Overhauling adjustable headlights

[Alwyn]

My e30 has the adjustable headlight option, however this does not appear to function correctly as the lights do not move and appear to set very low.

Ian332 believes that the system has developed a leak, so has defaulted to a safe position (well, safe for other road users).

Does anyone have any experience of overhauling and getting the system work?

Ian made me aware that there are kits available for manual adjustment, however before I go to that effort I would be very interested in knowing if anyone has encountered and resolved the same problem.

[ad318i]

v common problem lots of people with this.

not much you can do

[Brianmoooore]

Three options -
1/ check that the manual adjuster on the mechanism at the headlamps gives you enough range to set the headlamps to pass MOT, and then forget about adjustable headlamps.
2/ Replace the whole adjuster system with a new one from the dealer.
3/ Adapt the electric adjuster system from an E36 or E34 to fit an E30.

[Alwyn]

Brian,

Any guides as to how to do 3, also how to do 2 as I with a bit of patience I am sure I will be able to find a replacement system that works?

[316eyes]

"how to do 2 as I with a bit of patience I am sure I will be able to find a replacement system that works"


You might want to check the price with the dealer first, and have a valium before you go in.

[Taxin]

Hi there is a way to fix your adjustable headlights it is on e30.de I will translate this when I have time if anyone is interested there is also a way on there to make them electric using parts from a fiesta that looks pretty simple to do

[gilb]

mine are knackered to dont look like you can repair them and the dont look to easy to come out either

[Alwyn]

I was thinking along the lines of working on the actuators to ensure that they are function freely.

Once they are moving freely, try re-pressurising the system. I am not sure of what goes in the pipes (I have been told it could be various liquids), but with the correct fluid I believe it should be possible to get pressure in there.

Has anyone tried this?

Absolutely no chance of going to a main dealers for the parts: if I go for a replacement system, I will try and get a second hand one.

Taxim: I will get my mother (fluent in German, crap mechanic) to have a look at e30.de with me.

[Taxin]

Hi the fluid is ethylene glycol "antifreeze" basically all you need to do is bleed the system using Antifreeze

[Chris]

Is this the little knob under and to the right of the steering coloumn?

If so is there supposed to be some resistance when you turn it cause mine justy turns from one side to the other with no resistance.

[sabrje]

I managed to get a complete new system on ebay for about 20 quid (about 18 months ago - and its the only one I ever saw on there), but it really was a pain to take the old one out and thread the new one in. Would have been much easier to do when I changed the dashboard, six months earlier...

Its normally the plastic around the metal connentors at the headlamp end that goes brittle and breaks, so not much can be done apart from remplacing the whole system or doing the electric conversion.

[Alwyn]

Thedingbat: sounds like the same symptom as mine. Does yours aim too low?

I think that before I try anything I will try to repressurise the system, and get it working. I cannot see it being too difficult to fit a valved joint for topping the system up... then just need to find whatever caused the system to depressurise.

Taxin: any news on the translation??? I just tried calling my mother (fluent in German), but she was away for the weekend.

[e30bmlover]

mine work!!!!! just thought i would add that.

[ian332isport]

I think that before I try anything I will try to repressurise the system, and get it working. I cannot see it being too difficult to fit a valved joint for topping the system up... then just need to find whatever caused the system to depressurise.

Alwyn,

It's not really a pressurised system as such. It just needs to be full of liquid and have no leaks. It's not actually under any pressure.

I think the biggest problem you will have, is getting all the air out of the system. Manual adjusters or an electric conversion are probably the easier options.

Cheers,

Ian.

[Morat]

On both the tourings I've owned, the headlights were fixed in an acceptable position and the adjusters had been disconnected. I doubt many of them still work.

[Brianmoooore]

The hydraulic system you already have has a manual adjuster already fitted. The outer ribbed sleeve of the cylinder at the headlamp end is turned to provide up/down adjustment, and is a lot easier to use than the adjuster on manual headlamps.
You may find that this adjuster still won't be able to raise the beams high enough though. In this case, there's a second adjuster in the form of the threaded rod that goes out of the front of the hydraulic cylinder into the headlamp unit. You may be able to turn this with small grips, or dismantle the headlamp and adjust it using a cross head screwdriver into the socket in the ball end of the rod.

[Brianmoooore]

On both the tourings I've owned, the headlights were fixed in an acceptable position and the adjusters had been disconnected. I doubt many of them still work.

I've only ever seen one car with one side still working.

[doigal]

Hi there is a way to fix your adjustable headlights it is on e30.de I will translate this when I have time if anyone is interested there is also a way on there to make them electric using parts from a fiesta that looks pretty simple to do

Even just a direct link to let google translate have a crack at it? That would be great!

[Alwyn]

Brian: Ian has already had a play with the ribbed adjuster sleeves, which appear to have seized.

Before fitting a manual system, I will try and get the system working so that I am not left with a pointless hole in the shroud under the steering column.

[Brianmoooore]

The pointless hole is easily dealt with by a new underdash panel from a car without the adjusters.
Surprised that the ribbed adjuster is seized, as it's plastic on plastic.

[Bob_S]

I left the adjuster in place and took off the stupid adjusters and replaced with a standard adjuster like on the top of the unit, works perfect and ideal when it comes to mot time

[nickso]

I left the adjuster in place and took off the stupid adjusters and replaced with a standard adjuster like on the top of the unit, works perfect and ideal when it comes to mot time

did the same last week.

im on the lookout for e34 electric ones to have a play around with but to be honest in the grand scheme of e30 repairs this has got to rank as prettty low.

it passes an mot so i might not even bother

[Dr Firefly]

Hmmm... was thinking about trying to retrofit this system to my car as I'm trying to put all the extras on it that could have been put on from new... but this thread makes grim reading - might not bother!

And Brian you sounded very defeatist in this thread! What about the comment I saw you make that everything on an E30 should work? Was this just a bit of bad design in the hallowed E30?

[stonesie]

3/ Adapt the electric adjuster system from an E36 or E34 to fit an E30.

E36? that's the first time ive seen that mentioned, none of my local scrappers have any E34's but they do have 36's.... That's sorted where im heading tomorrow morning

[stonesie]

Well my verdict is that the E36 motors can be made to fit but it's some messing about and kept me entartained for a couple of hours. First i tested them on a spare 12v battery, no point modding them if theyre buggered.




The plastic bit is too wide and long for the E30 headlamps.


So a bit of alloy tube was cut, then a M6 thread tapped within to fit the old E30 adjusters i had lying about, the plastic bit of the headlamp motors was cut then the alloy roughed up with sandpaper, heated and pushed into position.



A bit of epoxy as a 'belt and braces' measure and the trimmed down E30 adjuster parts threaded in, ready for fitting when i get some appropriate wire to connect it all up.



More to follow when i fit them, the threaded section will provide the needed adjustment when the grills are removed.