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Thread: Any tips, tools to access this bolt (headlight assembly)?

  1. #1
    Senior Member S500E's Avatar
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    Any tips, tools to access this bolt (headlight assembly)?

    Hi, do you have any tips/tricks or know of good tools to access this 8mm bolt? Would like to tighten this bolt, holding the headlight (R, passenger side) assembly, but do not have good access. Thanks.
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  2. #2
    E500E Guru 2phast's Avatar
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    Re: Any tips, tools to access this bolt (headlight assembly)

    What works well for me is a small (about 3" long) 8mm open end/closed end wrench. You can use the closed end till the bolt is almost out, but then need to switch to the open end to get it the rest of the way out.
    1993 500E
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  3. #3
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    Re: Any tips, tools to access this bolt (headlight assembly)

    Ditto for me exactly what 2Phast says. Same technique that I've used.

    Cheers,
    Gerry

  4. #4
    I do believe...! Christian_K's Avatar
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    Re: Any tips, tools to access this bolt (headlight assembly)

    I've used a old 8mm socket/nut (dunno the english proper name) and a riffled flat-pliers to turn the bolt. What a luck it wasn't tightened very much.
    Christian K.
    06/1992 500E - DB199 Blauschwarz-Metallic
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    Re: Any tips, tools to access this bolt (headlight assembly)

    FSM to the rescue: Remove the U-shaped clips which hold the radiator and condenser to the upper radiator support. Push them forward an inch or two at the top. This provides better access to the bolt, using an 8mm open-end wrench as described above. A telescoping magnet helps to insert & extract the bolt.

    Dave M.
    1997 E420 (Bugeyes)
    1994 E420 (Blondie)
    1994 E500 (Q-ship)
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  6. #6
    Senior Member S500E's Avatar
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    Re: Any tips, tools to access this bolt (headlight assembly)

    Thanks all for your input. Just picked up this 8mm wrench, but still having difficulty tightening this bolt. Near impossible to tighten all the way. Looks to me that I need a thinner, angled, or custom made wrench to really grab this bolt head. I’ll also try gsxr’s method as well.

    Without this bolt all the way tightened, there’s too much “movement” in my R side headlight assembly. Headlight assembly also sits slightly more intruded when compared to the L (driver) side with this bolt loose. Is this all normal when this bolt is loose? L (driver) side assembly on the other hand feels rock-solid. I’ll go spend more time on it…
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  7. #7
    .036 Hoonigan™
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    Re: Any tips, tools to access this bolt (headlight assembly)

    It should be rock solid when tightened. However the adjustment is fully manual, meaning you'll have to eyeball the alignment with the hood/grille/etc, and tweak it as needed. Might take a few tried to get it lined up properly. Then, you need to adjust the aim of the headlight beam via the knobs on the back of the headlamp assembly, which is even more fun!

    Dave M.
    1997 E420 (Bugeyes)
    1994 E420 (Blondie)
    1994 E500 (Q-ship)
    1992 500E (Mach 5)
    1987 300D (Sportline Stage 2)
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    E500E Guru sheward's Avatar
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    Re: Any tips, tools to access this bolt (headlight assembly)

    I use an " ignition" wrench. VERY small and thin as you are thinking. Craftsman sells a package of them relatively cheap. I wish i had known it was that easy to get a little more room, Dave.

    drew
    Drew
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    92 500e 180,000+ miles
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    .036 Hoonigan™
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    Re: Any tips, tools to access this bolt (headlight assembly)

    Wish I could take credit for it, but it's in the FSM... one of those things where "RTFM" applies. See the note on page 2:

    http://www.w124-zone.com/downloads/MB%2 ... 2-4730.pdf

    All 400E/500E models (124.034, 124.036) have the double auxiliary fan.


    Dave M.
    1997 E420 (Bugeyes)
    1994 E420 (Blondie)
    1994 E500 (Q-ship)
    1992 500E (Mach 5)
    1987 300D (Sportline Stage 2)
    Click here for my website
    Click here for my YouTube channel

  10. #10
    Senior Member S500E's Avatar
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    Re: Any tips, tools to access this bolt (headlight assembly)

    Thanks sheward and gsxr for more tips. I will be getting a smaller, thinner ignition wrench and give a try again.

    gsxr, could you look up a part number for me? New to using EPC and can't seem to find this rubber piece/moulding that goes between the headlight wiper panel and bumper. You can see a hint of this rubber piece below. These rubber pieces are looking very old and squeezed. Thanks.
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  11. #11
    .036 Hoonigan™
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    Re: Any tips, tools to access this bolt (headlight assembly)

    Quote Originally Posted by S500E
    gsxr, could you look up a part number for me? New to using EPC and can't seem to find this rubber piece/moulding that goes between the headlight wiper panel and bumper. You can see a hint of this rubber piece below. These rubber pieces are looking very old and squeezed. Thanks.
    I use a standard Craftsman 8mm open/box end wrench, it's quite small and works ok. It's just tedious to remove this one screw.

    The rubber that plugs into the bottom of the trim panel is almost always reusable unless it's been damaged somehow. Some items are an absolute nightmare to locate in the EPC, and this happens to be one of them. It's in Group 88, subgroup 030, callout 89. For cars to 1993 it's two of p/n 124-885-03-85, for cars 94-up it's 124-885-11-85 left, 124-885-12-85 right. However the latter two part numbers (for 94-95 models) have been superceded back to the 124-885-03-85 for all years. They're cheap, $4.40 each list price.

    Dave M.
    1997 E420 (Bugeyes)
    1994 E420 (Blondie)
    1994 E500 (Q-ship)
    1992 500E (Mach 5)
    1987 300D (Sportline Stage 2)
    Click here for my website
    Click here for my YouTube channel

  12. #12
    Senior Member S500E's Avatar
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    Re: Any tips, tools to access this bolt (headlight assembly)

    Thanks gsxr for those part numbers.

    I am in the process of modifying a Craftsman 8mm ignition wrench to make this job easier.

  13. #13
    Senior Member S500E's Avatar
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    Re: Any tips, tools to access this bolt (headlight assembly)

    Finally got this screw tightened, and now the headlight assembly is rock solid. Headlight, wiper panel, and etc are all aligned nicely too. I got an ignition 8 mm wrench (as suggested) and modified its shape (see photo). Ground on the wrench to reduce its diameter, thickness, and also made a notch to clear the black plastic piece surrounding this bolt. Accessing this bolt was then a breeze without having to push on the radiator. Thanks everyone for your input.
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  14. #14
    E500E Guru KarlC's Avatar
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    Re: Any tips, tools to access this bolt (headlight assembly)

    Quote Originally Posted by S500E
    Finally got this screw tightened, and now the headlight assembly is rock solid. Headlight, wiper panel, and etc are all aligned nicely too. I got an ignition 8 mm wrench (as suggested) and modified its shape (see photo). Ground on the wrench to reduce its diameter, thickness, and also made a notch to clear the black plastic piece surrounding this bolt. Accessing this bolt was then a breeze without having to push on the radiator. Thanks everyone for your input.
    Nice !
    Will you now be selling those to the rest of us when in need ? LOL
    1993 500E - 040 / 271 - Porsche Type 2758 ~~~~ 1971 250C Ivory / Cognac Leather

    Past Cars - 1994 E500 - 2003 CL600 V12TT by SPEEDRIVEN - 1994 E500 - 1995 E320 Cab - 1988 BMW M6 - 1994 E320 Cab

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