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I just did both my headlights last night without cutting or baking. There's a pdf with step by step from a guy on another forum, but I changed a couple steps it in. When putting the blind adjusters in, first thread in the adjuster, then pop the socket on it after it's in. Too difficult getting them in while together. Then you can rotate the socket until it lines up with the base where the torx screw goes. I probably got my second lamp done in 30 minutes after doing the first.
Thanks for the instructions but part of it is cut off due to the PDF creator you are using. Could you put in some header space or repost with a different tool to loose the branding.
 
would also like to know, website now lists them for $89.95..
I get that the aluminum ones won't ever break again but really over 150.00 for these little parts. You would think that they could be cast for pennys even out of a cheaper metal. Its not like you ever get to see them again. I just ordered up some plastic replacments for 20.00. Even if they only last half of the factory ones did that so many years down the road. Plus I would prefer this cheap part to break rather then transfering that to a more expensive or non-replacable part.

I am going to attempt the instuctions in the thread but even if I have to cut my lights open you would simly put aluminum tape over the holes and call it day. That stuff sticks forever and could be pulled off to if needed.
 
It's not too bad with the right tools. I used some long surgical clamps, and it probably took me longer to get the lamps off the car than it took to thread in the new adjusters.
Well you are pretty good at getting adjusters in or your terrible at removing the headlights. I did this job just a couple weeks ago and getting the hidden one in place was a chore. having to use gravity and luck to drop that into place. I was successful in the end. Happy to have good lighting, my adjusters were broke when I got the car.
 
The harder of the 2 adjusters has me baffled; what's the best angle of attack? The lens facing down; or, having the assembly resting with the lens facing in a normal position? Are there any visual clues/ports to view the adjuster install, or is it blind?

I am really amazed how crispy the adjuster's get in that housing!
 
When putting the blind adjusters in, first thread in the adjuster, then pop the socket on it after it's in. Too difficult getting them in while together. Then you can rotate the socket until it lines up with the base where the torx screw goes. I probably got my second lamp done in 30 minutes after doing the first.
The blind adjuster is whats causing people, including myself, problems.

Check the link below for the orientation of the adjusters

Xenon Adjuster orientation

Heres an article which might be of help

Bavauto replacing adjusters
 
the adjusters are relatively easy to replace the way to do it is to open the headlamp by either baking it or best invest in a +- 30$ heat gun. Take the headlamp out by removing the 4 screws holding the lamp, disconnect all the plugs there are 5 or so plugs (they are all different so putting them back is easy, note that the short beam for xenons needs to be rotated to be disconnected DO NOT just pull! ) remove the trim under the lamp by prying it starting from the inner end careful with the inner end as it has a tab that needs to be compressed to pull the trim out.
Once you have the lamp out take the bulbs out (all of them) then take the heat gun and heat the lamp around then apply a little force to separate the lamp body by the glass, you can actually gently use a large flat screwdriver twisting it between the front glass lip and the lamp body. Make sure that you first heat the lamp around well. Once the glass starts separating force it gently and at the same time use the heat gun to help the black glue separate (you will reuse it after). Now that you separated the glass from the body of the lamp unscrew the three (four?) screws holding the electrical adjusting motor in place, after you take the screws out you need to move the motor lateral to pull it out of the C nut holding it (be patient and gentle though firm these nuts are either broken or if not they are resistant so don't be afraid to work on them). Depending which of the adjusters are broken the inner plastic piece should come out easily, don't forget to remove the angel eyes just lift them up they are not held by anything at this point. Remove the broken parts by unscrewing adjuster's base and replace them with the new ones, screw in the new adjusters (the adjuster screws are the withe ones on the back of the lamp. Putting back the lamp is the exact reverse of what you did taking it apart just remember the self leveling motor adjuster arm needs to be put back not by pressing it but by moving it laterally, on the other hand the lamp mirrors need to be pressed in the new adjusters; when you get to the point of putting the glass back heat the lamp around then put the glass and continue to heat it while pressing gently the glass onto the body.
Obviously you should clean the interior of the lamp, avoid to leave fingerprints on the inner parts, etc.
Honestly the process sounds worst than it is, took me 30 minutes start to finish, so someone that is not mechanically inclined but has logic can do it in an hour or so.
Good luck and if any questions lease feel free to contact me.
 
Can anyone confirm that the 03 lenses cannot be removed by baking or a heat gun? Ive done this on other cars and this one is so different that im afraid I'll break something.
 
Can anyone confirm that the 03 lenses cannot be removed by baking or a heat gun? Ive done this on other cars and this one is so different that im afraid I'll break something.
This is fact; they CANNOT be opened thru heat. You can probably order new Euro lenses and dremel yours off.
 
LMFAO no way! I'll just subject my hands to a painful lesson in BMW engineering and do it threw the headlight holes..... giggidy.
 
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LMFAO no way! I'll just subject my hands to a painful lesson in BMW engineering and do it threw the headlight holes..... giggidy.

Me and you are on the same tiny boat!

I have an extra set of OEM Hella euro lights and all the damn adjusters are broken.. might just have to order a new set of clear front lenses and break open the headlights. ouich
 
Just did my April 2002 headlight - took about an hour. I ended up baking them twice in order to separate the lens, otherwise all went well. I looked at trying to fix them without baking, and frankly, that looked like an exercise in frustration. 200 degrees isn't all that hot when you stop and think about it (your engine runs around 212 on a hot day, right?), and once you soften the materials a bit by doing so the chances of anything breaking are about zero. All of the clips are still intact, etc, on my lights - just be patient.

Doug
 
Just did my April 2002 headlight - took about an hour. I ended up baking them twice in order to separate the lens, otherwise all went well. I looked at trying to fix them without baking, and frankly, that looked like an exercise in frustration. 200 degrees isn't all that hot when you stop and think about it (your engine runs around 212 on a hot day, right?), and once you soften the materials a bit by doing so the chances of anything breaking are about zero. All of the clips are still intact, etc, on my lights - just be patient.

Doug

Holy Crap...Its Doug Baker!!! Glad to see your still in-it-to-win-it Doug....I hope your beast is as good as always
:byee55amg
 
Geez, you'd think I only stopped in once a month or so. Oh wait... Great to see you guys are still around :)

One of the joys of being a consultant is that I'm just now on Inspection 2 @ 85K. Lots of fun research coming to make sure I get the correct collection of parts over the next couple weeks. That and LED's. Angel eyes died, so off I go to find the collection of LED's to upgrade all the interior lights as well!

d-
 
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