enough resistance to cancel out a bulb warning! Dodged a bullet there. If y'all don't believe me I'll be happy to post proof in the comments.
I think that's about it. I covered all I can remember at the moment. I hope this reaches someone and they find it helpful. I also hope I don't get blasted. Any questions, let me know in the comments! I can also update with more information in the future.
Thanks guys, stay classy.
Video of lights in action:
https://imgur.com/a/4TP57qj
*actually not easy at all.
Sup y'all,
I'd like to preface this with letting you know that I have done tons and TONS of searching and I have not been able to find a writeup or video on how to take apart an A7 headlight specifically, so I wanted to put something together that would hopefully help someone in the future. There's A6 stuff all over the place, but nothing for A7.
Also, disclaimer: part of this project happened because I totally effed up when I took the first light apart and tore the ribbon cable for the LED's. In my defense, all I did was try to bend it off to the side and it was so brittle that it snapped.
Disclaimer 2: This write-up is for HID (NON-LED) ONLY. Full LED headlights (aka the fancy schmancy ones) are PERMASEALED and you need to sell your soul to Hades if you ever want to get those apart. HID, pre-facelift headlights use butyl like a normal person and are easy to take apart. Thanks Cameron for the reminder.
Disclaimer 3: ATTEMPT AT YOUR OWN RISK. I made plenty of mistakes during this project and some things did break, I'm here to try to prevent you from doing the same but I AM NOT responsible for any damage you incur on your own property.
Disclaimer 4: I know I'll catch a full ration of poop from this by a lot of you, but I would like to point out that this didn't go as I initially intended, and also it's my car I do what I want *Cartman voice*
Now, a look at the final product:
301766
Ok, so here's how it should go down. I suggest reading through the whole post before you think you want to do this/ gain a more general understanding.
Tools needed: Copious amounts of patience. Oven. Basic german car tools (torx bits, screwdrivers, large hammers). Flashlight. Pick set.
1. Remove bumper. It's so easy, there's like 4 screws on each side fender well and 2 on the top, pops right off.
2. Remove headlights and brackets. Pop off the connector on the back, like 4 bolts on all sides. You don't have to remove the bolts all the way, just loosen them. Brackets have a plastic key you pull up on, and 2 bolts holding them on.
3. Preheat oven to 200 degrees Fahrenheit.
4. Remove all bulbs/ ballasts and clips. Not sure if this is 100% necessary, but better safe than sorry. I replaced my bulbs with LED bulbs, but if you're planning on keeping your original bulbs be very careful with them. Each ballast has 3 screws on bottom of headlight. There are about 6 metal clips securing the lens cap to the housing. Use a flathead and pop them off.
5. Place headlight in oven for 15-20 minutes.
6. CAUTION HOT. You've been warned. Use gloves and remove headlight, and quickly bring it to your work surface. Use a flathead screwdriver and gently begin to pry between the lens and housing. Mine came off very easily, with no hassle whatsoever. Easiest part of this whole nightmarish job.
Should now look something like this:
301768
7. Have some flatheads, small to medium, and some curved/right angle picks available. The first thing to take off is the gloss black piece that lines the LEDs. One tab on the side, a couple underneath. I used a pick for these because they're kind of "blocked" by a clear plastic piece and you need to get behind them.
301771301770301769
8. Next is the upper chrome strip. It has one tab on the inside of the light, and one that goes through the back. It's easier to the the back one out first. I gave mine a good tug (you heard me) and it popped out, the second light I did that on, it broke. Use caution.
301774301773301772
9, Next is the lower chrome strip. It has one tab towards the back and one screw on the inside. Screw first, tab second. Much like my friday nights.
https://i.imgur.com/0QOn3hl.jpeg
https://i.imgur.com/0QOn3hl.jpeg
10. Time to take off the led strip. There are 4 screws that line the bottom and one on the top, pictured. I circled the wrong bolt in one of them but you get the idea. Give it a solid tug after and it should pop out, and at the same time totally rip apart the $#&&^(*& ribbon cable for the LEDs.
https://i.imgur.com/cv74KGB.jpeg
https://i.imgur.com/cv74KGB.jpeg
https://i.imgur.com/rZVaNzB.jpeg
https://i.imgur.com/rZVaNzB.jpeg
https://i.imgur.com/UqHABQc.jpeg
https://i.imgur.com/UqHABQc.jpeg
https://i.imgur.com/cAvEcaK.jpeg
https://i.imgur.com/cAvEcaK.jpeg
https://i.imgur.com/r0mAKtA.jpeg
https://i.imgur.com/r0mAKtA.jpeg
It'll look something like this now:
https://i.imgur.com/99t91sd.jpeg
https://i.imgur.com/99t91sd.jpeg
11. Next is the WORST part of the whole thing. This large plastic piece that makes up the back. Have some angled picks and a few extra hands available. I tried to capture where all the tabs are and how i put the picks in. If (when) you have trouble, try using a flashlight to get a good look in there. Try to have all the tabs popped up a bit and pull pull pull. I broke the top corner of mine off trying to pry it forward with a screwdriver. Somehow overall the first headlight went better than the second. Also be mindful of a screw and tab that need to be undone underneath the projector lens.
https://i.imgur.com/osCLk4x.jpeg
https://i.imgur.com/osCLk4x.jpeg
https://i.imgur.com/g2plPAy.jpeg
https://i.imgur.com/g2plPAy.jpeg
https://i.imgur.com/aq30BUw.jpeg
https://i.imgur.com/aq30BUw.jpeg
https://i.imgur.com/OMN6GiK.jpeg
https://i.imgur.com/OMN6GiK.jpeg
https://i.imgur.com/umukyLa.jpeg
https://i.imgur.com/umukyLa.jpeg
After the top strip of this piece is loose, you can bend it down a little and get to this screw that is holding it and the signal lens in.
