63 12 140 Removing and installing (replacing) left headlight - LED technology - (Cooper Convertible)

Special tools required: 

• 2 361 198
• 2 361 199

Attention! 

Follow the safety instructions for HANDLING BULBS/LIGHT SOURCES (EXTERIOR LIGHTING) .

Attention! 

Observe the information on protection from ELECTROSTATIC DISCHARGE .

Preliminary work needed: 

• Check adjustment of front compartment lid, adjust HOOD if necessary.

Note on removal: 

For a fixed screw, counter-hold the square nut (1) on the adjusting element with water pump pliers (2).

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Removal: 

Loosen the screws (2) at the headlight (1).

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Unlock and disconnect the connector on headlight (3).

Unclip cable clip from headlight (3).

Release screw (1; 2) on headlight (3).

Remove headlight (3).

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In case of replacement only: 

• US version: check blocking of HORIZONTAL ADJUSTMENT .
• Remount front light electronics CONTROL UNIT .
• If required, remount led module for CORNERING LIGHT .

Installation: 

Attention! 

Do not reuse screws (1) or adjusting elements (2)!

Do not screw the screws (1) in!

Press the screws (1) into the new adjusting element (2) only as far as the noticeable stop.

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Join the headlight (1).

Press the screws (2) into the new adjusting element only as far as the noticeable stop. Do not screw them in!

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Join the screw (2) to the headlight (3).

Press the screw (1) into the new adjusting element only as far as the noticeable stop. Do not screw it in!

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Loosen the detents (1; 2).

Remove seal (3) from headlight.

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• Check clamps (1) for damage.
• Check chrome ring for firm seating.

If one or both checks are not OK, replace the chrome ring at the end of the repair!

Do not install chrome ring immediately!

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Release detents (1) and remove the chrome ring from the front compartment lid.

The special tool for the alignment of the headlight consists of the following:

1x installation aid (2 361 198) for each of the left and right sides of the vehicle.

Set of clamps (2 361 199).

1x suction lifter (2 361 198 C).

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Insert the installation aid (2 361 198) into the hood from the outside.

Fasten the installation aid using clamps (2 361 199).

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Attention! 

Risk of damage: only let the front compartment lid rest in place 

Attach the suction lifter (2 361 198 C) to the headlight (1) as illustrated.

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Attention! 

Risk of damage: only let the front compartment lid rest in place 

Insert the installation aid (2 361 198) into the hood from the outside.

Fasten the installation aid using clamps (2 361 199).

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The clamps must engage correctly in the groove.

Lift, align and hold headlight (1) using suction lifter (2 361 198_ C).

Attention! 

Risk of damage, close front compartment lid carefully! 

The hood must be closed correctly on both sides.

When the front compartment lid is closed correctly, the headlight must still be able to shift within the installation aid.

Only if the headlight cannot be shifted should the next operation be performed.

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Attention! 

Perform this operation only when the headlight cannot be shifted within the installation aid! 

Open front compartment lid carefully.

Loosen nuts (1) and screw (2).

Shift headlight and stand back slightly.

Tighten nuts (1) and screw (2).

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Attention! 

Risk of damage, close front compartment lid carefully! 

Attention! 

The hood must be closed correctly on both sides! 

Correct the alignment of the headlight (1) if needed and use the suction lifter (2 361 198 C) to hold it in position.

Tighten the screws through the openings of the installation aid (2 361 198).

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Tightening torque 63 12 1AZ .

Check the alignment of the headlight on the installation aid (2 361 198).

Remove the suction lifter (2 361 198 C).

Open the hood.

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Affix the seal (3) to the headlight.

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Tighten the screw (2) to the headlight (3).

Tightening torque 63 12 2AZ .

Connect the connector and clip in the cable clip.

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Join the chrome ring to the hood and lock it in place on the clamps (1) by applying light pressure.

• Check clamps (1) for damage.
• Check chrome ring for firm seating.

If one or both checks are not OK, replace the chrome ring! 

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Required follow-up work: 

• Carry out PROGRAMMING/CODING .
• Carry out ADJUSTING HEADLIGHTS