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    VWVortex


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    Thread: Headlight Washer does not retract - Includes TB 92-05-01

    1. 03-03-2011 04:40 PM #26
      Hey all,

      I am missing a headlight washer nozzle. I do not want to replace the whole headlight washer assembly and take off the bumper if possible. For those of you that have already replaced your headlight washer assemblies, any chance you have a spare nozzle (just the very tip) off your broken assemblies??

      Thanks for any consideration or information,
      Jeff

    2. Member Kcmover's Avatar
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      06-15-2011 09:03 PM #27
      Hi,

      Hopefully Michael or somebody else might have a diagram of what the spring action of the Headlight squirter door might look like. The spring must be missing as it is constantly staying open just from road vibration. Is this a difficult repair to make?

      Below is a picture of it.


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      06-15-2011 11:17 PM #28
      I had an unfortunate meeting with a stop sign in an ice storm last winter. Hit the passenger side front bumper, and pierced the aux radiator. New bumper and radiator cost 8500.00. After I got it back, the drivers headlight washer door kept popping open during driving. Took it in for routine maintenance to the dealer, and asked them to re-hook up the retraction spring that was missing from the bodywork.... They quoted me 280.00-380.00 to fix. I swalked, and they agreed to fix on the original claim, but it'll take a week to get around to it. Argh!
      Overall I have been happy with the mechanical service ( at Westside VW), but the body shop is on a molasses in winter schedule.

      Mike

    4. Senior Member PanEuropean's Avatar
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      06-16-2011 12:22 AM #29
      Hi Larry:

      I don't think that there is a 'spring' in the conventional sense (a coil spring) involved. I believe that the spring action is provided by a metal clip or similar.

      It has been a long time since I took the front bumper cover off my car, and I can't quite remember what everything looks like in there. I do have one photo of the back side of the headlight washer door assembly (below).

      You will need to take the front bumper cover off to get at it. This is not a difficult job, but it is very labour-intensive, rather detail-oriented, and requires some special tools. This explains why Mike was quoted about $300 to re and re the bumper cover (second post, above). That's about 3 hours labour, and to be honest, it will take a careful worker about 3 hours to re and re the bumper cover if that person has not done the job before.

      I have attached the instructions for removal and installation of the bumper cover in PDF form. If you go to the post Retrofitting Dual Xenon Headlamps, you will find illustrated step-by-step instructions there that take you through the bumper cover removal process.

      Some suggestions for you, based on my recollection of doing this job before:

      1) It is a heck of a lot easier to re and re the bumper cover if you can lift the car about 3 feet off the ground. This puts all the fasteners at a convenient level to work at. I used the alignment rack at my VW dealer. A hoist would be equally effective.

      2) Be sure that you have the special tools needed. In particular, this means some kind of extension that will allow you to get 18 inches of reach to one Torx T25 fastener on the inside of the bumper cover (see the explanation and photo of this in the Retrofitting Dual Xenon Headlamps post).

      3) You will need a helper (second person) for about 5 minutes to remove the cover, and also for another 5 minutes when you are re-installing the cover. Don't try to do it yourself, you risk breaking the bumper cover if it is not properly supported during the re and re process.

      4) Wash the front end of the car really well before starting work, in particular, wash the inside of the two front wheel wells.

      5) If the lower valence on your front bumper is scuffed up from hitting ramps, etc., consider ahead of time if you would like to replace it while you have the front bumper cover off. It is very easy to replace this part when the bumper cover is off.

      6) You MUST RESPECT AND FOLLOW EXACTLY the sequence for tightening fasteners set out in the 'installation' instructions. This cannot be over-emphasized. If you do not tighten the fasteners in the order specified, the bumper cover will eventually break due to unwanted stresses. This problem has been discussed in another thread here in the forum, so, learn from the misfortunes of others...

      Best regards,

      Michael

      Inside view of headlight washer door
      Attached Files

    5. Member Kcmover's Avatar
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      06-16-2011 12:49 PM #30
      Michael. I always know that your the Phaeton expert. Thanks for the information and the pdf's. hope all is well with you.

      If VW ever wants to re-enter the USA / Canada Market with the Phaeton they should hire you as you know more about their product then the do......

      Best regards,

      Larry

    6. Senior Member PanEuropean's Avatar
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      06-17-2011 04:32 PM #31
      Hi Larry:

      Just one further tip - you might want to get your VW dealer to order you a half a dozen of the pan-head fasteners that are used to secure the front wheel well liners to the bumper cover. I believe that these are part number N 103 546 02 (item 40 on illustration 807-00 in the parts catalog), but I am not 100% certain of this). You might also want to order a couple of N 907 750 01, which are the fasteners that require the 18" screwdriver extension (item 39 on the same illustration).

      The fasteners are inexpensive, and my experience has been that the fasteners around the perimeter of the wheel well liner tend to get 'sandblasted' by road sand and it is difficult to re-use them because the heads are worn down. As for the two fasteners that need the long extension - well, if you order a couple of spares, then you won't have to take the bumper cover off a second time when you drop one and lose it trying to fit it into the hole...

      Michael

    7. 06-18-2011 05:23 PM #32
      Both sides of mine do the same thing. One will just randomly be sticking out and neither goes back in. One of these days I will get brave and do the fix =)

    8. 06-30-2012 10:29 AM #33
      If anyone is still having the problem of the washer doors staying open, I have a quick and CHEAP fix....and it works!!!

      Just let me know.

      Joe

    9. Member Paldi's Avatar
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      06-30-2012 11:19 AM #34
      OK, if it's cheaper than a bit of black electrical tape, I'm game. Maybe a coule of well placed magnets? Both of mine are floppy.

    10. Senior Member PanEuropean's Avatar
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      09-17-2012 03:27 AM #35
      Photos re-hosted.

      Michael

    11. 09-17-2012 04:43 AM #36
      I did not inquire as to the retaining ring issue reported by others.
      [img]http://www.**********/11.jpg[/img]
      Last edited by Dean55A; 09-17-2012 at 04:51 AM.

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      01-06-2014 03:37 PM #37
      Joe - Whats the quick fix???

      Randy

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