K9COP

Does anyone have a parts picture/exploded diagram of a D3 Left hand headlight please? I'm changing bulbs in mine and I'm pretty sure the up/down leveling unit is not connected at a 'ball and socket' joint, and I need to check/repair it. Can anyone help please? KInda urgent if possible, the car's in bits! Please please please.....

TIA

K9

mishar

Here, here...
Unfortunately I don't have anything better. If you can take some useful pictures we may be able to help. This reminds me of appendix surgery over the satellite phone.

K9COP

Thanks Mishar, I'll get on the pics tomorrow. I have the light out, but ran out of light/heat/inspiration. thanks so much...

K9

K9COP

OK, I've taken pics. Going to annotate/add them now.
Thanks.

K9COP

Ok, here's the first picture. It shows the view of the rear of the drivers side (left) headlight, through the port (where the ballast (?) is) looking forwards.

The black cylindrical object on the left is the headlamp range (up and down) motor, which has a small (6mm) ball on the end of what I presume is a threaded shaft in the motor. The white object is the 'socket' of the ball and socket joint. I'm assuming (again) that the ball should fall within the socket (actually an open ended 'C' section channel) thus moving the bottom if the low beam lens in and out and as such altering the 'range' of the beam.

I cannot easily get that ball back into that channel, without flexing things and I don't want to snap anything. What to do? It looks like the headlamps are built from the back forward at the factory, with the final flourish being to glue the lens on the front...

Help! LOL

Pic:




Thanks, K9

pic of 'spare part' (not directly related to this) to follow.

K9COP

Second pic is the same light, but looking through the 'high beam' port, again looking forwards. The thin metal object was laying loose in the bottom of the lamp assembly. Next pic shows it rescued and on the counter.

K9

K9COP

Last pic, the 'spare part' liberated and on the counter. It appears to be galvanised, and bears stamped part # 160549-00. I'm pretty sure it goes behind two of the four torx screws that hold the 'orange metallic' coloured bowl to the black carrier that the low beam bulb/xenon tube is attached to (see screw marks around holes), maybe there should be two, there's four screws...but how to get it back in there?? Can you remove the whole xenon 'tube' from igniter to lens complete? It just doesn't seem you can strip these light assemblies down...

Let the remote surgery begin!



Thanks so much, K9

mishar

It looks like it is pivoting around that point. Try it.

K9COP

thank you. i wondered that too, but the picture doesn't show it very clearly. That is actually a superfluous (sp?) bracket that has two holes in it, one with a 'doorman' type clip that secures door lock mechanism rods for central locking etc. It is the same in both lights, and not connected to anything. Maybe for another application? (see pic)

If I can establish that the ball should actually be in that socket, then I think that as the two top mounds are connected correctly, and I don't want to mess with them for fear of an expensive break, then my only option would be to remove the whole xenon tube with bulb, lens etc, and try and manipulate the black carrier to re-engage the ball and socket. I can almost get it there as it is, but not quite, and don't want to hear that dull, expensive, cracking sound....LOL



K9

K9COP

The fact that ball is above, but in line with, the socket in the pic you sent back is troubling to say the least, does it even go in there?

K9