Replacing xenon ballast, Audi A3, but how?

Hello everyone,

My Audi A3 8L facelift's xenon headlights recently stopped working.
Diagnosis: Short circuit in the xenon control unit.
Being as clever as I am , I naturally bought a new ballast (also called an ignition unit or control unit), as it's much cheaper than a new headlight.

I've been trying to get this plug and cable, which connects the burner to the ballast, out of the headlight for hours now.

Does anyone have any ideas on how to remove the cable with the plug and how to safely insert the new one?

I would be very grateful for any tips!

Best regards,

Chris.

"Hi... I'd probably need to see one in person first (there aren't that many 8L models with xenon headlights)..."

but: why don't you try?

a.) Should you first disconnect the burner's retaining ring and then unplug the connector?

b.) Simply rotate the plug 90 degrees...

But I don't know if it will break anything... it's just a guess.

Okay, so I have a Golf with Xenon headlights... did you still have that particular headlight installed, or did you remove it? Does he have the control units in the headlight assembly or behind it? (There was a change in the Golf starting in late 2002.) But regardless, I would almost say, take the headlight out; you'll have better working conditions, especially if it's as cramped as it is in the Golf.
I think I have a photo of the inside of my headlight somewhere... I'll try to find it, because I really don't remember taking it. My headlight stopped working after only 4 days, and I didn't fix it myself! But they took pictures! (Yes, the people at VW also thought I was crazy...)

I just took a quick picture of the headlight.

The headlight has been removed, and everything that could be taken off is gone.

The control unit is mounted externally, below the headlight.

In its unassembled state, it's impossible to access the control unit.

Oh dear, my photo isn't that good, and it wouldn't be helpful.

In other words, the large red and black connector needs to go through the square hole. The connector looks like the front part, which is attached to the black part with the red retaining clips, can be opened. Have you tried it?

Theoretically, it might be possible to open it, but unfortunately, it's sealed shut, so there's no chance.

Okay, then I'm logging off... because you won't be able to get him out of the "control unit" either. Sure, it's a good thing for customer-friendliness when it comes to repairs... but if you have a solution, please write it here. I'm sure these things won't last forever either.

Oh dear, I completely misunderstood you .

That seems to be quite poorly designed.

It seems like the only option you have is to cut or burn a slit outwards from the square hole, perhaps using heat, and then seal it afterwards with hot glue or something similar.

Short question: Which of the following scenarios is correct?
A) Does the plug not fit mechanically through the square opening, or...
B) Does it not reach that far because it gets stuck between the reflector and the housing?

Unfortunately, I'm not familiar with the headlight assembly, and I can't clearly see enough details in the pictures. However, if option B is correct: Was the reflector moved to the position that is most advantageous for you using the fiber optic cable? If that's still not enough, you can remove the reflector (you may need to remove the glass, as it is with the G3 model).

Regards,
Guste.

Thank you very much for your tips.

@guste100
A) The plug fits mechanically through the opening, no problem at all.
B) The connector is stuck between the high beam holder and the housing. The actuator motors have been removed, and the reflector is pushed all the way forward. I've turned the mechanical headlight adjustment as far forward as possible. The glass cannot be removed because it is clipped, screwed, and also glued in place. No chance.

@Schraubi-Schlumpf
I've now removed the old connector by cutting off the angled cable holder on the connector. Theoretically, no problem. I'll just add a little hot glue to the new one, and that should keep the cable in the correct position again.
It's unprofessional, but I can't think of anything else.

If anyone still has any ideas, I'm open to anything!!! I will only do the installation later.
Early next week.

Best regards,
Chris.