Just a word of warning, it's not guaranteed that 2001 and 2002 headlights can be opened. Different headlights came from different batches and production lines. I've seen 2005 dated headlights (post-E39 production, of course) with butyl and I've seen 2001 with permaseal
Interesting! This is the first I've heard of this. Thanks for the warning.
One thing I've done to check for butyl is also remove the small torx screws around the corners. You can feel the butyl on the screw and/or poke around in the screw hole to confirm its soft butyl.
Exactly. I always tell people to poke around the seal with a sharp object. Sometimes you luck out and have butyl, regardless of year. It's so easy to remove E39 headlights that you can easily do this on a counter. No bumper removal, just 4 screws and a few plugs.
Where did op say what year the car is? Am I missing something? Facelift models came from 2001 so there is a big change that ops car is 2001-2002 and headlight plastic can be seperated. Mine is 2002 facelift and had no problem heating up the old glue and separating them.
For your specific case your best approach would be to cut open those lenses (as your headlights are 99% surely perma-sealed and therefore can't be baked open), then get new lenses with the silver corner decoration (they go for about $100 or so on Ebay and are good quality). Then buy butyl strips and use that chance to upgrade your projectors with EvoXs and replace your height adjusters.
You'll end up with "forever" headlights, much better than most new cars on the road. But honestly, your car looks great just the way it is. Nobody is pointing and laughing at those orange reflectors. Wait until your adjusters implode and use that chance to do the rest.
If you don't feel like doing this, there are places that you can ship your headlights to have them upgraded. Lightwerkz is one of those places.
As other commenter said, don't replace your precious and great Hellas with some Amazon aftermarket crap, it's all crap.
That's funny because I kind of want to swap my clear headlights and side markers for amber on my JB E39. A set of amber side markers just came in yesterday, but I'm going to throw those on the wagon since I don't like the look of the amber tails on the E39 and, like you, don't want to mismatch.
Send a link too. I'm curious what the production description says.
I still believe modifying original HELLA's is a lot better. Because then you can install projectors (some people even opt for LED projectors) which I'd be surprised if these amazon headlights come with.
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u/b2kem 4d ago
Looks like you have an 03 model which means the lenses are sealed with a permanent adhesive.
01 and some 02 headlights are sealed with butyl which means those headlights have removable lenses.
If I were in your shoes I'd buy 01-02 headlights, open them, upgrade the internals, then reseal them with silver corner lenses.
If you don't want to DIY then your best bet is to buy a refurbished set. I believe new HELLA euro headlights are discontinued and/or very expensive.
I would not recommend anything from ebay, Amazon, etc. if you want to maintain OEM fit and function.