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      03-04-2016, 10:46 AM   #1
Persian Whisperjet
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Replacing Xenon headlight unit -- merely difficult or serious a** pain?

After hitting a bottomless DC pothole a couple weeks ago one of the headlights started drooping and could not be adjusted to the right height.

I took the car in to my local independent. They want $1,600 for the job including $1,300 for the part. OEMbimmerparts has it for $799. Amazon sells the Hella part for $750.

Naturally, the markup is part of my Independent's business model and I do not begrudge them that profit, but I'm wondering how hard it would be to do this on my own. Any advice?
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      03-04-2016, 10:57 AM   #2
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It's not too difficult. I just replaced my DS headlight internals and resealed it because of the same problem you have. The crystal ball broke off the tabs inside it and needed to be put back on.

Steps involve:
Jack up car
Take front wheels off
Remove fender liners (8mm, 10mm)
Remove bumper (torque screws, forgot what size, 8mm for undertray)
Unbolt headlight from top and side, then Unbolt bracket holding headlight (torque screws again).

Reverse steps.

It takes maybe an hour total if you have a replacement headlight. If your breaking open the current one and fixing it, it'll be 24 hours because of curing time.
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      03-04-2016, 02:57 PM   #3
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Wrecker thanks -- very helpful. No coding or anything once you're done?
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      03-04-2016, 05:40 PM   #4
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None needed, just readjust the head light angles.
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      03-04-2016, 10:06 PM   #5
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Op, do you know what broke in your headlight? Or can you post a picture from the outside showing your projector?
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      03-05-2016, 08:54 AM   #6
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Quote:
Originally Posted by Yozh View Post
Op, do you know what broke in your headlight? Or can you post a picture from the outside showing your projector?
Yozh I can take a photo but I can't really see anything broken, it is more an inference based on the fact that the adjustment screw only raised the headlight a tiny bit. The Independent who looked at it said there is some sort of adjustment arm inside the unit that (naturally) cannot be replaced, you have to buy the whole assembly. They did note that there is a guy (who makes repro odometer gears) who has started fabbing the part but so far only for older models.
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      03-05-2016, 08:57 AM   #7
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Quote:
Originally Posted by Persian Whisperjet
Quote:
Originally Posted by Yozh View Post
Op, do you know what broke in your headlight? Or can you post a picture from the outside showing your projector?
Yozh I can take a photo but I can't really see anything broken, it is more an inference base don the fact that the adjustment screw only raised it a tiny bit. The Independent who looked at it said there is some sort of adjustment arm inside the unit that (naturally) cannot be replaced, you have to buy the whole assembly. They did not that there is a guy (who makes repro odometer gears) who has started fabbing the part of older models.
You can replace that adjustment arm. Whether or not you want to break open your headlight is the question.
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      03-05-2016, 09:01 AM   #8
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I had a broken manual adjuster in one of my headlights. Had to replace the entire headlight assembly.
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      03-05-2016, 10:15 AM   #9
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Quote:
Originally Posted by Wrecker335d View Post
You can replace that adjustment arm. Whether or not you want to break open your headlight is the question.
Wrecker where do you source the part? I have looked.
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      03-05-2016, 10:23 AM   #10
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Quote:
Originally Posted by Persian Whisperjet
Quote:
Originally Posted by Wrecker335d View Post
You can replace that adjustment arm. Whether or not you want to break open your headlight is the question.
Wrecker where do you source the part? I have looked.
No part number on them, I got mine from a broken headlight I bought off eBay. If your passenger side is broken I can just mail you the part.
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      03-05-2016, 10:26 AM   #11
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Quote:
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No part number on them, I got mine from a broken headlight I bought off eBay. If your passenger side is broken I can just mail you the part.
Doh. You're the best. Unfortunately it is the driver's side. Was it tricky doing the install?
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      03-05-2016, 10:39 AM   #12
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It was a pain to break open the headlight. If you want to save $700 you can, but it won't look the best. The glue used on the LCI is pretty strong and heating it up takes a lot of patience. I did a mix of 240*F @8mins oven and a 840*F hot air gun. They have some tutorials on the lens removal.

Once your inside the headlight, the dis/ass was fairly easy.

