Hi all. Got an issue with my headlight on my '04 coupe. Some days ago, the driver's side low-beam gave up... I bought a new bulb, but trying to replace this thing was not as easy as I imagined. After taking the rubber cover off I tried to remove the black electrical connector which proved to be...impossible. I feel like I am about to yank out the entire assembly, but the connector won't move at all. Getting to the clip is not a problem, but i can't release the bulb unless I remove the connector first.

What is the trick? Is there a plastic tab somewhere that releases a pin through the holes in the bulb connectors or something stealthy like that? Or maybe they decided to glue the connector onto the factory bulb?! I also find it sort of funny that the manual emphasizes (with a picture) the easiest step of the process, namely removing the rubber cover...

I should probably mention that after yanking on this thing for a while without going anywhere, I happen to retest the lights again...and now it worked again... Seems like my car has some bad contact problems (my dome light is the same way)...

But for the time when it REALLY burns out...any connector advice would be greatly appreciated!

 

I was able to remove the connectors "easily" by using a pair of curved needle-nosed pliers. Grip the center 'spine' of the black connector pull straight out...it comes right off with much less resistance. I was pleasantly surprised after seeing all the horror stories here.

 

That was what I thought as well (at least for the driver's side)... but alas...I ended up tearing a section of the center of the connector off instead (stuck in the pliers). The thing ain't moving... I guess Karmann DID glue it in place.

I can only imagine the horror getting pliers into the right spot on the passenger side...

I have to admit I was using straight pliers...maybe if they were small enough I could get a better grip on the center spine. Worth a shot. Thanks for the advice. How much force did you have to use? 1) Minimal 2) medium, or 3) enough to roll the car uphill with the parking brake on?

 

Does this help?

Low Beam Bulb
REMOVAL

1. Disconnect the negative battery cable.
2. Remove the headlamp unit.

1. Remove the headlamp bulb access plug.
2. Disconnect the headlamp bulb harness connector (2).
3. Disengage the bulb retaining clip (1) and remove the bulb from the headlamp unit.

INSTALLATION

CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. Do not use bulbs other than those indicated in the Bulb Application table. Damage to lamp and/or Illumination Control Module can result. Do not use fuses, circuit breakers or relays having greater amperage value than indicated on the fuse panel.

1. Install the headlamp bulb (1) into the headlamp unit
2. and engage the retaining clip (3).

1. Connect the headlamp bulb harness connector.
2. Install the headlamp bulb access plug.
3. Install the headlamp unit.
4. Connect the negative battery cable.

 

It is very difficult. I actually cut my hand up removing the passenger side one because it was really stuck and it is located right in front of the coolant tank? Anyways I grabbed some curved pliers as previously mention and with some jiggling and pulling it still wouldn't come out. After that I pulled on it with my hand and it came out easily.

P.S. After you finally get it out its much easier the next time.

 

Wow, that alldatadiy info you pasted is great! Thanks for posting! I made sure to bookmark that site for future reference.

Obviously I didn't remove the assembly, but jumped right to step 3. I get stuck at step number 4 as the connector just won't come off. Can't proceed to step 5 without it.

 

Probably medium force...I just applied steady pressure against the pliers with one hand while maintaining grip with the other...didn't have to use a pry-bar or anything like that.

 

Just as a "heads-up" you can't just access that alldata site - you have to pay for a subscription. Just figured I would try to help you out with your problem...

 

I had trouble disconnecting the wire from the bulb so I just took the clip out, then when I had the bulb out I wiggled the connector off.

 

Xfire2005: I just followed the links and got in. Thought I was in wonderland! Didn't think more about it. Guess I got in on your subscription... Now the links don't work anymore though. But the original pics you posted seem to be randomly replaced with other stuff from the site. Funky.

Snowtop57: I tried this too, but there was no way I could get the clip over the connector. It was like forcing an elephant through a hula-hoop. I even tried to unhinge it on one side (which didn't work either).

I think I just have to get me some small curved needle-nosed pliers.

Thanks all for your input.