Bosch H4 headlamp dis-assembly

[Jeremy R65]

Dear all.  I've noticed that I have some corrosion on my headlamp reflector and on the bulb cover.  New reflectors seem unobtainable at present and expensive if they are.  Is it possible to separate glass from reflector to clean it all and then re-assemble them?  If so, how best to do it and what do I need to buy to re-assemble?  All hints gratefully received.  Thanks

[Barry]

It's supposed to be possible but mine was so firmly stuck I chickened out and cleaned the reflector by pouring in a hot mixture of distilled water, alcohol and soap followed by a good shake and a distilled water rinse. Light output was noticeably improved. 

Being able to physically clean the reflector might be a mixed blessing as the surface is very delicate. If you do get it separated I would google "cleaning telescope mirrors" for advice on cleaning solutions and the degree of care needed.

My heat shield is corroded to. I've thought of taking it out as all halogen lamps have an opaque end cap these days.

[georgesgiralt]

Hello,
The rubber band sealing the glass to the reflector cooks and seize the glass on the reflector.
You can separate the glass from the reflector by destroying the rubber band.
You can buy a new one at every BMW dealer P/N : 63 12 1 353 623 for less than 8 euro.
It is a /5 P/N but the same as the R65 one which is not listed on the fiche...
Edit : It is NOW listed for the R65 P/N  63 12 1 243 595 and cost 14 Euro....  I've always used the /5 version...


Edit :
I use talcum powder on the rubber band and it seems to prevent it to stick too hard on the reflector...
Refrain to remove the center light protector otherwise you will blind incoming traffic...
And do not ask how I know...
Do not break the glass... It is available (P/N  63 12 1 243 541 ) but cost about 100 euro apiece ....while the reflector is at 175 euro each 
All that make for a very expensive headlight !
You may find lower prices at a Bosch dealer if you can find the Bosch P/N ...

[Justin B.]

Another option is to replace it with something aftermarket.  Although I have no doubt the Bosch designed reflector and "lens" is superior to an inexpensive aftermarket unit the nice shiny reflector may more than make up for it.  This is what I used on the Junkyard Dawg project.

http://www.bmwr65.org/YaBB2.612/cgi-bin/yabb2/YaBB.pl?num=1228860638/1#1

[Bob_Roller]

The lens can be removed from the reflector .

Just be prepared to be frustrated on reassembling it !!

Those spring clips that hold the lens in, can be stubborn to get them in correctly .

[Jeremy R65]

Thanks for the advice chaps.  I have ordered a rubber gasket and will give dis-assembly a go when I get a minute.

[tunnelrider]

Jeremy, I too will be playing this game in the next couple of weeks while installing a new headlight bezel (yes I may've dented it a couple of times with road scratches!).  What I'm really not looking forward to is placing those spring clips, as Bob has pointed out... Lets keep each other posted on progress    I've decided to repaint the headlight cover as well which will add a bit of time to my job.  Good luck my man!

[tunnelrider]

Jeremy, can I make a recommendation.. After releasing the lens clamp screw, removing the bezel and moving the lens forward, take a photo of how the spring clips behind the lens lay before removing them, it should hold there long enough without moving. I didn't, thought that makes sense, can't get that wro! Ummmm can picture now who knows in a couple week's time... ha ha.