What is the procedure for headlamp removal on a 2006 beetle?

Answer 1

FYI - The bulb for the 2006 is DIFFERENT than the 98-05 beetles

GE - H7 55w I will start with the tools I used: (Locking mechanism)

1/4" drive ratchet with a 10" extension and a 3/16" socket. I found my 3/16 socket would not fit, I had to use a 6mm

* A 3/16" bit driver will also work if the handle is long enough (secondary locking mechanism)

wooden paint stir stick (freebie from your local hardware or paint store)

Passenger's Side

This is the easiest of the two as there is not as much in your way of both locking mechanisms. If you shine a light towards the front of the bottom of the light housing inside the engine compartment you will see a small silver pin with a 3/16" head that has instructions on how to lock/unlock the primary locking mechanism printed on the black plastic above the pin. Turn the pin ONLY 1/2 a turn and take care as the pin should turn VERY EASILY. Now the light housing should be able to move slightly out of it's seat, but it will not come more than about 1" out of the front of the car. A secondary locking mechanism still holds it in place. If you look a little further back, about 3" - 4", from the primary locking pin; behind a wrapped wire, a/c line, and the power steering reservoir; you will see a horizontal silver lever, about 3" - 4" in length, pointing towards the front of the car. Just simply hold this lever down about 1" to 2" and pull out the light housing at the same time. The entire housing should freely and easily come completely out of the front of the car. Take care removing it as there are no wires connected to it and it will fall to the floor if you are not holding on to it. Just open the back of the housing and replace the bulb that is out.

Driver's Side

This is the most difficult one. The battery location is your enemy. In front of the battery, if you look with a flashlight, you will see the primary locking mechanism. It is the only silver looking pin there with a 3/16" head. It looks like the headlamp adjusters on other cars. There are instructions printed on the black plastic above it. You should ONLY turn this 1/2 a turn, and you will NOT need to put much effort into turning it as it should turn very easily. You are not done yet. The entire headlamp assembly should be able to pull out of the fender about 1" now, then it will stop as if something else is holding it. There is a secondary locking mechanism that is just a simple metal lever. If you look on the back of the battery, between the air filter housing and the battery, you should see the end of the small shiny silver lever. Just simply hold this lever down about 1" to 2" and pull out the light housing at the same time. The entire housing should freely and easily come completely out of the front of the car. Take care removing it as there are no wires connected to it and it will fall to the floor if you are not holding on to it. Just open the back of the housing and replace the bulb that is out. Putting the housing back to the assembly. It is not as simple as reverse the procedure above. there is no guard or anything helping you to slide it in correctly. There is a chance of misalignment that the light would not come on. The key is to ask someone to pressure the lever down, or with a stick thick enough to hold the lever down by pressure on the stick by the battery and air filter housing (about 1.5" wide). Try to align visually or use marker(s) on housing and car body before removal to help you align. carefully slide it in. This is the only way I find that work satisfactory. Once it is tight fit (if it is not aligned right, there is gap between body and head light cover), turn the lock nut counter-clockwise to lock it in place. The last thing is to remove the stick. then test headlight.