63 12 003 Removing and installing (replacing) left/right headlight

WARNING: This page does not describe the selected car, but rather 6 other vehicles, including the 2019 MINI Cooper, 2018 MINI Cooper, 2017 MINI Cooper, 2016 MINI Cooper, and 2015 MINI Cooper. However, it is still accessible from the selected car via links, so may be relevant.

Special tools required:

IMPORTANT: Follow the SAFETY INSTRUCTIONS for handling bulbs/light sources (exterior lights).

IMPORTANT: Read and comply with notes on PROTECTION AGAINST ELECTROSTATIC DAMAGE (ESD PROTECTION) .

Necessary preliminary tasks:

Check the HOOD SETTING

Removal:

Release screws (2) on headlight (1).

Fig 1: Headlight And Screws

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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).

Fig 2: Headlight And Screws

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NOTE: In case the screw is stuck, counter support the square nut (1) on the adjusting element by means of pliers for a water pump (2).

Fig 3: Water Pump And Square Nut

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Installation:

IMPORTANT: Do not reuse screws (1) or adjusting elements (2)!
Do not screw the screws (1) in !
Push the screws (1) into a new adjusting element (2) until the limit position is reached.

Fig 4: Adjusting Element And Screws

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Join headlight (1).

Push the screws (2) into a new adjusting element until the limit position is reached but do not screw them in!

Fig 5: Headlight And Screws

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

Push the screw (1) into a new adjusting element until the limit position is reached but do not screw them in!

Fig 6: Headlight And Screws

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Release the latch mechanisms (1; 2).

Remove gasket (3) from headlight.

Fig 7: Latch Mechanisms And Gasket

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NOTE: Check the following prior to disassembly of chrome ring:

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

If one of the checks is not OK, renew chrome ring when finishing the repair work !

Do not install chrome ring immediately !

Fig 8: Chrome Ring Clamps

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Release clamps (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 fitting aid (2 361 198 ) each for left and right side of vehicle.

Set of clamps (2 361 199 ).

1x suction lifter (2 361 198 C).

Fig 9: Special Tool For Alignment Of Headlight

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NOTE: Auxiliary lugs (1) are provided for correct installation of fitting aid.

Fitting aid (2 361 198 ) is inserted into the front compartment lid from the outside.

Fitting aid is attached by means of clamps (2 361 199 ).

Fig 10: Inserting Fitting Aid (2 361 198) Into Front Compartment Lid

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IMPORTANT: 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.

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

Insert fitting aid (2 361 198 ) from outside in front compartment lid.

Secure the fitting aid by means of clamps (2 361 199 ).

Fig 11: Attaching Suction Lifter (2 361 198 C) To Headlight

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NOTE: Ensure correct fit of fitting aid (2 361 198 ) and clamps (2 361 199 ).
The clamps must engage correctly in the groove.

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

Fig 12: Inserting Fitting Aid (2 361 198) From Outside In Front Compartment Lid

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IMPORTANT: Risk of damage, close front compartment lid carefully!

The front compartment lid has to be closed properly on both sides.

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

Fig 13: Holding Headlight Using Suction Lifter (2 361 198 C)

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

IMPORTANT: Perform this operation only when the headlight cannot be moved within the fitting aid!

Open front compartment lid carefully.

Loosen nuts (1) and screw (2).

Move headlight and fixture back slightly.

Tighten nuts (1) and screw (2).

Fig 14: Front Compartment Lid Nuts And Screw

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IMPORTANT: Risk of damage, close front compartment lid carefully!

IMPORTANT: The front compartment lid has to be closed properly on both sides!

Correct the alignment of the headlight (1) if necessary and hold in position by means of suction lifter (2 361 198 C).

Tighten the screws using the openings of the fitting aid (2 361 198 ).

Tightening torque 63 12 1AZ .

Fig 15: Tightening Screws Using Openings Of Fitting Aid (2 361 198)

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

Remove the suction lifter (2 361 198 C).

Open the front compartment lid.

Fig 16: Removing Suction Lifter (2 361 198 C)

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Mount the gasket (3) on the headlight.

NOTE: Ensure proper latching (1; 2) of the gasket (3) on the headlight.

Fig 17: Latch Mechanisms And Gasket

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

Tightening torque 63 12 2AZ .

Connect the connector and clip in the cable clip.

Fig 18: Headlight And Screws

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Join the chrome ring in the front compartment lid and lock by applying slight pressure on the clamps (1).

NOTE: Check the following after installation of chrome ring:

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

If one of the checks is not OK, renew chrome ring !

Fig 19: Chrome Ring Clamps

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Required reworking:

Carry out HEADLIGHT ADJUSTMENT