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Since I've had mine off at least 10 times and was asked, here's a down and dirty on the front bumper removal. I did find a few pics I could use that I took a while back. If needed I'll post a more in depth version when I get back from Afghanistan.
 

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Thanks for the great DIY!! Was able to remove the front bumper to replace a broken fog light assembly from road debris - piece of cake but took me a little longer first time through. Very nice job on the DIY 30yrVet! :thumbup:
 

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Great Tutorial

@ 30yrVeteran, I just came across your PDF on front bumber removal. My nearside headlight was full of condensation when I bought the car back in April this year. I suspect the seller knew about the problem and the cost of fixing it and that's why he got rid of the car. I cleared the condensation simply by removing the rubber cover from the rear of the headlight unit but obviously by then the controller must have been full of water because the headlight failed during my recent trip to France, Spain and Italy. The bumper is noew off the car and I'm awaiting delivery of a replacemt controller so I can start driving the beast again .
Thanks a million for the PDF, couldn't have done it without your help.
Alan
 

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DIY: Front Bumper Removal

. I cleared the condensation simply by removing the rubber cover from the rear of the headlight unit but obviously by then the controller must have been full of water because the headlight failed during my recent trip to France, Spain and Italy. The bumper is noew off the car and I'm awaiting delivery of a replacemt controller so I can start driving the beast again .

Thanks a million for the PDF, couldn't have done it without your help.

Alan
So you had to remove the bumper to get to the rear of the headlight housing?

Sent from BimmerApp mobile app
 

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I didn't need to remove the bumper to get to the rear of the headlight to remove the rubber cover, you can get to that from under the bonnet. But if your ballast unit has failed then you will need to remove the bumper to replace the ballast unit. The ballast is screwed to the under side of the headlight and the only way to get to it is to remove the bumper.

If you do need a ballast unit then Vauxhall use the same part but they charge a lot less than BMW. I got a second hand Vauxhall unit off ebay for £20.00 plus £5.00 postage.

Incidentally, removing the bumper isn't as daunting as it may first appear. 30 minutes is ample time, just watch for the windscreen washer bottle located behind the bumper, it can be a pig to disconnect and when you re-connect it, test it for leaks before re-fitting the bumper. That was my experience :eek:(
 

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The one I removed was accessible from under the hood. I think it was covering the sidelight bulb. I'm not too sure because I got rid of my 645 as soon as I fixed the lights, I certainly didn't need to remove the cover in the wheel well.
However, if like you say your low beam is out due to condensation then it sounds like the damage has already been done and you'll need to replace the ballast unit.

Edit: I just realised you're not UK based so may not know what a Vauxhall is :D Try General Motors.
 

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That's scare-mongery. Once you have the bumper off the car it's quite obvious which bolts (I think they're are 4) hold the headlight on. Have you read the PDF posted by 30yrVeteran at the top of this page? It doesn't describe the actual headlight removal but you should read it before attempting bumper removal.
 

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I was reading on taking out headlight housing and the author was saying NOT to unscrew certain bolts, to be super careful and mindful with the positioning and stuff because of how they calibrate.. What is the trick to getting it out?

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Probably what they are referring to is the adjustment screw that is behind the headlight on the left/right outside corner of the light. It positions the headlight beam. If memory serves me correctly the screw for the light where I marked goes into an adjustable receiver that also screws in and out, therefore changing the angle of the light. Just make sure you either mark where the backside adjustable receiver is or just make sure and not move it. When you get the bumper off and can see the headlight just take a look at that area, it will make sense when you see it.

In this picture I took from 30yrveterans PDF the adjustable post is completely out:

 

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Actually this one is easy.
1) Screw off number plate, there is like 2 torx 20 screws behind it (or torx 25).
2) Then you are basically home free. 4 screws at the bottom of the bumper
3) Three-four screws on each wheel basket. Removal if wheels is just to your benefit.
4) And two dowels are on each side of the bumber, next to the rear wheels. If you can push them from top to down then you don't need to replace them.

I think that there is some pictured manual also in some thread here. Keep looking, but otherwise it is easy one.

Cheers.
 
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