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Headlight Bulb Replacement
 
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Pelican Technical Article:

Headlight Bulb Replacement

Steve Vernon

Time:

1 hour1 hr

Tab:

$2 to $320

Talent:

**

Tools:

Hands

Applicable Models:

BMW E65 7-Series (2002-08)

Parts Required:

Bulbs

Hot Tip:

Do not touch the bulbs with bare skin

Performance Gain:

See better

The BMW E65 comes with the Angel Eyes headlight assembly, which requires the entire headlight assembly to be removed from the vehicle that includes removing the front bumper. This article will not cover this procedure but show how to change all the other bulbs. If you need to replace the Angel Eyes bulb or remove the headlight assembly from the vehicle please see our article on those procedures.

All of the bulbs with the exception of the Angel Eyes in the headlight can be changed without removing the assembly from the vehicle even though it is a tight fit. I have removed the assembly to get better pictures of the procedures, as you will be doing some of this by feel. When changing bulbs be sure to never touch the bulb with your bare fingers or hands. The oils in your skin can cause a hot spot on the bulb and greatly decrease the life of the bulb.

The lenses on the headlights cannot be replaced independently so if you damage a lens you will need to replace the whole assembly. Procedures are the same for both sides.

The bulbs featured in this article can all be replaced without removing the headlight assembly from the vehicle.
Figure 1

The bulbs featured in this article can all be replaced without removing the headlight assembly from the vehicle. It is a tight fit working behind the assemblies (red arrows). If you have any worries you can remove them or the airboxes to give you additional room. Please see our articles on these procedures for additional assistance.

With the assembly out of the vehicle you can see the bulbs you can access; they are the push to pass (blue arrow), turn signal (red arrows), side marker (yellow arrow) and the Zenon bulb (purple arrow).
Figure 2

With the assembly out of the vehicle you can see the bulbs you can access; they are the push to pass (blue arrow), turn signal (red arrows), side marker (yellow arrow) and the Zenon bulb (purple arrow).

Remove the push to pass bulb access door by unclipping it form the top and pulling it off.
Figure 3

Remove the push to pass bulb access door by unclipping it form the top and pulling it off. Reach in and twist the wiring harness and base of the bulb counter-clockwise until it is free (red arrow).

The base and wiring harness will stay together (yellow arrow).
Figure 4

The base and wiring harness will stay together (yellow arrow). Use a clean rag and gently wiggle the bulb out from the base (yellow arrow). When replacing the bulbs never touch them with your bare skin, as the oils in your skin can cause a hot spot on the bulb and diminish the life expectancy.

The two turn signal bulbs turn counter-clockwise from their sockets (yellow arrows).
Figure 5

The two turn signal bulbs turn counter-clockwise from their sockets (yellow arrows). There is a rubber gasket on the base of the socket (red arrow) that you should inspect for a weather tight seal every time you change bulbs.

The bulbs are replaced by pulling them straight out from the socket.
Figure 6

The bulbs are replaced by pulling them straight out from the socket.

The side marker bulb and socket turn counter-clockwise and are pulled out from the assembly (yellow arrow).
Figure 7

The side marker bulb and socket turn counter-clockwise and are pulled out from the assembly (yellow arrow). The bulb is replaced by pulling it straight out from the base (red arrow).

To replace the main bulb or in our project car's case the Zenon bulb, begin by releasing the door clip on the top and pivoting the door down and removing it (red arrow).
Figure 8

To replace the main bulb or in our project car's case the Zenon bulb, begin by releasing the door clip on the top and pivoting the door down and removing it (red arrow).

Disconnect the wiring connection from the Zenon base (red arrow).
Figure 9

Disconnect the wiring connection from the Zenon base (red arrow).

Reach into the assembly and turn the base counter-clockwise (red arrow).
Figure 10

Reach into the assembly and turn the base counter-clockwise (red arrow).

You can now replace the bulb, or in the case of the Zenon system, the unit.
Figure 11

You can now replace the bulb, or in the case of the Zenon system, the unit. Installation is the reverse of removal.

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Page last updated: Wed 12/7/2016 03:02:41 AM