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E46 (1999 - 2006)
The fourth generation 3 Series (E46 chassis) was introduced in 1999 and set the standard for engineering and performance during it's years of production including being named to Car & Driver's 10 best list every one of those years! ! -- View the E46 Wiki

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  #1  
Old 02-21-2016, 08:03 AM
djkicks djkicks is offline
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Facelift headlight disassembly

Howdy. I'm hoping the community could help me a bit here. I have an '05 CI convertible. The PO had a fender bender that was 'repaired' before I bought the car (about a year and a half ago). I noticed the the lens on the headlight (xenon auto adjusting) was cracked but didn't seem to cause anything other than cosmetic issues.

Well, with the super El Nino rains we got recently, the cracked headlight filled up with water. Like 1/2 full, fishtank looking. Any way, the entire bottom of the headlight electrical system is shot and corroded. Control units, connector wiring etc. Bulbs and ignitor are still ok.

I picked up another headlight assembly from a salvage yard that had a destroyed lens and mounting points but good electrical.

I cannot figure out how to take the interior part of the assemblies apart so I can swap the harnesses and save $600-1200.

I don't want to do it wrong and screw up what I have already.

Has anyone ever done this?

Thanks,

DJ
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  #2  
Old 02-21-2016, 08:07 AM
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Solidjake Solidjake is offline
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You will need to bake the light to soften the glue and remove the lens. Sucks since that's the only way to do it for the facelift coupe headlights. After that you can pop out the arms that hold the assembly together.
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  #3  
Old 02-21-2016, 08:11 AM
djkicks djkicks is offline
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Ok. I already have the lens cover off. I'm not seeing how to get the assembly out. I don't see a place to 'pop' them off. that's where I'm stuck. Do you have a pic of what you are describing?
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  #4  
Old 02-21-2016, 08:16 AM
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Solidjake Solidjake is offline
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Let me see if I can dig around the forums for some pics.
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  #5  
Old 02-21-2016, 08:17 AM
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Solidjake Solidjake is offline
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http://forum.e46fanatics.com/showthread.php?t=595976

Quote:
Disassembling the Headlight.
Torque wrench/screw driver needed
Remove the connectors on the bottom of the headlight, 2 silver blocks with connectors, 3 screws each.
Take off, 2 rubber tubes on each side of the headlight
Remove the rubber trim on the side of the headlight
Remove the turn signal bulb
Remove 2 screws on the back
REMEMBER WHERE EVERYTHING NEEDS TO GO BECAUSE YOU WILL NEED TO PUT IT ALL BACK TOGETHER

Hope that helps
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  #6  
Old 02-21-2016, 08:19 AM
djkicks djkicks is offline
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Cool. I appreciate it. Most of the work and repairs on this car have not been difficult or too expensive but these f'n headlight assemblies are ridiculously expensive. If I could find one for less than $350, I'd just swap it out. :-P I just don't have $700 for aftermarket or $1100 for factory replacement.
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  #7  
Old 02-21-2016, 08:22 AM
djkicks djkicks is offline
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Ok. I just saw the directions. It doesn't sound like that's what I'm seeing on my assembly but I'll check it out when I get back home. I really hope it's that easy. :-)

THanks again,

DJ
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  #8  
Old 02-21-2016, 08:23 AM
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Solidjake Solidjake is offline
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You got it, let us know how it turned out
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  #9  
Old 02-21-2016, 09:35 AM
djkicks djkicks is offline
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Following those instructions only gets me to where I already am. That takes the reflector for the turn signal and stuff off. I need to remove all the stuff behind that. The motors for the adjusters and all the associated wiring harness
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  #10  
Old 02-21-2016, 10:22 AM
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Solidjake Solidjake is offline
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Post up some pics or make a vid if you can
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  #11  
Old 02-21-2016, 10:23 AM
djkicks djkicks is offline
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I took a pic of the process as of where I am. I don't know how to upload directly I'm using my phone and I don't have any internet at the house so I guess I have to wait till I get to a computer and the Internet
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  #12  
Old 02-21-2016, 10:57 AM
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Solidjake Solidjake is offline
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you can click on "Go advanced" and below you will see manage attachments. you can directly add the pics, click upload, close the window and then post the reply
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  #13  
Old 02-21-2016, 02:22 PM
djkicks djkicks is offline
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It keeps asking me for a URL for the image
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  #14  
Old 02-21-2016, 10:45 PM
GoForthFast GoForthFast is offline
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Quote:
Originally Posted by djkicks View Post
It keeps asking me for a URL for the image
click Manage Attachments

Then click browse to search for the jpg on your computer.
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  #15  
Old 02-21-2016, 10:53 PM
djkicks djkicks is offline
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OK. Thanks. :-)

I need to take this stuff out so I can change the wiring harness and motors.
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