I dug through some old chat logs - and copied some stuff I sent to someone else. It might seem a bit janky because they're all PMs, but you should get the gist of it.
So read this guide first
How to: Front Bumper Removal It has some picture which will help.
- Tape up the bumpers around the headlight using cloth tape (not masking tape, it won't help you) to protect the paint.
- Remove the undertray from the front bumper
- Remove the front wheels and arch liners.
- Refer to the link for how to remove the fog lights, with one change, you'll use a hooked awl to remove the fog light. Get the awl behind the edge of the glass - one on each side and pull forward. It would come out very easily, it isn't anywhere near the big deal people make it out to be.
- Disconnect the cables to the headlight.
- Undo the bolts three bolts holding the light in place.
- Undo the mounting point at the rear of the headlight and remove it completely. I've highlighted it below, it is held in by a single bolt from underneath.
- Push the headlight forward to allow you to rotate it in such a way that you can pull it out through the wheel well. Removing it from the rear should allow you to protect the paint, especially if you have the Xenon headlights which have a ballast attached to the bottom.
Just some things to keep in mind:
- You may need to push the light forward to remove the rubber gasket before you can get it out the back.
- Be patient getting the headlight back in.
- Only tighten the bolts in loose when you do your headlights until all three are located. If you fully tighten one bolt at a time you'll never get it lined up.
As I said before, I haven't tried removing it from the back, as I didn't realise till I was nearly done, but doing it this way seems so much more logical once you get at it. If you find this works let me know and I'll write up a full headlight removal guide.
Also, if you want to ship your headlights to Australia, I can refurbish the lenses and send them back to you.
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I have opened them before. It is a difficult task. Before you start, do you have proper polishing equipment? You can't polish acrylic by hand, it just won't work. If you don't have the equipment to do it properly then I would advise you against it.
This is the thread I followed to do mine
Headlight polishing inside and out
Some other things to keep in mind:
1- Polish the outside to completion before considering opening the headlight. You want to be certain the inside is deteriorated before you do anything.
2- You will need to get the coloured insert resprayed, the paint will flake off as soon as you touch it.
3- Be
very careful with the chrome rings, just rubbing them will rub the chrome off.
I'm all about DIY, so believe me when I say this is a difficult job and you should reconsider doing it DIY if you don't have the right equipment.
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You only need to pick out the silicone at the red edge. Once you can get your fingers in there you will be able to pull it apart - it will take a bit of force, but it will work!
Once I got into the gap I was able to wedge it apart progressively and it was pretty easy. What I did have an issue with though was the paint on the insert flaking off, so I had to get them resprayed. If that happens to you, be very carfeul with the chrome rings because the chrome will come off when you touch them.
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The lens is some kind of acrylic - it is very soft and will be very difficult to bring to a nice finish.
For mine (which were far more degraded) I started at 80 grit, then went down to 8000 grit. After that I used a cut, polish, finish and then used a UV protectant spray over them. However, I'd suggest using a Clear Protection Film (basically a car wrap in clear) instead as it is easy to replace that every few years and provides more physical protection. The only way you will be able to get the polish to a decent standard is to use an random orbital, or orbital polisher, with fittings that will reach to the areas you want. I strongly suggest that once you have finished polishing it you wipe them clean with a decent solvent or polish remover while wearing gloves and using a lint free cloth. You won't want dust and fingerprints on the inside lens. I'd also suggest that you finish the inside 100%, then glue the whole thing back together, then do the outside, that way you won't risk scratching or dirtying the inside of the lens again. Another suggestion would be wrapping the main body of the lens in cling film to prevent it getting any dust on it - remember what I said about how if you touch the chrome it will come off? - well don't let it get dusty and you won't need to clean it!
As for the sealant, I used an automotive body sealant.
Sikaflex®-227 I wouldn't be too pedantic though, just find something suitable for automotive use and go with that. If you search around you'll probably find more suitable products that soften in the oven!
P.S. I spent 12 hours per lens!