Headlight beam throw adjustment BMW 5 Series (E34)

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BMW Installation Instructions
Headlight beam throw adjustment BMW 5 Series (E34)

Tools and materials required:

Phillips-head screwdriver
Pliers
Flat-bladed screwdriver
1/4 inch changeover ratchet 1/4 inch extension
1/4 inch socket wrench insert, 13 mm across flats
Tube light
Universal knife Soap
Serial No.   Illustration   Designation
I                  F32 72 075   Special tool
II                 F34 65 208   Extractor  BMW No. 61 1 132
Headlight beam throw adjustment BMW 5 Series (E34)

Contents

Chapter

  1. Disconnecting the battery
  2. Removing the steering wheel
  3. Removing the instrument cluster
  4. Removing the footwell trim
  5. Removing the left-hand lower trim
  6. Removing the left and right dipped headlight covers
  7. Removing the panel
  8. Removing the left and right dipped headlights
  9. Converting the dipped headlights
  10. Installing the left and right mounts for the headlight beam throw adjustment
  11. Installing left and right headlight beam throw adjustment
  12. Installing the additional wiring harness (models with optional equipment only)
  13. Connecting up the additional wiring harness
  14. Installing the control element
  15. Functional check

1. Disconnecting the battery

On models with an additional battery (e.g. with car telephone or auxiliary heater), disconnect the negative terminal from the additional battery.

F34 71 002

Headlight beam throw adjustment BMW 5 Series (E34)

BMW 520i, 525i

Important

Print out the fault memories (the memories are automatically erased when the battery is disconnected).

Unscrew the negative terminal (arrow) and lay it aside.

F34 71 003

Headlight beam throw adjustment BMW 5 Series (E34)

BMW 530i, 535i, 524td, M5

Important

Print out the fault memories (the memories are automatically erased when the battery is disconnected) .

Pull off the cap (1) at the bottom right of the rear seat base. Unscrew hex bolt (2) and remove cover (3).

F34 61 002

Headlight beam throw adjustment BMW 5 Series (E34)

Unscrew hex nut (1), take off washer (2) and disconnect negative terminal (3).

2. Removing the steering wheel

F34 61 023

Headlight beam throw adjustment BMW 5 Series (E34)

The steering wheel can only be removed or fitted when the steering lock is disengaged.

Insert the ignition key and disengage the steering lock. Disengage position lock (1) for height adjustable steering wheel in direction of arrow .

Pull out the steering column (2) as far as it will go and re­ engage the position lock (1) for the height adjustable steer­ ing wheel.

F34 61 024

 

Headlight beam throw adjustment BMW 5 Series (E34)

All models (excluding M5)

Carefully lever off the BMW badge (1).

Unscrew self-locking hex nut (2) and take off washer (3). Mark the position of the steering wheel in relation to the steering spindle, and remove the steering wheel.

Important

Renew the self-locking nut (2).

F34 64 292

Headlight beam throw adjustment BMW 5 Series (E34)

BMW M5

Tightening torque of self-locking nut (2): 80 Nm.

Detach horn push (1), disconnect plugs (2, 3), unscrew self­ locking hex nut (4) and take off washer (5). Mark the position of the steering wheel in relation to the steering spindle , and remove the steering wheel.

Important

Renew the self-locking hex nut (4).

Tightening torque of self-locking hex nut (4): 80 Nm.

F34 71 043

Headlight beam throw adjustment BMW 5 Series (E34)

Models with airbag

Caution:

For safety reasons, steering wheels with a built-in airbag should only be removed by an authorized BMW workshop.

Remove the Phillips-head screws (1).

Remove lower trim (2) of the steering column.

F34 71 044

Headlight beam throw adjustment BMW 5 Series (E34)

Pull connector (1) out of retainer (2), and disconnect plug from socket.

F34 71 045

Headlight beam throw adjustment BMW 5 Series (E34)

Take off the 4 steering wheel retaining screws using special tool I.

When installing:

Tightening torque of steering wheel retaining screws : 5 Nm.

F34 71 046

Headlight beam throw adjustment BMW 5 Series (E34)

Pull off plug (1) in direction of arrow and remove the airbag.

Important

The airbag should be set down as illustrated only , with the plug side facing upwards .

F34 71 047

Headlight beam throw adjustment BMW 5 Series (E34)

Unscrew self-locking hex nut (1), and take off washer (2). Mark the position of the steering wheel in relation to the steering spindle , and remove the steering wheel.

Important

Renew the self-locking nut (1).

Tightening torque of self-locking nut (1): 80 Nm.

