Replacing headlight covers/adjusters on E39

[GrGreasemonkey9]

I have a 1998 BMW 540i, Would this be a way that i could install an angel eyes kit, rather than replacing the whole assembly. I've seen sets that are simply the lights rather than the whole headlight assembly and to me it looks like you would have to dissasemble the headlights to install these and if they are sealed headlights i would rather not have to deal with re-sealing them.

[rc5695]

I took on the task of replacing my mother-in-law's adjusters on her '99 528i last night. It took 2 hours, and I did not have to remove the headlight. This job can easily be done with the headlight in place and just removing the lens.

The old adjusters were so brittle I couldn't even grab any parts with needlenose pliers! I had to just push on it a LITTLE bit with a screwdriver and it would just disintegrate. Blow it out with the airhose, install new ones, and done. Jared sells the new adjusters from EAC Tuning cheap! Especially compared to a whole new light!

I just installed DEPO's on my '99 528it (from Joe @ Euro-Dyne), and I'd like to give a quick comparo to the OEM Hellas. Both are HID.
Dims: DEPO's have a "whiter" light appearance to them, and seem to be a little brighter.
Brights: Hella's by far are brighter! WAY better! The DEPO's don't seem to spread the light out as much as the OEM's. I want to try some higher wattage "off-road only" bulbs in my DEPO's brights sometime and see if I can help this out some. I know it made a HUGE difference on my motorcycle.

[putnampunk]

Disclaimer: Note this is for my 2000 BMW 540i with HID and adjustable beams.

I've tried looking... but can't find part # or info on those headlights. I like the pre-01 look without angel eyes, and want to replace halogens eventually with HID. Info on what you have?

thanks

[wquiles]

I've tried looking... but can't find part # or info on those headlights. I like the pre-01 look without angel eyes, and want to replace halogens eventually with HID. Info on what you have?

thanks

I don't know what the part # would be, but you can find the original parts numbers here:
http://www.realoem.com/bmw/select.do

And please keep in mind that if you do replace your lights, the wiring harness might be different

Will

[putnampunk]

I don't know what the part # would be, but you can find the original parts numbers here:
http://www.realoem.com/bmw/select.do

And please keep in mind that if you do replace your lights, the wiring harness might be different

Will

Thanks - I looked there, but under my year. Apparently I did something wrong or the HIDs were not offered until 2000. But found it now under 2000 and should hopefully be able to replace my adjusters and install HIDs at the same time. (might just get parted out headlights too)

Different parts between the same style headlights:
LOW BEAM COVER 2 09/2000 63128362835 $24.40
Covering cap high beam 2 09/2000 63128370312 $33.90
STICK-ON LABEL XENON-LIGHT 2 09/2000 71237211223 $5.58
BULB HB3 12V 60W 2 09/2000 63217160785 $18.86
CONTROL UNIT XENON LIGHT 2 10/1998 09/2000 63128387114 $449.90
Set braclets.ctrö imot Xenon light left 1 10/1998 09/2000 63128386555 $37.47
Set braclets.ctrö imot Xenon light rght 1 10/1998 09/2000 63128386556 $37.47

But I have been employed at the dealer in the past, and one of the guys in parts went to school with me / E30 pal so he can probably help and investigate how to get it all from Halogen H7 to HID.

Good writeup

[marcos80]

Hello to all of you. I am a new member from Montenegro, Europe. I am interested where to buy glass - headlight cover which is crushed for my BMW E39 2002 production year (european model). My xenon lights are working properly but protetcting glass has been broken. One more question - is it possible to replace the crushed headlight cover from older regular (non xenon) light from old BMW 5 series?

Best regards to all of you guys from Podgorica!

[waggin it]

Thanks wquiles and OP Vince for a great tutorial. Just replaced mine and all the tips were a great help. Waiting for dark to adjust -- it'll be nice to see where I'm going!

[Giancarlo976]

I have these for sale. Amber part is broken on left side, but asking 100 cash obo, local pickup only though.



Uploaded with ImageShack.us

adjusters broken, but i have a set.

[switlikbob]

FYI: Pelicanparts.com is selling the adjusters for $7 per side with $5.50 shipping.

[switlikbob]

I just replaced the adjusters. The only tip that I have to offer is concerning the ball & socket connection with the adjusters themselves. Instead of screwing the adjusters onto the studs and forcing the balls back into the socket...I installed the balls into the socket 1st, since they would not fit into the socket without massive persuasion. I actually pulled the sockets out of the metal headlight frame, installed the balls into the sockets and then put the whole piece back into the frame. Then lines the adjusters up with the screw, and tightened them up.

[hgdon]

Well i attempted this on my 2003 525i what a PITA!!
I got nowhere with removing the cover, ahd the thing in the oven for 7mins at 200 degrees

i'm going to try again with a blow dryer and hope for the best

If not Tie Straps here i come !!

[BimmerBreaker]

Well i attempted this on my 2003 525i what a PITA!!
I got nowhere with removing the cover, ahd the thing in the oven for 7mins at 200 degrees

i'm going to try again with a blow dryer and hope for the best

If not Tie Straps here i come !!

If you would have done a little more research you would know that the 02+ headlights used a different adhesive and can NOT be baked open

[hgdon]

If you would have done a little more research you would know that the 02+ headlights used a different adhesive and can NOT be baked open

Aare you serious!!
Darn, If i only clicked a few more times

So what the fix? New Headlights??
Tie Straps?

