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      12-30-2011, 07:24 PM   #1
nj335i
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How to replace ballast on passenger side?

I have a 335 sedan with oil cooler and it seems impossible to replace the ballast myself (for stock xenon headlights). Any tips from someone who has done this before? Are there special tools (smaller ratchet wrench) that could aid in the process? The oil cooler hoses and some other stuff are in the way and I can't seem to reach the screws well enough to turn them...

Any input would be welcome!
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      12-31-2011, 03:34 AM   #2
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Removing the bumper and then the headlight would be best option.
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      12-31-2011, 08:11 AM   #3
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Yikes, not what I wanted to hear. Ok, I guess it's going to a shop because that sounds like more than I want to get into.
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      12-31-2011, 08:24 AM   #4
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Maybe losses the oil cooler and move it out of the way? Not sure if thats possible but worth a shot.

A shop will charge you at least 1 hour labor, most likely 2 hours.
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      01-02-2012, 12:29 AM   #5
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Decided to take it to a shop. Didn't feel like going through the trouble. Will let you know how it turns out.
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      03-24-2012, 04:38 AM   #6
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I was able to change the ballast on the passenger side and both pair of bulbs without taking out the wheels, jacking up the car, nor removing the bumper.

I have a 06 e90 with sports package and I had enough room to change the ballast when I turned the steering wheel completely to the right.

The trick is.. I got a 1.5cm long hex bit that fit the screw for the ballast and used a wrench to turn it about 10 degrees per turn... It was a bit of a work, but eventually I was able to get the screw out.

The hardest part was taking out the ballast from the socket of the headlight assembly because there is a rubber seal and a screw that holds the ballast very tight from sliding out.

But I found a trick to that as well:
First you take off the HID wire from the ballast (it's hard, but it's possible. MAKE SURE YOURE NOT PULLING ON THE WIRE, BUT YOURE PULLING ON THE METAL PIN CONNECTOR)
Then just pull the ballast away from the headlight assembly, towards the drivers side. Don't worry about the other wire connector as it's long enough to handle this
Once you pull the ballast away from the ballast socket, and the rubber seal is completely out, slowly but with a little bit of strength, slide the ballast out towards the rear of the car until the second wire connector is visible from the outside of the assembly.
Once the second wire connector is visible, get a hook tool or something of sort to unlatch the wire connector before pulling it out. Once you get both of the connections out, slide out the ballast and you just successfully removed the ballast.

Make sure you take out the rubber seal band from the old ballast and put it on the new one if the new ballast does not come with the rubber seal.

Do the steps backwards and you can easily put the new ballast..

Putting the ballast in isn't as hard as taking it out..

It took me exactly two hours to replace one passenger ballast and change both of the d1s bulbs and it did not require me to do any wheel removing, jacking up the car, nor removing the bumper...

I'm sure a lot of people might not recommend the method that I used, but I was able to do the job without damaging the car in the end
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      03-24-2012, 04:41 AM   #7
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If someone needs pictures of how this was done, I will gladly do this process over to help the people in need... I wasn't able to find any DIY this way and was stumped at the weekend project myself
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      04-18-2012, 01:49 PM   #8
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Quote:
Originally Posted by xacoffeemx View Post
If someone needs pictures of how this was done, I will gladly do this process over to help the people in need... I wasn't able to find any DIY this way and was stumped at the weekend project myself
I would love to see some pics. That's a pain though so I understand if your motivation isn't there.
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      04-28-2012, 12:08 AM   #9
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Could I see some pics here??
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      05-02-2012, 01:01 PM   #10
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Quote:
Originally Posted by rjive View Post
I would love to see some pics. That's a pain though so I understand if your motivation isn't there.
Quote:
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Could I see some pics here??
Sorry I wasn't on the forums for quite a while lately.

When I'm home tomorrow, I will try to get pictures posted
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      05-13-2012, 01:47 PM   #11
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Quote:
Originally Posted by xacoffeemx View Post
Sorry I wasn't on the forums for quite a while lately.

When I'm home tomorrow, I will try to get pictures posted
Looking forward to it. I need to find a ballast replacement part as well. Anyone have a suggestion on where I can find that?

I need the drivers side though.
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      07-11-2012, 10:09 AM   #12
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i have the same issue, any updates on the pictures?
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      10-17-2012, 08:42 PM   #13
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When replacing the ballast, is it plug and play? Or does your car need to be reprogrammed? Thanks.
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      02-05-2013, 09:09 PM   #14
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Anyone have any updated pictures or additional information to share?
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      02-23-2013, 01:05 PM   #15
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Anyone out there who can advise me how to replace the ballast? A Tech friend of mine helped me try changing the bulb (D1S) twice first to no effect?

The ballast is attached to the side of the light and has three bolts; two are accessible the third slot appears that you would need to take out the headlight and it looks like two torque bolts on top should do it? Checking?

Dealership is telling me that it's two hours labour (after a $135 diagnosis) to re and re the ballast and that you have to take out the headlight, hoist the car and remove the bumper just to get at one bolt?+ cost of part around $625 (saw on ebay for around $300? Where is the best online store or local Toronto store to buy?).

My light flickered and was weaker than the right side and then went out completely. The bulb has the igniter as part of it, so that rules out that possibility.

Was thinking that it might be best to swap out the working ballast to the driver's side to test to confim issue? I guess it could be a wiring issue or whole light assembly? Unlikely I think, as all the other lights are working (turn signal and parking lights etc.)

Would appreciate some guidance from the Bimmer Pros out there I'm technical and handy but have not worked on a BMW before.

Thanks in advance!

Steve
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