F34 71 048

Headlight beam throw adjustment BMW 5 Series (E34)

When installing:

Detent pin (1) must be felt to engage in aperture (2).

3. Removing the instrument cluster

F34 71 052

Headlight beam throw adjustment BMW 5 Series (E34)

Take off the Phillips-head screws (arrows).

F34 71 053

Headlight beam throw adjustment BMW 5 Series (E34)

Important

To prevent the instrument cluster (1) from becoming scratch­ ed, cover the steering column (2) with a cloth.

Carefully pull forward the instrument cluster (1) as far as the steering column (2), and turn it over .

F34 64 129

Headlight beam throw adjustment BMW 5 Series (E34)

Disengage interlocks (1) in direction of arrow , disconnect plug (2) and remove the instrument cluster (3).

4. Removing the footwell trim

F34 65 003

Headlight beam throw adjustment BMW 5 Series (E34)

Turn stopper (1) through 90°, and take it out. Remove Phillips-head screws (2).

Carefully pull down the footwell trim (3). Remove the plug from the gong.

F34 64 293

Headlight beam throw adjustment BMW 5 Series (E34)

Detach plug (1) and vacuum hose (2) from the temperature sensor (3).

Remove the footwell trim (4).

5. Removing the lower left-hand trim

F34 65 004

Headlight beam throw adjustment BMW 5 Series (E34)

Lever off caps (1), take out Phillips-head screws (2) and remove the left-hand lower trim (3).

6. Removing the left and right dipped headlight covers

F34 64 347

Headlight beam throw adjustment BMW 5 Series (E34)

Turn Phillips-head screws (1) through goo, and take off headlight cover (2).

F34 64 131

Headlight beam throw adjustment BMW 5 Series (E34)

BMW 520i, 525i

Detach hose (1) from air duct (2). Detach air duct (2) from clip (3) and headlight cover (4).

F34 63 028

Headlight beam throw adjustment BMW 5 Series (E34)

Press clips (1) together and push in air duct (2) in direction of arrow .

Turn Phillips-head screws (3) through goo .

Remove the left-hand headlight cover (4).

7. Removing the panel

F34 63 029

Headlight beam throw adjustment BMW 5 Series (E34)

Carefully press clips (1) at the left and right of panel (2) in direction of arrow, and pull forward panel (2) slightly.

F34 64 334

Headlight beam throw adjustment BMW 5 Series (E34)

Take out spreader rivet (1).

Carefully lift up clips (2) in direction of arrow , and push for­ ward the panel (3) slightly .

F34 64 335

Headlight beam throw adjustment BMW 5 Series (E34)

Carefully lever off the clips (1), and remove the panel (2).

8. Removing the left- and right-hand dipped headlights

F34 63 030

Headlight beam throw adjustment BMW 5 Series (E34)

Remove spreader rivets (1).

Take out Phillips-head screw (2).

Remove the left- and right-hand decorative grilles (3).

F34 63 031

Headlight beam throw adjustment BMW 5 Series (E34)

Carefully pull off decorative ring (1) in direction of arrow . Destroy plastic sleeves (2) using pliers.

Carefully pull forward the dipped headlight (3).

F32 63 047

Headlight beam throw adjustment BMW 5 Series (E34)

Press together the clips in direction of arrow . Disconnect plugs (1 and 2).

Remove the dipped headlight (3).

F34 63 032

Headlight beam throw adjustment BMW 5 Series (E34)

Turn the adjusting screw (1) in direction of arrow, and remove it from the headlight mount (2).

9. Converting the dipped headlight

F32 63 052

Headlight beam throw adjustment BMW 5 Series (E34)

Insert plastic sleeves (1) in holes (2).

Insert plastic sleeve for headlight beam throw adjustment (3) into hole (4).

10. Installing the left and right mounts for the headlight beam throw adjustment

F32 64 054

Headlight beam throw adjustment BMW 5 Series (E34)

Break off spreader pins (1) at holder (2).

Insert spreader pins (1) such that the tapered side is located inside the holder (2).

Insert holder (2) into the headlight mount. Press in the spreader pins (1).

Note

Before re-installing the dipped headlight, lubricate the ball sockets with Vaseline.

Re-install the dipped headlight in the reverse order of dismantling .

11. Installing left and right headlight beam throw ad­justment

F34 63 033

Headlight beam throw adjustment BMW 5 Series (E34)

Position headlight beam throw adjustment (1) at where it is to be installed.

Carefully press the ball sockets into the headlight mounts. Carefully turn headlight beam throw adjustment (1) in the direction of arrow until it engages .

12. Installing the additional wiring harness

Note

Whether or not it is necessary to install an additional wiring harness depends on the car’s individual equipment specification .

