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Xenon Headlight Replacement
 
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Pelican Technical Article:

Xenon Headlight Replacement

Nick Czerula

Time:

1 hours1 hrs

Tab:

$300

Talent:

**

Tools:

Phillips & flathead screwdriver, T15 T25 Torx

Applicable Models:

BMW Z4 Convertible (2003-06)
BMW Z4 Coupe (2006)

Parts Required:

Headlight assembly, headlight bulb, active headlight or Xenon module

Hot Tip:

Do not touch bulbs with bare hands

Performance Gain:

Repair damaged headlight assembly, replace faulty headlight bulb

Complementary Modification:

Replace turn signal bulbs

BMW Z4 vehicles with optional high intensity discharge (HID) or xenon headlights utilize a special high voltage bulb and control unit for the headlights. The bi-xenon headlight is equipped with an electrically activated shutter, which directs the low beam cone of light in the same direction as the high beam.

The headlights assemblies seals can wear out over time resulting in water leaks and repeat bulb failures. On models with high intensity discharge (HID) or Xenon lights, the HID module is located at the bottom of the headlight. Water can enter the module electrical connector causing headlight faults. If this happens to you, you will have to replace the headlight, the electrical harness and the HID module. The procedure below highlights Xenon style bulb replacing. Halogen bulb replacement is similar, but not covered in this tech article.

Remember that your car may have been serviced before and had parts 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're 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. Never work on your vehicle if you feel the task is beyond your ability.

Our vehicle may vary slightly from yours as models do change and evolve, as they grow older. 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.

When replacing the headlight, first you will have to remove the front bumper.
Figure 1

When replacing the headlight, first you will have to remove the front bumper. See our tech article on front bumper replacing. If you have a foggy headlight (green arrow), you can refinish it to look new (red arrow). 

With the bumper removed, working at the outside corner of the headlight, remove the T25 Torx fastener (red arrow).
Figure 2

With the bumper removed, working at the outside corner of the headlight, remove the T25 Torx fastener (red arrow).

Working at the bottom and top of the headlight, remove the T25 Torx fasteners (red arrows).
Figure 3

Working at the bottom and top of the headlight, remove the T25 Torx fasteners (red arrows). Support the headlight when the last fastener is removed.

Disconnect the headlight electrical connectors (red arrows).
Figure 4

Disconnect the headlight electrical connectors (red arrows).

Slide the main electrical connector lock in the direction of the green arrow to unlock it.
Figure 5

Slide the main electrical connector lock in the direction of the green arrow to unlock it. Then pull the connector straight off the headlight. Then remove the smaller connector by pressing the release tab and pulling it straight off (red arrow). Once disconnected, remove the headlight from the vehicle and place it on your workbench.

This photo shows the main connector being removed, once the lock has been slid to the side.
Figure 6

This photo shows the main connector being removed, once the lock has been slid to the side.

Flip the headlight over to service the control module.
Figure 7

Flip the headlight over to service the control module. To remove the Xenon headlight module, remove the three T18 Torx fasteners (red arrows).

Lift the Xenon module up to remove it.
Figure 8

Lift the Xenon module up to remove it. When removing the Xenon module, inspect the module for corrosion. If needed, replace the module as well as the headlight. Reverse the instructions for reinstallation.

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Page last updated: Sun 2/19/2017 02:59:11 AM