2004 Headlamb Bulb Replacement DIY
 

Long time member and user of many helpful hints and DIY tips that I figured I would like to use this opportunity to contribute as a way of saying thanks to alot of very helpful members.

I've searched and searched but really haven't found a step by step process in replacing xenon bulbs from year 2004 and above so here it is.

First of all, you need a bendable extender socket wrench like this. It really made it easy for me to do the job especially when it is really tight at the back of the headlamp and if you're like me who doesn't want to remove the whole bumper...you need this

http://xoutpost.com/gallery/files/8/3/7/4/tool.jpg

PASSENGER SIDE:

Remove 4 bolts holding the headlamp cluster to the body. Two on top of the cluster which are black and two at the back of the cluster which are just silver/no color

http://xoutpost.com/gallery/files/8/3/7/4/pass2.jpg

Once you pull the headlamp cluster out a little, it should give you enough room to take out 4 screws that are on the back of the headlamp cluster by using an allen wrench preferrably the bendable extender which is pictured above

http://xoutpost.com/gallery/files/8/3/7/4/pass3.jpg

There is a black plug at the farthest left side next to the fender of the back cover. Use two fingers to press the top and bottom of the plug to unlock then pull out. Once all 4 screws have been taken out of the back of the headlamp cluster, use a flat head srew driver to pry open the back. It is a bit tight so be patient.

http://xoutpost.com/gallery/files/8/3/7/4/pass4.jpg

Now that the back has been pulled open it shows a metal block with a wire plugged into it. Simply pull/slide the plug backwards to remove. Then grab the metal block and twist till it stops then pull out.

http://xoutpost.com/gallery/files/8/3/7/4/pass5.jpg

Once the bulb is exposed, there are two metal prongs holding the bulb tight. All you have to do is use a finger and press it in towards the center then it releases. Do the same thing to metal prong on the other side of the bulb. Then when both prongs are released just pull the bulb out.

http://xoutpost.com/gallery/files/8/3/7/4/pass6.jpg

Make sure you wear gloves or use a rag to hold the bulb. Don't touch the glass part with your fingers since our fingers have natural oil and it will break the bulb when heated.

DRIVER SIDE:

It is pretty much the same on the driver side but you have to deal with the air filter box. Again, there are 4 screws that holds the cluster. Two black screws on top and two silver/unpainted screws on the back. There are two bolts that are close to the fender. Just take those two out and pull the hose that leads to the center vent.

http://xoutpost.com/gallery/files/8/3/7/4/driv1.jpg

When the air filter/box is lose, lift up and push backwards toward the windshield a little so you can have more room to work with. Unscrew the 4 screws that are holding the back of the cluster so you can have access to the bulbs.

http://xoutpost.com/gallery/files/8/3/7/4/driv2.jpg

Again, there is a plug on the farthest right next to the fender. Use two fingers to press the top and bottom of the connector to unlock. Once all 4 screws are taken out, take a flat head screwdriver and pry open the back end of the cluster. When open, pull/slide out the wire that is plugged to the metal box. Once unplugged, grab the metal box and twist until it stops then pull out.

http://xoutpost.com/gallery/files/8/3/7/4/driv3.jpg

The bulb should be exposed but don't forget to use a finger to push two metal prongs lose. Push towards the center then out. Do the same to the other side of the bulb. Once both metal prongs are released. Just pull bulb out.

http://xoutpost.com/gallery/files/8/3/7/4/driv7.jpg

When done replacing bulb. Just put everything back the same way! Good luck! If anyone needs help, don't hesitate to PM me and I'd be glad to help you out. If you're local...let me know and I can come over or something.

Hope this helps some of you!

Pics of the results aren't that good. But I upgraded to 6000K D2S bulbs that I got from ebay!

http://xoutpost.com/gallery/files/8/3/7/4/passside.jpg http://xoutpost.com/gallery/files/8/3/7/4/drivside.jpg

Nice!! It's also not very often I'm happy to have a 2001 instead of a 2004+ LOL

Yep, I actually had an easier time doing bulb replacement on my old '03 than the new one I have.

Nevertheless, it is a great learning experience...

Thanks a ton for this write up! Purchased the tool $15 on Amazon and was able to change the bulb in my 2005 3.0i post facelift with headlight washers without taking off the bumper. Bought the Wagner DS2 at RockAuto for $28.99. Got genuine Phillips bulbs for the price of fakes.

