Can the outer glass be removed? Or do I have to remove the entire headlight assembly? I have the same issue on my 545i but the glass itself is dirty and would like to clean it out if possible.

On my E39 it was easy, but it had no active headlights or XENON for that matter, now my E60 however is a different story.

Thanks

 

No, the lenses cannot be removed without damage (glued to the housing). The entire headlight assembly can be removed by releasing four screws/bolts and two electrical connectors. Then, wiggle it out. To make it easier, also remove the upper bulb access cover.

When polishing my headlight lenses, I inadvertantly introduced moisture into the assembly which caused them to fog over. I removed the headlight assemblies again, oven dried them and the foggin has not returned.

 

could just pop off the rear cover on the headlight and blow a hair dryer in there for a bit, and on the front to heat it up a tad.

 

I remove the cap and just let it sit like that for a few hours, when I don't have to drive anywhere. Clears it right up. I've come to live with it and treat it like a little "quirk". Just don't forget to put the cap back on, or the heat from the engine compartment might make it worse

 

+1 v_therussian

Just open the cap and let it overnight, it will clear eventually.
I think It's due to bad air circulation inside the headlight.
I also didn't over tight the cap... Result is no more condensation..

 

Yea, from what I know, it's actually "ok" to take off the inner cap. By design, water/rain shouldn't get into there, but don't take this as a guarantee.