Headlight Replacements 2010 6R Polo RHD

[dazz]

Hi
I have a wiring fault in one of my headlights. I can't remove the connector to get at the faulty wire. There is physically not enough space to remove the connector to access the wire.
I need to replace my headlight(s) and I am trying to make sure I get compatible versions.

A new headlight price is eye watering. The price of a used headlight is expensive, and close to the cost of a pair of aftermarket headlights.
I don't have or need Xenon.

The problem I am having is identifying the correct version for my car. (non-TSI, non-GTI)
I know I need RHD drive versions. I know the connectors are different to a GTI.
The years seem to range from 2009 to 2022 depending on country of manufacture.

Are the Mk5 headlights interchangeable with the later Mk6 versions?

I am in New Zealand so Aliexpress is a viable supplier.

Any info or advice gratefully received.

[iichel]

if you first take out the screws holding the headlight and then pop them out a bit, you can take off the connector more easily.

what headlights do you have now? do you have a picture?

[dazz]

Hi
I don't have a problem getting the headlight out of the car.
My problem is that the bad wire connection is inside the head light. The internal structure prevents the connector going in far enough to get it out far enough to work on the wiring.

My symptoms are that the right high beam dull. It is not a problem with the halogen lamp. If I plug-in the right head light into the left head light connector, the fault moves with the light. It is not a problem with the car wiring.
To fix this, I need to remove the connector from the right head light. I can't do that. The head light has been assembled from the front, working forward until the poly-carbonate cover is glued on.

[dazz]

Hi
The lights currently fitted to my car are shown in this photo.

[ciclo]

6R2941008F RHD Right

E was replaced by F.

you can even install the halogen twin headlights from the POLO '6C' (2015->...). Direct swap.

You mention that used headlights are expensive... hmm, what is expensive for you? ...no answer necessary... I guess expensive is something that doesn't suit your pocket.

At least there's a YouTube video showing how to disassemble (take a part) these headlights piece by piece, in case it inspires you to do so to get to those damaged internal wires, but I don't recommend it under any circumstances. Some parts of the video are a bit difficult to handle personally due to the damage caused to the headlight housing, despite the excellent work done by the author.

[SRGTD]

you can even install the halogen twin headlights from the POLO '6C' (2015->...). Direct swap.

Yes, it is a direct swap but didn’t VW change the design of the reflectors within the headlamp units as part of the 6C facelift? If so, then if the OP just wanted to replace one headlamp, replacing a Polo 6R’s headlamp with one from a Polo 6C would mean the replacement wouldn’t match the existing headlamp.

[ciclo]

The correct thing to do is replace both headlights at the same time.
If the existing headlight isn't new, it must be replace due to incompatibility with a/the new one. Other drivers and other vehicles' driver assistance systems will thank you for spending the money for your own safety.

However, I came up with an alternative in case the 6C twin headlights weren't as expensive as the 6R's... they may even be easier to find second-hand these days.

[amer6R]

you can remove the harness from the headlight assembly. To pull it out.
Its a bit difficult, but you place your finger thru the cover for the bulbs to reach the connector from inside. You have to pry on s little tab, and from outside pry with a tool (screwdriver etc.) in the same time.

[dazz]

Hi
Thanks for the answers.

The VW agent's mark ups here are HUGE. Over $BPS 400 for one head light assembly.

I can buy a VLAND after market pair from Australia for about $BPS 250.

I can buy a used part for about $BPS 150.

It appeared that the 6C and 6R lights are the same so good to get confirmation of that.

The physical layout prevents the head lamp connector being removed. I would either need to drill a large hole in the side of the assembly or remove the poly carbonate lens and reverse assembly. I will watch the video.

[dazz]

Hi
I have watched the guy change the lens here. https://www.youtube.com/watch?v=8ABOPNv ... WL&index=1
I am definitely going to try this. I can get a lens from Aliexpress for not much $$$. My headlight is junk unless I can fix it, so I don't have much to lose.
If it works, I have saved a good amount of cash.

[ciclo]

Check out this video in case it helps you make a new decision.
https://www.youtube.com/watch?v=7AvAAPK9svE
... you may need to adjust the video speed to your needs in the video settings.

I fully understand all the possible circumstances, but keep in mind that you must have a lot of experience and/or good skills for the job to be acceptable.
Repairing the headlight could end up being more expensive than buying new ones.

The best option, without a doubt, is to replace both headlights with a pair of the same age. Try to find some headlights that fit your budget (6R or 6C - RHD).

[dazz]

Hi
I have already ordered a new lens from China. Based on previous experience, likely made in the OEM factory.
If I fail, I will just revert to plan B.

There is absolutely no way I would replace both lights unless it was to retrofit aftermarket lights.

The flaw I have seen in the linked videos is that they remove the lens in one piece. I am going to try removing the lens a piece at a time. This should reduce damage to the housing if I get it right.
I am also going to experiment with softening the glue. If it is silicone based, petrol will soften it.

[ciclo]

Hi.
Nice project, please, when possible, take a couple of photos of the process and keep us posted. Thank you so much.

[dazz]

Hi
I sourced a headlight lens from Aliexpress. The lens looks OEM, and probably is. It is absolutely identical to the existing light lens.

I experimented with different methods of cutting away the front of the lens.
Sanding with a disc sander is very slow.
A wood rasp, with really coarse teeth, is the best hand tool.
I found a router to be the best method, but be very careful.
Cut along the corner of the lens.

The glue holding the lens in place is very strong. I found a 50% 50% combination of Acetone and Kerosene worked well to weaken the lens and weaken the glue. Acetone or kerosene alone are not effective. The combination significantly weakens the glue. The key to success is time.
The mix mix needs a couple of days to soak though the glue line. I ran a bead of toilet paper around the glue line to provide a reservoir of solvent, but the acetone evaporates quickly.
The longer the acetone/kerosene is in contact with the glue line, the weaker it will be.

If it is all done right, the remaining strip of lens will just peel out of the glue line. Easier said than done. IMPORTANT Be sure to wear safety googles. If/when plexiglass breaks it flies like sharp shrapnel.

I could not repair my light because the internal assembly is glued in place with tabs that are just too difficult to separate without breaking.

By the time I got to removing the remains of the lens, I had already decided to bin the headlight so I was not careful about damaging the remaining headlight assembly.