Video tutorial on how to remove the headlight assembly on a BMW E39. This procedure applies to the pre-facelift version found between the years 1996 and 2000, but the similar procedure can be applies to the facelifted version 2001 to 2000. This particular tutorial was done on a 1997 BMW 540i.
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-8mm 3/8″ drive socket
-6″ 3/8″ drive extension
-3/8″ drive ratchet
-start by opening the hood
-remove the high beam and low beam wiring harness plugs from the rear of the light
-remove the four (two on the top, tow towards the bottom), 8mm bolts
-both the top and bottom bolts are a different diameter, so do not mix them up
-pull the headlight assembly from the grill side first, the fender side of the headlight is clipped into the fender
-once you have the headlight assembly slightly out, remove the parking light wiring harness plug
-pull assembly straight out
-in order to remove the lower plastic painted trim piece, start to pull from the fender side of the headlight assembly, there will be two clips on the bottom side
-then depress the clip on the grill side (three clipped areas in total)
-the trim piece will then be separate from the assembly
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