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Xenon Control Unit Replacement
 
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Pelican Technical Article:

Xenon Control Unit Replacement

Steve Vernon

Time:

3 hours3 hrs

Tab:

$150 to $360

Talent:

**

Tools:

T20 Torx, 8mm socket, long extension, long handles magnet

Applicable Models:

BMW E65 7-Series (2002-08)

Parts Required:

Xenon control unit

Hot Tip:

Check for dirt

Performance Gain:

Working headlights

Complementary Modification:

Polish the headlight lens

Each headlight assembly has a Xenon control unit that sends the original signal to the Xenon ballast to ignite the Xenon gas in the bulb and then send the maintenance signal to keep the gas burning. If this unit fails your headlights will not work. Replacement of the unit itself is quite simple once you get to it, but the control unit is mounted on the underside of the headlight assembly and cannot be replaced without removing the front bumper cover and the complete headlight assembly.

The procedures are the same for both sides.

Please see our article on front bumper cover removal for step-by-step instructions on removing the bumper cover.
Figure 1

Please see our article on front bumper cover removal for step-by-step instructions on removing the bumper cover.

There are six 8mm screws holding the headlight assembly in place, two on the top of the assembly (red arrows), two that are behind and below in the rear (yellow arrows) and two accessed from underneath (blue arrows).
Figure 2

There are six 8mm screws holding the headlight assembly in place, two on the top of the assembly (red arrows), two that are behind and below in the rear (yellow arrows) and two accessed from underneath (blue arrows). The two on the rear (yellow arrows) are removed by using a long extension with a magnet so when the screws come lose you will not loose them

With all the hardware removed slide the assembly forward and disconnect the small upper wiring connection (red arrow).
Figure 3

With all the hardware removed slide the assembly forward and disconnect the small upper wiring connection (red arrow).

Slide the assembly further out and remove the main wiring harness from the fender side of the housing (red arrow).
Figure 4

Slide the assembly further out and remove the main wiring harness from the fender side of the housing (red arrow).

You can now remove the headlight assembly completely.
Figure 5

You can now remove the headlight assembly completely. With the assembly removed you can see the mounting points for the hardware you removed earlier. It is color coded with picture 3.

Turn the assembly upside down.
Figure 6

Turn the assembly upside down. The control unit is located on the bottom of the headlight assembly. Use a T20 Torx and remove the four screws holding it to the housing (red arrows).

Pull the control unit straight up and off from the housing.
Figure 7

Pull the control unit straight up and off from the housing. The unit comes complete. The new one just needs to be pressed into place and tightened down. Make sure to check the area around the connection. If the old unit failed because of corrosion or dirt and debris you will want to make sure everything is cleaned up before installing the new unit. Installation is the reverse of removal.

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