A little background for easier understanding: I had to replace my driver's side headlamp, because it was cracked before I got the car, and little by little, water had been dripping into the headlamp (making a streak across the glass - plastic actually). I've managed to source another headlamp, from a 2011 car, and I've received both the xenon ballast (power unit) and the turning module (both working). Both the ballast and the turning module on my old headlamp died on me, probably due to water ingress at some point when taking out the headlamp from the car. Anyways, when I finished replacing the headlamp, I was faced with the issue, which still stands to day, of having non-calibrated headlamps (meaning, the turning won't work, as well as the automatic beam adjustment - both speed and height influenced). The VCDS reports the situation as follows:

 

                Address 55: Headlight Range       Labels: 5M0-907-357-V2.LBL
Control Module Part Number: 5M0 907 357 C    HW: 5M0 907 357 C
  Component and/or Version: AFS-Steuergeraet    0148
           Software Coding: 1376839
            Work Shop Code: WSC 33361 790 00999
           Additional Info: 7L6941329B  AFS-Lst.-Modul l    0005   7L6941329B  AFS-Lst.-Modul r    S004   
                      VCID: 3460C79247A02FE13D-8060
2 Faults Found:

01539 - Headlights Not Adjusted 
            005 - No or Incorrect Basic Setting / Adaptation - MIL ON
             Freeze Frame:
                    Fault Status: 11100101
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 61
                    Time Indication: 0

             Freeze Frame:
                        Invalid
                        Invalid
                        Invalid

02234 - Right Headlight Power Output Stage (J668) 
            002 - Lower Limit Exceeded - MIL ON
             Freeze Frame:
                    Fault Status: 11100101
                    Fault Priority: 3
                    Fault Frequency: 1
                    Reset counter: 61
                    Time Indication: 0

 

The second error is probably related to the right D1S bulb being on its last breath (noticeable discoloration). I've replaced the ballast (that's so like me: having a spare ballast, but not a spare xenon bulb ... ), and the error remains.

 

 

Regarding the main issue, I drove the car to the dealer, and they pinpointed the issue in the central headlamp module (which is located behind the air-con panel in the cabin, supposedly their diag kit couldn't communicate with it, I don't know what they use). Ok, I've sourced a working, used one, and the issue remains - tested with VCDS, as far as I'm concerned, the old one was working properly. Followed Ross-Tech and some other online sources, I can't figure out what the actual problem is, all I know is that I can't enter the headlight adjustments (yes, I have security access). One thing to note, both headlamp's turning modules are currently not identical (one new module costs around 175 GBP), used ones are 10x cheaper, but getting the exact one like I did have on the car before is a lottery (or two of the same). New ideas welcome.

 

I think you'll need to fix the second error code and once that's done, run the basic settings as described here: http://www.ross-tech.com/vag-com/cars/xenonalignment.html

 

Not sure what you've trying to achieve in your screenshots but I never need to do it when I retrofitted xenon's. After coding it was just the basic settings.

1 hour ago, langers2k said:

I think you'll need to fix the second error code

 

I wanted to change the current xenon bulbs for something with even more light, so I might as well and use this opportunity do do them both ... I'll probably go for the Osram's Cool Blue 6000k

Installed the new Osrams (D1S Cool Blue 6000k) today, no change in the situation (yes, the bulbs are better than the old ones, regular Osrams), but the opening issue still isn't solved ... so, which part exactly is the J668, is that the right ballast or is it something else? The current ballast is new there, that also didn't help.

I think J668 is the AFS slave rather than the ballast. I wouldn't surprise me if you had water ingress which is causing a bad connection. Annoyingly, you'll probably need to take the bumper off to access it so it's worth checking both while it's off.

 

Another car with J668 issues that was fixed with a new AFS slave: https://forums.mwerks.com/showthread.php?7006230-quot-No-bend-lighting-

It's not a problem to source a used one (per the part no), but then I'll still have the potential issue of compatibility (left is now 0005 - that was already changed, right is S004 - from the factory)., It would be great if it is just that, though, as it is, I'll have almost half of the AFS mechanism renewed ...

Might be worth switching them first and see if the fault moves sides.

1 minute ago, langers2k said:

Might be worth switching them first and see if the fault moves sides

 

If I currently had the bumper off, sure, that'd be the easiest thing to do ... I'll first order another module (they're actually very cheap), and have it as a spare, then I can easily switch them around as required) ... by the way, I can do the AFS slaves replacement without taking the front bumper off, but the wheels and wheel arch covers need to be off ... not exactly the most pleasant and accessible position, but less hassle than removing the bumper for x-th time for me (why didn't they put a pant's zipper on it, it would make things much easier)

I'll order one AFS slave module then, can't hurt to try ... I've managed to locate one that is the closest resemblance to the current left side one (manufacturing date, and full part no), so we'll see how that goes

Finally solved the issue, installed another slave to the right headlamp, and it works (wasn't able to do it sooner, busy with work). Did the adjustment via VCDS, no errors, the headlights now do the "dance" after starting the  engine ... can't remember when was the last time my instrument panel was error-free, probably 5-6 months ago ... ... the bumper must come off for the right side one, I can do the left side slave module and ballast (even on the 3.6 engine) with just the front left wheel off and the arch liner off.

 

Now I have all three relevant modules updated, the central one and the AFS slaves ... the headlamp modules are identical now (AJ revision). On the photo below, the left one is the "new" one, on the right is the old, faulty one.

 

You could remove the right headlamp at this point to be faster with the module change, but I wanted to see if it is doable without doing so - which it is, if you have the proper tools and if you're slightly more flexible and athletic ... 

 

Glad to hear it sorted

 

31 minutes ago, langers2k said:

Glad to hear it sorted

 

Now the left side mirror replacement is next (which is a PITA job, especially now when the temperatures are below 10° C), just asking for something to break while dismantling ... the door panel being the first one on the list ...