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BMW E39 Headlight Replacement
 
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Pelican Technical Article:

BMW E39 Headlight Replacement

Kerry Jonsson

Time:

1 hour1 hr

Tab:

$250

Talent:

**

Tools:

Phillips & flathead screwdriver, plastic prying tool, 8mm nut driver.

Applicable Models:

BMW E39 5-Series (1997-03)

Parts Required:

Headlight assembly, headlight bulb

Hot Tip:

Do not touch bulbs with bare skin, wear gloves. Oil from your skin can damage the bulbs.

Performance Gain:

Repair damaged headlight assembly, replace faulty headlight bulb

Complementary Modification:

Polish lens if it is cloudy

The headlight assembly seals can wear out over time resulting in water leaks and repeat bulb failures. You may also need to replace or repair your headlight assembly if the lens is cloudy and will not pass a motor vehicle inspection.

Headlight Bulb Replacing:

Do not touch bulbs with bare skin, wear gloves. Oil from your skin can damage the bulbs

Working at rear of headlight assembly, unplug headlight bulb electrical connector by squeezing release tab and pulling off.
Figure 1

Working at rear of headlight assembly, unplug headlight bulb electrical connector by squeezing release tab and pulling off. Low beam bulb (green arrow) High beam bulb (yellow arrow). To disconnect the low beam bulb electrical connector, press the release tab and pull straight off the bulb. To disconnect the high beam bulb electrical connector, lift up on the catch and pull connector off bulb.

Low beam bulb: Next, rotate headlight bulb holder counterclockwise and remove from headlight assembly.
Figure 2

Low beam bulb: Next, rotate headlight bulb holder counterclockwise and remove from headlight assembly.

Low beam bulb: Pull headlight bulb (green arrow) out of bulb holder (yellow arrow).
Figure 3

Low beam bulb: Pull headlight bulb (green arrow) out of bulb holder (yellow arrow). Install new headlight bulb into holder and install holder into headlight assembly. Connect electrical connector and check bulb operation.

High beam bulb: Next, rotate headlight the bulb counterclockwise and remove from headlight assembly.
Figure 4

High beam bulb: Next, rotate headlight the bulb counterclockwise and remove from headlight assembly. Install new headlight bulb into headlight assembly. Connect electrical connector and check bulb operation.

Headlight assembly replacing:
Working at rear of headlight assembly, unplug headlight bulb electrical connector by squeezing release tab and pulling off.
Figure 5

Working at rear of headlight assembly, unplug headlight bulb electrical connector by squeezing release tab and pulling off. Low beam bulb and High beam bulb (yellow arrows), Side marker bulb (green arrow). To disconnect the low beam bulb electrical connector, press the release tab and pull straight off the bulb. To disconnect the high beam bulb electrical connector, lift up on the catch and pull connector off bulb. Then disconnect the side marker bulb electrical connector by squeezing the release tab and pulling it straight off.

Remove the four 8mm headlight mounting fasteners (green arrows).
Figure 6

Remove the four 8mm headlight mounting fasteners (green arrows).

Then, remove the headlight assembly from the vehicle by pulling straight out toward front of vehicle.
Figure 7

Then, remove the headlight assembly from the vehicle by pulling straight out toward front of vehicle.

If installing a new headlight assembly, you will have to transfer over the painted trim piece.
Figure 8

If installing a new headlight assembly, you will have to transfer over the painted trim piece. Press the release tab and remove it from the headlight assembly. Install it on new assembly and snap in into place. Install new headlight assembly and tighten fasteners. Connect electrical connector and check bulb operation.

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Page last updated: Fri 12/9/2016 02:05:21 AM