The driver's side of the N62 4.4 & 4.8is ain't as easy as you guys with the 3.0 . :(

The PS reservoir and expansion tank are mounted to a bracket that is easily moved out of the way with a few screws...but there's still not much room to access all of the torx screws in the headlight assembly since the headlight washer jets don't give the headlights much room to move forward enough. Removing the bumper is preferable than trying to not lose the torx screws while holding a mirror and flashlight...ARRRGHH!!!

Glad you found it helpful. I never thought anyone would actually use this when I posted it almost 10 years ago that's why I did it because I didn't find anyone who did it.

Let's see...5 replies & 4381 views since you posted this DIY. It's the silent majority doing their thing again.

I'm sure there have been many others that have found this info useful...they come to the forum and read and gain knowledge...but just fall into the major category of never or rarely posting.

On most forums...the vocal participants are the minority...and the silent participants are the majority. :D

Even in a "hot" thread where there are a lot of replies...the "views" will still heavily outnumber the replies...again, the silent majority reading and taking it all in...but choosing not to participate in the discourse. :)

Thank you for the post that this COULD be done without the bumper removal. I was able to replace the right side Xenon bulb by loosening the headlight housing and pulling it forward and then gently working the rear cover torx screws out without dropping them. The lower right torx was the hardest but actually being able to see it from the turn signal area with the headlight assembly pulled forward made all the difference. Thanks again! :thumbup:

Glad I was able to do this write up for everyone!

I have a 4.8 and I'm trying to do this. But your pics no longer work unfortunately. I already got the passenger side assembly lose, but I was unable to remove it. Just seemed like the base of the headlamp kept getting caught on the bumper.
Did u completely remove the headlamp assembly?


Sent from my iPhone using Tapatalk

Pics are working for me? :dunno:
I did not take the headlight out, just loosened it and brought it forward against the bumper headlight washers as far as I could and worked at it from all angles. It can be done without removing the bumper to remove the headlight. :thumbup:

See if this video I did helps: https://youtu.be/5RmGmhlAO98


Sent from my iPhone using Tapatalk

Since this is an older thread...if you're asking the OP (original poster)...then take a real good look at the last pics in the 1st post and note that they DO NOT have the headlamp washers. If you do...then that's why you cant completely remove the headlight assembly.

Still can't see pics, but I got it done. Wiggles it enough to give me room to work and take the covers off.
Good stuff. Still can't get the angel eye bulb to unlock tho. Lol.
Thanks guys.


Sent from my iPhone using Tapatalk

The angel eye housings can be difficult. Just add some more force, it will come out. I noticed this morning (still dark)when I left the house the drivers side xenon flickered a few times so I may be headed for a failure. I have a spare D2S bulb so I might try that first. The right side failed about a year ago so after 13 years, I guess it's time... :(

Deleted post (wrong info)

I posted in this thread several years ago when I replaced my headlamps on a 2005 facelift x5 with headlight washers. It worked. Since then I've had to remove the bumper for other reasons and realized it comes off in 10 minutes. The only issue is supporting it when it's off so it doesn't hang by the hoses. A walmart swimming inflatable circle thing would probably work fine to rest it on. Here is the video I used.

https://youtu.be/QkPxUSSa0L8

Oh snap. That is very easy, and I'm already missing the 5 below the bumper. That's good to know.

Any chance you have - video for the rear bumper too, I need to do a hitch install soon.


Sent from my iPhone using Tapatalk

The rear bumper is even easier. 2 large T55 torx bolts and 2 8mm screws in each fender liner. Don't forget to disconnect the PDC harness if you have PDC.

Sweet.


Sent from my iPhone using Tapatalk

Just an update, swapped out the bulb and still having a flickering issue. It leaves the ballast or igniter as my problem so more troubleshooting to come.

*EDIT* Picked up a used ballast on fleaBay for $44 and should be here by the weekend. Pulling the front bumper... Again... http://s1.e46fanatics.com/forum/imag...palmsmiley.gif

Ouch. Wife's e53 messed up on me one night when I made a cig run. The light flickered and didn't come on. Figured it was the ballast but it never messed up again after that so I guess I got lucky.

Spent my birthday today testing the steering angle sensor on the e53 again. Weird how it works a few times then quits. I guess the brushes are shot in it.

Swapped out the ballast this morning and seems to have fixed it, no flickering. I didn't need to completely pull the front bumper, only slide it forward about 3 inches to maneuver the headlight out. I still had to pull all the fasteners to the point of completely removing it but it was a lot easier not having to pull any of the wiring or washer hoses. I have this front bumper removal down to 10 minutes now... :nanana:

Hope my steering able sensor job next week goes as smoothly.