If the necessary terminals for the headlight beam throw ad­ justment are already included as standard with the car’s wir­ ing harness, chapter 12 does not apply .

If optional extras are fitted, refer to the “Retrofit facilities for E34” Parts microfiche.

F32 65 263

Headlight beam throw adjustment BMW 5 Series (E34)

Removing the left- and right-hand wiper arms

Lift up cover (1) of the wiper arm.

Unscrew hex nut (2), and remove the wiper arm.

F32 65 264

Headlight beam throw adjustment BMW 5 Series (E34)

Lever out spreader rivets (arrows) from the left-hand decorative grille (1).

Remove the decorative grille (1).

F34 65 108

Headlight beam throw adjustment BMW 5 Series (E34)

Cut along markings (arrow) to form the aperture in the flat rubber seal.

F34 65 109

Headlight beam throw adjustment BMW 5 Series (E34)

Before passing the wiring harness through the aperture, lubricate the flat rubber seal (2) with soap.

Run the additional wiring harness (1) from the passenger compartment, through the flat rubber seal (2) and into the engine compartment.

Insert rubber sleeve (3) into aperture in flat rubber seal (2).

F32 63 049

Headlight beam throw adjustment BMW 5 Series (E34)

Note

In the interests of clarity, the flat rubber seal (1) is illustrated as it would look when removed.

Cut into rubber support (2) as illustrated.

Insert additional wiring harness (3) into cutout.

F34 63 034

Headlight beam throw adjustment BMW 5 Series (E34)

Run the additional wiring harness (1) as illustrated along the inside of the engine compartment.

Important

Wherever possible, use the standard cable straps for retain­ ing the additional wiring harness (1).

The additional wiring harness (1) must be run such that there is no possibility of it becoming kinked, chafed or other­ wise damaged.

F34 63 035

Headlight beam throw adjustment BMW 5 Series (E34)

Run additional wiring harness (1) as illustrated up to the right-hand headlight mount.

Models with radiator cover

Lift out spreader rivets (2) and carefully push back cover (3).

Models with coolant line

Unscrew hex bolt (4).

Carefully press coolant line (5) in direction of arrow.

13. Connecting up the wiring harness

F34 63 036

Headlight beam throw adjustment BMW 5 Series (E34)

On the left- and right-hand sides of the car

Connect plug (1) to the mating socket of the headlight beam throw adjustment.

F34 64 074

Headlight beam throw adjustment BMW 5 Series (E34)

Press together the retaining tabs and pull connector (2), located below the instrument panel, out of its mount.

Release interlock (3) in direction of arrow and pull apart con­ nector (2).

F32 63 057

Headlight beam throw adjustment BMW 5 Series (E34)

Carefully pull apart the outer plug at retaining tabs (2).

F32 63 058

Headlight beam throw adjustment BMW 5 Series (E34)

Pull inner plug (3) in the direction of arrow as far as it will go.

F32 63 059

Headlight beam throw adjustment BMW 5 Series (E34)

Note

Using extractor II, push back the steel spring interlocks (4) of the relevant contact and pull out the cable.

F32 63 060

Headlight beam throw adjustment BMW 5 Series (E34)

Press out contacts 8 and 30 from plug (3).

Insert contact 8 with black/grey cable into socket 1 of con­ nector (4).

Insert contact 30 with grey/red cable into socket (2) of con­ nector (4).

Plug connector (4) into its mating socket (5) in the additional wiring harness.

F32 63 061

Headlight beam throw adjustment BMW 5 Series (E34)

Insert grey/black cable (1) of the additional wiring harness into socket 8 of of plug (3).

Insert grey/red cable (2) of the additional wiring harness into socket 30 of plug (3).

Lock plug (3), press it together and install it.

F34 64 075

Headlight beam throw adjustment BMW 5 Series (E34)

Attach brown earth cable of additional wiring harness (2) at earthing point (1), located below the instrument panel.

14. Installing the control element

F34 63 037

Headlight beam throw adjustment BMW 5 Series (E34)

Carefully lever off cover (1) from panel (2).

Pass plug (3) of the additional wiring harness through aper­ ture (4) and connect it to control element (5).

Insert control element (5) ii:i the aperture.

Re-install all parts in the reverse order of dismantling.

15. Functional check

F34 63 038

Headlight beam throw adjustment BMW 5 Series (E34)

Set the control element to zero.

Check headlight setting and, if need be, reset.

0 = 1 – 2 persons at front, without luggage
1 = 2 persons at front, 3 at rear + luggage
2 = 1 person at front, luggage compartment full

Printing and other errors and omissions excepted. Subject to amendment.

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