VW Golf manuals

Volkswagen Golf Service & Repair Manual: Lights, lamps, switches outside

Operation and safety notes for gas discharge bulbs
–  If repairs are to be made to the headlight with gas discharge bulbs, observe the following:
Notes on dangerous high voltage/currents → Anchor
Notes on pressure, temperature, radiation/arcs → Anchor
Assembly notes for gas discharge bulbs → Anchor
Disposal regulations for gas discharge bulbs → Anchor
Special tools and workshop equipment required
Safety goggles
It is absolutely necessary to disconnect the battery earth strap before working on parts of the gas discharge headlights marked with yellow high voltage symbols.
Then switch dipped beam on and off again. This will eliminate any possible residual voltage.
The gas discharge lamp control unit must never be operated without a gas discharge lamp.
Due to the high voltage (above 28000 V when igniting the gas discharge bulb) and temperatures, the gas discharge bulb must only be operated in the headlight housing.
Never change bulbs if you are not familiar with the appropriate procedures, safety precautions and tools.
Notes on dangerous high voltage and current
Control units for light systems, connectors and components pertaining to bulb holders conduct lethally high voltage.
Operating the control unit and the starter unit is permitted only with the bulb fitted.
Switch off ignition and all electrical consumers and remove ignition key.
When working on the headlight system, ensure that there is no voltage in any component, including dissipation of residual voltage after the headlights are switched off.
Residual voltage can be dissipated by turning the dipped beams on and then off again after withdrawing the ignition key.
When working on the headlight system, ensure that the lights cannot be switched on.
Notes on pressure, temperature, radiation/arcs
The bulbs may be operated in the headlight housing only (protection against contact due to very hot bulbs, absorption of UV radiation, avoidance of dazzling light, protection against explosion).
The glass of the bulbs can be very hot – danger of burns.
Avoid looking directly into the beam, as the UV rays from the gas discharge bulb are about 2.5 times greater than normal halogen bulbs.
Avoid looking into the light beam (danger of glare); vision may be impaired for a substantial time.
Avoid contact with burst bulbs.
H7 bulbs and gas discharge bulbs (xenon and bi-xenon) are under pressure and can explode while being changed – danger of injury.
Always wear eye protection and gloves when removing and installing gas discharge bulbs!
Repair notes for gas discharge bulbs
Always switch off the affected consumers before exchanging a bulb.
Switch off ignition and all electrical consumers and remove ignition key.
Do not touch the bulb glass with bare fingers; use clean cloth gloves. When the light bulb is switched on, the heat would vaporise the oil of the finger prints which would then settle on the reflector, impairing the brightness of the headlight.
A light bulb must always be renewed with a bulb of the same sort. The designation appears on the base of the bulb or on the bulb glass.
Properly engage connectors during installation and the connection is seated tightly.
Disposal regulations for gas discharge bulbs
Gas discharge bulbs must be disposed of as hazardous waste; never dispose of gas discharge bulbs as consumer waste.
Gas discharge bulbs contain metallic mercury (Hg) and traces of thallium; never destroy these bulbs.
These components must be recycled in the correct manner according to national law.
Only dispose of in containers intended for this purpose at an authorised collection point.
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