I resealed it silicone adhesive. People use Butyl as well
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      03-05-2016, 12:44 PM   #13
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Persian, I may offer you the following, but please keep in mind that this is just my opinion and your situation may be different. That is why a photo, even from the outside would be useful.

So, basically, there are three connections to the body of the headlight that the bracket that holds the projector is attached. Two to them are the adjusters, one for height, one for sides. These are attached at the top of the bracket on each respective side. In relation to the headlight, the inner adjuster is for height, the outer is for sides. The third connection is the connection for the electric stepper motor that controls the auto levelling, it is connected to the bracket at the bottom inner point. Here are some photos to help, these ones are the passenger side headlight:

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And this is the bracket for the passenger light. Arrows shot where the top is and where the outside of the headlight is. Looking from the inside out.

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Here is the bracket in the headlight. Looking from the outside.

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In my uneducated opinion, there are a few things that could contribute to your headlight drooping. First thing to check is the outside mounting points of the headlight. Once you take off your bumper, you should check, may be that will solve your problem.

If thinking on the inside off the light, I think it is hard for any of the adjusters to snap off. Yes that are plastic, but unless old and brittle or has been stripped, I think it would be hard. But in the same respect an auto levelling motor shaft can snap as well. Btw, easy to check if your headlight is off the car. Two screws from behind the headlight, if you can fully pull it out, it's snapped.

Any of the connection points to the bracket are fairly good, except one. And this one I think is a weak point here. But I think it is easy to fix without taking the light apart. Here is a picture of the one I mean, it's the one for side adjustment and mounts to the bracket on the top outside point:

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If you have your headlight off the car, remove the blinker unit out and you can reach inside and fix the mounting point:

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Hope this helps.
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      03-05-2016, 02:44 PM   #14
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Yozh this is amazing thanks!

Also, just found the OEM replacement assembly (with leveling) at $631 with shipping (Rock Auto). The Independent wanted $1,300. Is that kind of markup standard? I don't mind them marking up parts but that is more than double.

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      03-05-2016, 06:33 PM   #15
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Yohz, those tabs can break, but it takes a bit of effort. Mine did break on the DS side so I had to scavenge them from another light.

Thanks for the pictures.
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      03-06-2016, 09:29 AM   #16
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Here is the droopy headlight.
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      03-07-2016, 01:35 PM   #17
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I'm willing to bet it's the left/right adjustment tab (I had no idea it existed until my headlight was off) that broke off. Looks exactly like how my light was. I believe you mentioned you maxed out the up/down screw. I'll see if it's identical on each side, if it is I'll mail you that tab.
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      03-08-2016, 07:11 AM   #18
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Quote:
Originally Posted by Wrecker335d View Post
I'm willing to bet it's the left/right adjustment tab (I had no idea it existed until my headlight was off) that broke off. Looks exactly like how my light was. I believe you mentioned you maxed out the up/down screw. I'll see if it's identical on each side, if it is I'll mail you that tab.
Is there any way you can take a picture of what you're talking about? I've got a similar problem and I'm not sure whats causing it. I've replaced the leveling adjuster servo and the position sensor on the control arm, I'm about to just break down and buy a new headlight.
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      03-08-2016, 08:19 AM   #19
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Roth, I bought an OEM unit, Xenons, adaptive, PN 354692051, at Rock Auto for $630 shipped.
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      03-08-2016, 08:24 AM   #20
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Quote:
Originally Posted by Persian Whisperjet
Yozh this is amazing thanks!

Also, just found the OEM replacement assembly (with leveling) at $631 with shipping (Rock Auto). The Independent wanted $1,300. Is that kind of markup standard? I don't mind them marking up parts but that is more than double.
Great stuff Yozh
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      03-09-2016, 02:10 AM   #21
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Quote:
Originally Posted by Persian Whisperjet View Post
Here is the droopy headlight.
Most likely one of the top adjusters. I would still be checking that side adjuster attachment to the bracket that I had posted. At least check all the options before you dish out that $700 for a new one.
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      03-15-2016, 09:05 AM   #22
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Quote:
Originally Posted by Persian Whisperjet View Post
Roth, I bought an OEM unit, Xenons, adaptive, PN 354692051, at Rock Auto for $630 shipped.
I saw those on there last night, it looks like a good deal. I also found an OEM headlight on ebay for $550.

My headlight looks like like the one posted above, its a bummer we can't buy individual parts.
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