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DIY: W203 Sedan Headlights Removal

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Old 12-28-2006, 05:31 PM
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2004 C32 ///AMG
DIY: W203 Sedan Headlights Removal

I replaced my Bi-Xenons with the Stock healights.
You can use this process to put in Bi-Xenons, Clear Headlights or Depo Projectors into your car.

Lets Start on the Driver's Side

1) Remove the 8mm screw in this hole



2) Remove the 8mm bolt here



3) Jack up the car and remove the wheel



4) Remove the bottom bumper cover by taking out a few push pins and some 8mm screws

5) Remove a few push-pins and 10mm nuts, then push aside the inner fender



6) Remove the T20 Torx screw under where the bumper meets the fender



7) Pull out the bumper-fender clip. You may need a screwdriver to pry it out





8) Remove the 8mm bolt on top of the headlight



9) Remove the 8mm bolt on the left side of the headlight



10) Pull the bumper down a little, and remove the 8mm bolt on the right side of the headlight



11) Unplug the connector from the headlight

Old 12-28-2006, 05:31 PM
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2004 C32 ///AMG
12) Take off the two T20 Torx screws and put the black piece on the new headlight





13) Place the headlight back in the hole carefully, and plug in the connector

14) Put the 8mm bolt back on top of the headlight



15) Put the 8mm bolt back on the left of the headlight



16) Put the 8mm and the plastic piece that goes with it back on the right side of the headlight





17) Make sure the fender clips on to the bumper



18) Put the bumper-fender clip back in, pushing towards the front of the car



19) Put the T20 Torx screw back into bumper-fender clip



20) Put the 8mm bolt back in here



21) Put the 8mm screw back in the hole



22) Put the wheel back on
Old 12-28-2006, 05:32 PM
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2004 C32 ///AMG
Result:




Now the Passenger Side

1) Remove the 8mm screw in this hole



2) Remove this 8mm bolt



3) Jack up the car and remove the wheel



4) Remove the bottom bumper cover by taking out a few push pins and some 8mm screws

5) Remove a few push-pins and 10mm nuts, then push aside the inner fender



6) Remove the T20 Torx screw under where the bumper meets the fender



7) Pull out the bumper-fender clip. You may need a screwdriver to pry it out.





8) Remove the 8mm bolt on top of the headlight



9) Remove the 8mm bolt on the right side of the headlight



10) Pull the bumper down a little, and remove the 8mm bolt on the left side of the headlight



11) Unplug the connector from the headlight

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Old 12-28-2006, 05:32 PM
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2004 C32 ///AMG
12) Take off the two T20 Torx screws and put the black piece on the new headlight





13) Place the headlight back in the hole carefully, and plug in the connector



14) Put the 8mm bolt back on top of the headlight



15) Put the 8mm bolt back on the right side of the headlight



16) Put the 8mm and the plastic piece that goes with it back on the right side of the headlight



17) Make sure the fender clips on to the bumper

18) Put the bumper-fender clip back in, pushing towards the front of the car



19) Put the T20 Torx screw back into bumper-fender clip



20) Put the 8mm bolt back in here



21) Put the 8mm screw back in the hole



22) Put the wheel back on

Final Result:

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Old 12-28-2006, 05:51 PM
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1959 220S / 1979 230 G / 2002 A210 AMG / 2003 C320 SC / 2004.5 C320 SS / 2005 ML350 SE / 2008 smart
ok, cool.

so why would I want to replace my BiX with stock headlights ?
Old 12-28-2006, 06:05 PM
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2004 C32 ///AMG
Originally Posted by Saprissa
ok, cool.

so why would I want to replace my BiX with stock headlights ?
because BiX is so goddam ugly!

haha j/k man. im parting out and returning the car to stock
Old 12-28-2006, 06:08 PM
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Thankyou very much. Are you interested in selling your Bi-xenons?
Old 12-28-2006, 06:15 PM
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2004 C32 ///AMG
Originally Posted by SUPR C
Thankyou very much. Are you interested in selling your Bi-xenons?
they are already sold
Old 12-28-2006, 06:16 PM
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2012 MERCEDES CLS63 AMG
hes planning on leaving the w203 family
Old 12-28-2006, 06:23 PM
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Thanks for the DIY, rlee. This is going to be a sticky.

drex
Old 12-28-2006, 06:43 PM
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Thumbs up

Very nice instructions.
Old 12-28-2006, 07:05 PM
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Thumbs up

Originally Posted by rlee02135
because BiX is so goddam ugly!

haha j/k man. im parting out and returning the car to stock
perfectO !!
nice job.... DIY with photos in true Saprissa fashion....

it brings a to my eye !
Old 12-28-2006, 07:36 PM
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cclass05
looks like ur car wont be able to see any more
Old 01-12-2007, 02:34 PM
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02 C230 Coupe
Nice write-up hommie...what are you moving onto next?
Old 01-12-2007, 03:21 PM
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02' C240 Luxury Model
Very similar to the install of my lights, only I didn't need to remove the wheel. I just turned it full lock towards the opposite side I was working on. The was plenty of room for me. Very cool of you to take pics of the process for those who aren't as mechanically inclined.
Old 01-13-2007, 12:13 AM
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2004 C32 ///AMG
Originally Posted by EnkeiDynamics
Nice write-up hommie...what are you moving onto next?
s/c 330ci
Old 01-21-2007, 05:47 AM
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Do I need any specialist help to set the ECU to xenon headlights?I'm using the halogen one right now.I also want to change my headlights.Thanks

Last edited by hankeymeal; 01-21-2007 at 11:59 AM.
Old 01-26-2007, 05:21 PM
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Very nice write up. I see that you did the method of not removing the front bumper. I know its not necessary but do you know the extra steps that are needed if I do want to take of the bumper? Good luck on your 3 series.
Old 01-26-2007, 05:23 PM
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2004 C32 ///AMG
Originally Posted by hankeymeal
Do I need any specialist help to set the ECU to xenon headlights?I'm using the halogen one right now.I also want to change my headlights.Thanks
you need your mercedes dealer to set the xenons


Originally Posted by Tangerine
Very nice write up. I see that you did the method of not removing the front bumper. I know its not necessary but do you know the extra steps that are needed if I do want to take of the bumper? Good luck on your 3 series.
i think you just remove the screws on both sides instead of just one, and the bumper will pull right offf
Old 01-26-2007, 06:19 PM
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Very nice post!!
I like it. Thanks!
Old 01-29-2007, 03:59 PM
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this DIY helped me install my bix today in less than three hours.. Thanks rlee
Old 01-29-2007, 06:50 PM
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Did you have to go to the dealer and have them set Xenons=Not Present, or did they turn right on without any dealership efforts?
Old 01-29-2007, 07:27 PM
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Originally Posted by mbarrad
Did you have to go to the dealer and have them set Xenons=Not Present, or did they turn right on without any dealership efforts?
No need to change anything.
Old 01-29-2007, 07:32 PM
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Originally Posted by mbarrad
Did you have to go to the dealer and have them set Xenons=Not Present, or did they turn right on without any dealership efforts?
it depends...

i had stock halogens, so i had to set the Xenons at the dealer
if you have the frosty xenons, you don't need to set the xenons to present..
Old 01-29-2007, 08:38 PM
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step three of your diy is optional...


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