My A1 1.6 Tdi headlamps have severe road rash on them, from previous keepers, and are starting to obscure the headlight lens’s and compromising the efficient illumination of both lamps, making it difficult to see at night. If I purchase cheaper generic replacement units, will they have to be paired with the ECU & have members had problem with these units? 
 

Sounds like you’ve got nothing to lose regards headlight restoration.

Plugging in non OE units is likely to throw up can bus errors. Assuming the headlight lens are plastic, then try wet sanding with a Sealey kit, all you will need is a variable speed drill. Usually sandpaper disc ranges from 600-3000 grit, wet lubed as you work.

The kits usually have a cutting compound once sanding is done which will be something like Menzerna, then coat with a UV protectant.

I’d remove the headlights and work on a bed of old towels. Masking bodywork will end in tears otherwise. Blank the headlight backs with a suitable rubber tape to stop water ingress.

Hi Richard / Spartacus68, 

Many thanks for your comprehensive and informative reply! I’ve heard about this  refurbishment cure before, but not in so much detail! I admit to doubting myself being able to successfully perform the job, but with your information, I’ll seriously consider having a go. If it goes terribly wrong, I know where I can obtain replacements now! 😂

Use a little Fairy Liquid in warm water and keep spraying the headlights while you work. It always looks worse to start with, sweep the headlight working methodically at medium speed, horizontal passes, then vertical. The courser sandpaper to start to flatten the road rash, then work to progressively fine. The headlight lens will look opaque.

Don’t concentrate on one area or you’ll burn the plastic. Once the sandpaper part is done, move to the cutting compound with foam pad. The headlight just needs ocassional spray to keep damp and stop compound from clogging. Don’t press to hard. Wipe off with microfibre. Only apply UV sealant once you’re completely happy.

As a starter, you could just buy an old headlight to practice on.

I’m sure there’s YouTube videos too, so watch them before you start. Post some picture too.

Okay Richard, 

Im a keen follower of University You Tube, and have indeed watched  many ten minute or so sessions, which did bolster me with the confidence to ‘have a go’, in the past! I’ll do a study session and see. Cheers 👍