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Headlight Replacement
 
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Pelican Technical Article:

Headlight Replacement

Nick Czerula

Time:

1 hours1 hrs

Tab:

$50

Talent:

**

Tools:

8mm socket, ratchet and long extension.

Applicable Models:

BMW X5 (2000-06)

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 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 X5. Depending on which side you have to service, you have the challenge of squeezing behind the engine compartment components. Each bulb and assembly can be replaced without removing additional components and the procedure is the same for both sides. On the left side, you have to squeeze behind the power steering and coolant reservoir to access the bulbs. On the right side you have to squeeze behind the intake air housing.

Do not touch the bulbs with bare skin. Wear gloves. Oil from your skin can damage the bulb.

Headlight Bulb Replacing: 
Headlight Bulb Replacing: Working at the rear of the headlight assembly, unplug the headlight bulb electrical connector by squeezing the release tab and pulling it off.
Figure 1

Headlight Bulb Replacing: Working at the rear of the headlight assembly, unplug the headlight bulb electrical connector by squeezing the release tab and pulling it off. The low beam bulb is designated by a blue arrow, while the high beam bulb is indicated by the green arrow.

Headlight High Beam Bulb Replacing: 
Headlight High Beam Bulb Replacing: To disconnect the high beam bulb electrical connector, press the release tab and pull it straight off the bulb.
Figure 2

Headlight High Beam Bulb Replacing: To disconnect the high beam bulb electrical connector, press the release tab and pull it straight off the bulb. Next, rotate the headlight bulb counterclockwise and remove it from the headlight assembly.

Headlight Low Beam Bulb Replacing: 
Headlight Low Beam Bulb Replacing: To disconnect the low beam bulb electrical connector, press the release tab (green arrow) and pull it straight off the bulb.
Figure 3

Headlight Low Beam Bulb Replacing: To disconnect the low beam bulb electrical connector, press the release tab (green arrow) and pull it straight off the bulb. Next, rotate the headlight bulb holder (yellow arrow) counterclockwise and remove it from the headlight assembly. Pull the old bulb (red arrow) out of the holder (blue arrow). Install the new headlight bulb into the holder, then into the headlight assembly. Rotate it clockwise to lock into place. Connect the electrical connector and check the bulb's operation.

Headlight assembly replacing:
Headlight assembly replacing: Working at the rear of the headlight assembly, unplug the headlight bulb electrical connector by squeezing the release tab and pulling it off.
Figure 4

Headlight assembly replacing: Working at the rear of the headlight assembly, unplug the headlight bulb electrical connector by squeezing the release tab and pulling it off. The blue arrow indicates the low beam bulb. A green arrow indicates the high beam bulb.

Remove the four 8mm headlight mounting fasteners.
Figure 5

Remove the four 8mm headlight mounting fasteners. The green arrows point to three of the fasteners. The yellow arrow and inset show the final headlight fastener. Disconnect the side marker bulb electrical connector (blue arrow) by squeezing the release tab and pulling it off. The connector is mounted on the headlight near the rear outer fastener.

Slide the headlight assembly from the vehicle by pulling it straight out toward the front of the vehicle.
Figure 6

Slide the headlight assembly from the vehicle by pulling it straight out toward the front of the vehicle.

Once the headlight assembly is removed, transfer the plastic trim piece over to the new headlight.
Figure 7

Once the headlight assembly is removed, transfer the plastic trim piece over to the new headlight. Release the retaining tabs. Detach the tab indicated by the green arrow. Squeeze the tabs (yellow arrow) to release the trim piece. Connect the electrical connector and check the bulb's operation.

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Comments and Suggestions:
Mike Comments: My car is a 3.0D 2005 I dont seem to be able to pull the headlight assembly clear as at the bottom it is below the bumper and headlight washers also seem to be in the way, the angel eyes have stopped working and the indicator lights up instead if you try to use side lights only
September 19, 2016
  Followup from the Pelican Staff: You have to detach the washers first, pull them straight out to remove. Then if you can;t clear the bumper, remove the front bumper. - Nick at Pelican Parts  
makadoo Comments: Excellent instructions. I'd followed them and was able to replace the low beam bulb on my 2003 BMW X5 3.0i in less than 10 minutes. Thank you.
September 5, 2016
  Followup from the Pelican Staff: Thanks for the feedback. Glad we could help.
- Nick at Pelican Parts
 
Nick Comments: What is the size of screws torx?? On e53 headlight
September 13, 2015
  Followup from the Pelican Staff: They should be 8mm hex, not Torx. - Nick at Pelican Parts  

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Page last updated: Mon 12/5/2016 02:23:42 AM