https://i.imgur.com/2PkJMTL.jpeg
https://i.imgur.com/2PkJMTL.jpeg
I'm done numbering steps now. Too much work. Plus now I can say "in just 11 easy* steps!". Anyway here's the whole thing removed finally and a couple scrapes later.
https://i.imgur.com/nlS6khA.jpeg
https://i.imgur.com/nlS6khA.jpeg
Now to the high beam (unused) housing. This one is easy, it's just held in by some tight fit clip thingies. I used a large screwdriver to pop it off from the front and the back. I circled all 3 of the thingies. They are tight, force is not only necessary, but encouraged.
https://i.imgur.com/ioo8Xbv.jpeg
https://i.imgur.com/ioo8Xbv.jpeg
https://i.imgur.com/sU0bDFA.jpeg
https://i.imgur.com/sU0bDFA.jpeg
https://i.imgur.com/dfnIRg4.jpeg
https://i.imgur.com/dfnIRg4.jpeg
For the signal housing, you already removed one screw, there's a second behind the high beam housing.
https://i.imgur.com/0PatELZ.jpeg
https://i.imgur.com/0PatELZ.jpeg
Here's where things get pretty optional. Also if you like me so far, I would stop reading now so as to leave our delicate relationship intact.
I'm serious.
Taking apart the LED strip very straightforward, same tabs as the gloss black piece, just more of them.
https://i.imgur.com/yYopqQm.jpeg
https://i.imgur.com/yYopqQm.jpeg
So because I royally effed the ribbon cable, through no fault of my own, I was forced to order some pretty cool LED strips from Amazon, one so I could get them immediately, two because they have a cool sequential turn signal. Judge away. The best option i could think of was to hot glue these bad boys into the original LED channel, using the raised sides of the individual bulbs as a gluing point.
https://i.imgur.com/12yuvvM.jpeg
https://i.imgur.com/12yuvvM.jpeg
The new LEDs need somewhere to exit, so take your best pair of dikes and cut open a slot at the end of the strip, and at the same spot in the housing. I used hot glue as a buffer so it won't rub on any sharp edges.
https://i.imgur.com/0EM8t13.jpeg
https://i.imgur.com/0EM8t13.jpeg
https://i.imgur.com/CXuHQqZ.jpeg
https://i.imgur.com/CXuHQqZ.jpeg
Since the LED lens is fairly clear and the new LED's are a little rough and slightly embarrassing, i used some sandpaper to give it an opaque look, so you can't see directly in. These new bulbs are quite bright, so don't worry about visibility going out. I think I used 320.
https://i.imgur.com/XmWF9Tz.jpeg
https://i.imgur.com/XmWF9Tz.jpeg
I took all the chrome pieces and painted them black, which was kind of the original point of all this. That and my lens caps were garbage. I used Krylon Fusion All-in-one Satin Black because it's good for plastic and adheres well. I made sure to very thoroughly wipe down all surfaces with alcohol. I did NOT sand, because that would just create extra dust that could ruin the paint job.
Assembly is reverse of removal, boys! All painted up, I'll let the pictures do the talking:
https://i.imgur.com/zRrG2XX.jpeg
https://i.imgur.com/zRrG2XX.jpeg
https://i.imgur.com/hcQcBCo.jpeg
https://i.imgur.com/hcQcBCo.jpeg
https://i.imgur.com/uvoM8yS.jpeg
https://i.imgur.com/uvoM8yS.jpeg
https://i.imgur.com/IRD3tnW.jpeg
https://i.imgur.com/IRD3tnW.jpeg
https://i.imgur.com/RqRBvTq.jpeg
https://i.imgur.com/RqRBvTq.jpeg
https://i.imgur.com/7010DGH.jpeg
https://i.imgur.com/7010DGH.jpeg
They look lovely. For the new lens caps, I bought some Butyl headlamp sealer. Since there's a good amount still stuck in the housing, I took strips of the sealer and rolled them thinner like one does with playdough and laid it in the channel. Oh also, where the new LED harness comes through, i put a very thin layer of sealer underneath the cable, and then put the normal amount of sealer on top of the cable, between it and the lens. Squeeze the lens on and pop the clips back on, and I threw mine back in the 200 degree even for like 10 minutes. Not sure if this is the proper way or not, idk, google it.
After everything is together, we probably want to hook up the new DRLs and turn signals, right? Right??? Well I wish i took some pictures. What I can tell you, is that these new LEDs have 3 wires (drl, signal, ground). You just have to splice them into existing wires on the headlight connector. I used a PowerProbe to find the correct wires. Ground should be obvious, it's a giant brown wire. DRL power I BELIEVE was a blue/red wire on pin 12, and signal was a blue/brown wire on pin 10. Those may be reversed, i suggest you check your wires before you go a-splicin' all willy nilly. But anyway After I spliced in the wires and verified the lights were working as intended, I used weatherstripping adhesive to seal all the connections up to protect them from the elements. I also proved my own personal theory correct, in that even though the connection to the original LEDs was severed, the car takes resistance readings to see if bulbs are out. The new LED strip provides enough resistance to cancel out a bulb warning! Dodged a bullet there. If y'all don't believe me I'll be happy to post proof in the comments.
I think that's about it. I covered all I can remember at the moment. I hope this reaches someone and they find it helpful. I also hope I don't get blasted. Any questions, let me know in the comments! I can also update with more information in the future.
Thanks guys, stay classy.
Video of lights in action:
https://imgur.com/a/4TP57qj
*actually not easy at all.