In Reply to: cracked headlamps posted by tom530i on December 21, 1999 at 13:18:46:
Yep, that grille is a real bear until you've done it,then it gets easy. Go to the site below for a description and picture, with instructions. the hard part is the first step, you can use a long thin screwdriver to go in a little slot above and behind the headlights,and push down on a clip while you pry (gently) on the trim strip (body color) which runs along the bottom of the grille above the bumper. This clip is stiff and you will feel like you are breaking something. I couldn't find a screwdriver long and thin enough, so I took off the plastic covers inside the engine compartment which go over the back of the headlights. Then you can peer in there with a flashlight and see the little slot, and push down with a thin (but short) screwdriver. Then there are the 4 clips which hold the center kidney grille on. The top two are out in the open, visible when the hood is open. The other two are at the bottom, behind the kidneys, accessed by going through the grille itself. Do the top two first, so you can see how they work, then do the bottom ones. Finally there is a little plastic screw at the top of the kidney at the center of the car.
Once this is off, the rest is obvious until you get to the lights themselves. The lights are held on by 3 pressed in fittings which the Bentley manual tells you to heat up with a heat gun and pry off. I found that I could release mine with a large pair of pliers applied carefully. You might want to get a couple of spares from the dealer as they look fragile.
BTW, you will need to use BMW specific replacement units. They may look like the standard 5 3/4 inch round lights but they are not and the usual replacements won't work. Bavarian Autosport has good prices. You should also order a Bentley manual for the E34 while you are there.
Email me for more details if you want.
92 535i 5sp <------ has projector lights from
a'95 540, big improvement