How do you replace a headlight in a 2004 VW Beetle?

Answer 1

This answer applies to a 2004 Beetle. It might work for other Beetles, too. It's a surprisingly easy fix, even though it means removing the entire headlight assembly.

1. The first step is to open the hood. If you're attempting this repair, you've probably already opened the hood numerous times to fill windshield fluid, check and add oil, and for other engine-compartment maintenance and repair. It should also go without saying that you should do this with the lights in the off position, and with power off in the car.
2. Under the leading edge of both the passenger and driver's side fender inside the engine compartment, you can see part of the headlight assembly. There is a hook-like lever extending at about 45 degrees toward the hood. This is the most difficult part - identifying the lever. It's very hard to take a picture of it, and it's difficult to distinguish from other parts if you haven't done this maintenance before.
3. Pull the lever toward the fender and hood. Don't force it. Apply gentle pressure, perhaps using the side of a screwdriver or other tool, until you feel a gentle "pop" or a disconnect of the locked plastic parts.
4. Gently push the headlight assembly capsule forward toward the lens, using your hands or a tool. Some people describing this procedure find it the most difficult - you are sliding the assembly on its tracks which are most likely caked with dirt, and against the pressure of a rubber seal and some adhesive (Note: don't attempt to remove the lens or any outside part of the headlamp; this will just break the internal seals and possibly subject your new bulb to wet and dirty conditions).
5. Once the lamp assembly slides out of the fender, you'll see the power wire (near the front) attached with a plastic clip. Carefully unlock the clip and remove the wire connector.
6. Place the headlight assembly on a working surface with some protection to avoid scratching the lens.
7. At the back of the housing is a fairly large black plastic cover with a plastic clip. Remove to reveal the bulb assembly.
8. Unlatch the wire clip holding the bulb in the larger assembly. Disconnect the wire clip on the back of the bulb and install the new bulb. Note the orientation of the bulb base (it is basically a circle with a slice out of one side). As you may know, touching the glass of halogen bulbs usually reduces their life because of the oils and other substances on your fingers. However, unlike many home light fixtures, the ample metal base makes it unlikely that you'll have to touch the bulb itself (if you need to, use a cloth or paper towel).
9. Reconnect the power cable; you may also wish to clean the guide rails and lubricate them with dry lubricant before you return the assembly in its place.
10. Line up the assembly guides with the guide rails (this may take several tries; and there are three, the first two engaging at 9 and 6 o'clock positions). Some guides suggest lifting the lever to engage the assembly, although a firm push may be all that's necessary.
11. You may have already tested the lamp on step nine. If not, put the key in the ignition and turn on the lights. Also, check the rubber gasket where the assembly meets the fender, and adjust it for best fit. If this is the second time you've done this, it's taken you all of 5 minutes; if not, this may have been an hour repair/replacement.