DIY: BMW E39 Headlight Adjuster Replacement (Pre Facelift)

Video tutorial on how to replace the headlight adjusters on a BMW E39. This tutorial only applies to the pre facelifted version of the E39, both for the sedan and touring models found between the years 1996 to 2000. As for the facelifted version, it is a different process. This particular video was done on a 1997 BMW 540i E39 body style.

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DIY: BMW E39 Headlight Removal :    • How to Remove BMW E39 540i Headlights  
DIY: BMW E39 Headlight Lens Removal (Pre Facelift):    • DIY: BMW E39 Headlight Lens Removal (...  

Tools/Supplies Needed:
-standard/flat screw driver
-razor knife (optional)
-T20 torx screwdriver
-pliers
-replacement adjusters (part #63120027924)
-soft gloves

Procedure:
-first remove the headlights from the vehicle
-remove the outer headlight lens
-next using a T20 torx screwdriver, remove the screw behind the reflector which can be seen roughly in the middle of the housing on the bottom
-using a standard screwdriver, pry over the black plastic bracket and twist in a clockwise orientation
-pull the bottom outward to ensure it's disconnected
-unscrew the adjusters if one is not broken
-push in the rubber grommet on the backside inside the housing
-pull out reflector
-remove the broken adjuster pieces
-unclip the black plastic bracket from the bottom side of the reflector and screw it back into place
-screw in the new headlight adjusters into the housing, they may need to be assisted into place
-screw them in until they are about half way
-when working with the reflector, use gloves as this reduces the risk of smudging the chrome reflector
-put the reflector back into place
-first snap it into the black bracket
-then snap it into place on each adjuster
-pull the rubber grommet through the back of the housing
-reinstallation in reverse
-aim headlights according to factory specifications

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