Parts Catalog Accessories Catalog Tech Info Tech Forums
 
Follow Pelican Parts on Facebook Follow Pelican Parts on Twitter Follow Pelican Parts on Instagram Follow Pelican Parts on YouTube Follow Pelican Parts on Pinterest Follow Pelican Parts on Tumblr
  Search our site:    
View Recent Cars  |   Cart  | Project List | Order Status | Help    
 >  >
Headlight Assembly Replacement
 
Bookmark and Share

Pelican Technical Article:

Headlight Assembly Replacement

Nick Czerula

Time:

1 hour1 hr

Tab:

$750 to $1,500

Talent:

**

Tools:

8mm socket, ratchet and long extension.

Applicable Models:

BMW Z3 (1996-02)

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:

Working headlights Comp Modification: Polish lens if it is cloudy

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 are cloudy and will not pass a motor vehicle inspection. In this tech article, I will show you how to replace the headlight assembly and the headlight bulbs on your Z3. Depending on which side you have to service, different items have to be removed. I am going to show you how to remove these items in separate steps. Once the items are out of the way, the procedure is the same for both sides.

To adjust headlight beam aim, open the engine hood and look for large plastic knurled knobs in back of the headlight assemblies for up-and-down and side-to-side aiming. On the left side you may need to remove the air filter housing to access the headlight adjusters. When adjusting headlight aim, be sure to have the tires at the correct pressure, the fuel tank full and the weight of one person in the driver's seat.

Keep in mind that when your car was serviced before, parts may have been replaced with different size fasteners used in the replacement. The sizes of the nuts and bolts we give may be different from what you have, so be prepared with different size sockets and wrenches. 

Protect your eyes, hands and body from fluids, dust and debris while working on your vehicle. If you are working with the electrical system, disconnect the battery before beginning. Always catch fluids in appropriate containers and properly dispose of any fluid waste. Recycle parts, packaging and fluids when possible. Do not work on your vehicle if you feel the task is beyond your ability. 

Vehicle models change and evolve, as they grow older, so the vehicle shown in our illustrations may vary slightly from yours. If something seems different, let us know and share your info to help other users. Do you have questions or want to add to the article? Leave a comment below. When leaving a comment, please leave your vehicle information.


Accessing the driver side assembly:

Using a flathead screwdriver, loosen the secondary air pump inlet hose clamp.
Figure 1

Using a flathead screwdriver, loosen the secondary air pump inlet hose clamp. (green arrow)

Then remove the secondary air inlet hose from the air filter housing by pulling it straight off.
Figure 2

Then remove the secondary air inlet hose from the air filter housing by pulling it straight off. (green arrow) Then pull it off the air pump and store in a safe place.

Next, you will unclip the three air filter housing retaining clips.
Figure 3

Next, you will unclip the three air filter housing retaining clips. (green arrows). One of the clips was hidden beneath the secondary air inlet hose. You will have to reach in behind air filter housing to access it.

Disconnect the intake air sensor electrical connector by pressing the wire release tab and pulling the connector straight off.
Figure 4

Disconnect the intake air sensor electrical connector by pressing the wire release tab and pulling the connector straight off.

Working at the air flow meter, twist electrical connector counterclockwise to disconnect.
Figure 5

Working at the air flow meter, twist electrical connector counterclockwise to disconnect. (green arrow). Then loosen the air flow meter hose clamp (yellow arrow). Once loose, remove the air filter housing from the engine compartment.

Next, you have to loosen two 10mm nuts from the lower air filter housing (green arrows).
Figure 6

Next, you have to loosen two 10mm nuts from the lower air filter housing (green arrows). Loosen them about 10 turns. This will be enough to get it out.

With the lower air filter housing unbolted, lift it up, fastener side first, feeding the intake tube (green arrow) out of the shroud at radiator.
Figure 7

With the lower air filter housing unbolted, lift it up, fastener side first, feeding the intake tube (green arrow) out of the shroud at radiator. You can now access the back of the headlight assembly. Continue with procedure you are performing below. Accessing passenger side assembly

First, you will have to remove the washer fluid reservoir to access the check valve.
Figure 8

First, you will have to remove the washer fluid reservoir to access the check valve. You can suction out the fluid if you want, but if you leave the lines connected and place the reservoir out of the way, you can leave the fluid in it. Using a flathead screwdriver, remove the reservoir mounting fastener.

Then, lift the reservoir up and place it to the side or on radiator support.
Figure 9

Then, lift the reservoir up and place it to the side or on radiator support. You now have access to the back of the headlight assembly. Headlight Bulb Replacing Do not touch bulbs with bare skin, wear clean gloves. Oil from your skin can damage the bulb.

Working at rear of headlight assembly, unplug headlight bulb electrical connector by unclipping release tab and pulling off.
Figure 10

Working at rear of headlight assembly, unplug headlight bulb electrical connector by unclipping 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. (photo shows left side headlight)

This photo shows how to unclip the bulb connector release tab.
Figure 11

This photo shows how to unclip the bulb connector release tab.

Low beam bulb: Next, rotate headlight bulb holder counterclockwise and remove from headlight assembly.
Figure 12

Low beam bulb: Next, rotate headlight bulb holder counterclockwise and remove from headlight assembly. Install new headlight bulb into headlight assembly, rotate clockwise to lock into place. Connect electrical connector and check bulb operation.

High beam bulb: Next, rotate headlight bulb holder counterclockwise and remove from headlight assembly.
Figure 13

High beam bulb: Next, rotate headlight bulb holder counterclockwise and remove from headlight assembly. Install new headlight bulb into headlight assembly, rotate clockwise to lock into place. Connect electrical connector and check bulb operation.

Headlight assembly replacing:
Working at rear of headlight assembly, unplug headlight bulb electrical connector by unclipping release tab and pulling off.
Figure 14

Working at rear of headlight assembly, unplug headlight bulb electrical connector by unclipping 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. (photo shows left side headlight)

Remove the three 8mm headlight mounting fasteners (green arrows).
Figure 15

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

When removing the upper fasteners, counter-hold the plastic adjuster with a pair of pliers so it does not spin during removal.
Figure 16

When removing the upper fasteners, counter-hold the plastic adjuster with a pair of pliers so it does not spin during removal.

Remove the final 8mm headlight mounting fastener through the opening in the radiator support.
Figure 17

Remove the final 8mm headlight mounting fastener through the opening in the radiator support.

Slide the headlight out far enough so you can disconnect the side marker bulb.
Figure 18

Slide the headlight out far enough so you can disconnect the side marker bulb. Rotate the bulb socket 90 degrees counterclockwise to remove.

Then, remove the headlight assembly from the vehicle by pulling straight out toward front of vehicle.
Figure 19

Then, remove the headlight assembly from the vehicle by pulling straight out toward front of vehicle. Install new headlight assembly and tighten fasteners. Connect electrical connector and check bulb operation. If headlight alignment with body is not even, you can adjust it via the plastic adjusters at the top of the headlight.

Bookmark and Share

  Search our site:    

View Cart & CheckOut | Project List | Order Status |  Help    

 

[Home] [Customer Service] [Shopping Cart] [Privacy Statement]
 [Contact Us] [About Us] [Shipping] [Map to our Location] [Careers]

Copyright © Pelican Parts Inc.

Page last updated: Fri 12/9/2016 02:07:18 AM