BTW thanks for replying

[jamesdc4]

Aare you serious!!
Darn, If i only clicked a few more times

So what the fix? New Headlights??
Tie Straps?

BTW thanks for replying

Mark (e39dream; Mark@eactuning) has a procedure for doing the 2003 headlight adjusters. PM him.

I hearts e39dream. He did my 2003 lights which can NOT be opened at all. I dont know how he did it and nor do i care. All I know is that i have solid adjusters in my lights and believe they might have been "beamed" into the lights or perhaps teleported into them.

He did a headlight for me too. Professional work was done, and I was happy with the job on it. I don't know how he did it, but like Gumbi said, he probably has teleportation powers of some sort....is "teleportation" even a real word? lol.

I suggest anyone with broken adjusters on their 2001+ lights give E39Dream a holler, he knows what he's doing and does a great job.

DIY for the DIY section?

Mark,

In your experience, is that true of all 2003 headlight housings? If so, I want to change the title of the headlight adjuster DIY to reflect that.
Headlight Adjusters Replacement (2001-2003)

Apparently 2001-2002 headlights have this different adhesive which is softer and melts in the oven, which makes it possible to be opened. BUT seems like most if not all 2003 headlights have this rock solid rubber adhesive which doesn't melt in the oven. I had this late 2002 headlight though, which had this super adhesive and the damn thing would not have pried opened, so there is where Mark comes in and saves the day.

[siny528i]

Thanks wquiles (and Vince) again for this excellent write-up!

I hit the pothole and my right light started to point about 6 feet away from the car.
So this tutorial went completely handy...

I got mines from Pelicanparts.com for $19.50 shipped (thanks switlikbob for the info) and did them (only one side though, but I have adjusters for another one as well) yesterday after work! I took me about 30-45 minutes. They went to dust when I was removing them. I used small 5/64 and then 7/32 bit to drill (crush) old ones out.

I just replaced the adjusters. The only tip that I have to offer is concerning the ball & socket connection with the adjusters themselves. Instead of screwing the adjusters onto the studs and forcing the balls back into the socket...I installed the balls into the socket 1st, since they would not fit into the socket without massive persuasion. I actually pulled the sockets out of the metal headlight frame, installed the balls into the sockets and then put the whole piece back into the frame. Then lines the adjusters up with the screw, and tightened them up.

thanks switlikbob,
for suggesting pelicanparts and btw I did it exactly like you suggested... I pushed all new adjusters into reflector first and then screwed whole thing in place!

[MehMan]

Great guide! Helped a lot. The one thing that I couldn't do was detach the headlight from the servo with the pliers. It wouldn't budge, so I used a bit of cable and tied it where I could, then give a good tug and heard that dreadful pop. After that I was quite surprised at just how brittle the old adjusters were.

[get2it]

Meh, next time read the thread a bit further and you wouldn't have had such a hard time

Outstanding job on the DIY! Just finished one headlight, I'll do the other tomorrow. Thanks for taking the time to post up!

[twdubs]

Can I just replace the outer cover and not go through the whole adjuster/HL housing ordeal? My interior lenses are fine it's just my exterior lens cover. I have a 99 540 - so I'm just looking for the easiest/least time solution. I really don't want to go the plastic polish route.

[98 528i]

Can I just replace the outer cover and not go through the whole adjuster/HL housing ordeal? My interior lenses are fine it's just my exterior lens cover. I have a 99 540 - so I'm just looking for the easiest/least time solution. I really don't want to go the plastic polish route.

changing the covers out won't affect the adjusters, all you have to do is pop the tabs out and your set

[twdubs]

changing the covers out won't affect the adjusters, all you have to do is pop the tabs out and your set

thank you - so if my adjuster aren't bad i'm good to just replace the lens cover? appreciate the help.

[98 528i]

thank you - so if my adjuster aren't bad i'm good to just replace the lens cover? appreciate the help.

Yes sir,

The photo in my sig is stock xenon headlights with covers from Umnitza p39s, something similar to these:

http://cgi.ebay.com/ebaymotors/97-00...ht_4275wt_1165

[Steve Pocock UK]

I have non xenon lights on my 99 523i - replaced the broken adjusters but forgot to lubricate them properly on re-install. Have now rounded the plastic knob hold on the knurled end of the screw which goes into the adjuster. Knob has fallen off.

I will attempt to stick it back in place with Araldyte or similar, but can anyone advise a supplier of a new part - aside from a breakers please?

[cvn54o]

Just finished replacing adjusters on one side (driver's). Much easier than the DIY indicated or expected. During adjustment last night, I made the collosal mistake of touching the passengrer's side headlight adjusters. I'll be replacing those this weekend. I will also replace the stock 55W halogen bulbs (hey - this is a 97 540i) with the PIAA Super Whites. Still - very happy with the results.

[BeamerGuru]

Hi everybody,

I am selling headlight adjusters for BMW E39:

E39 1996-2000 prefacelift headlight (xenon headlights also)
14 $ (for 1 headlight)



E39 2000-2003 facelift headlight (xenon headlights also)
24 $ (for 1 headlight)


Shipping charge: 6 $.

Really great quality. Good feedback from buyers!
Paypal payment accepted.

PM or E-mail (AutoForce@inbox.lv)

[MehMan]

Hehe, bought about 5 sets from you already.