Headlight Lens Replacement. Which Way Is Correct? Options

[J Dubb]

Hello everyone. I’m ready to do a headlight lens replacement job on my 1991 240. I’m stumped though. In one thread I read that the lens just snaps off with an out and uplifting motion, with there being no need to remove the assembly. Another thread, however states that the assembly must be removed to replace the lens as it is attached with some sort of sealant. Which is the correct way? In the case of the sealant, what should I use to re-seal the lens? For those of you who have done this job, any help would be greatly appreciated. Thanks...

[nice86]

The lens is bonded to the housing at the factory. But after 18 years the sealant might be degraded to the point where you can simply pull the lens off. Sealing the new lens is the tricky part without removing the headlight assembly. Seems to me you would get goop all over the place trying to do it the quick and easy way. Better to remove the assembly to get a good seal.

[Doogwhan]

Was there any sort of clip(s) in addition to the sealant originally? I didn't see any, but there are probably scores of clips, trim, and other things missing from my 240, and most old Volvos in general.

[J Dubb]

I didn’t see any clips unless they have all gone missing over time as you suggest. My sealant, however was in pretty good shape. For what it’s worth, here is the procedure I went through to replace the headlight lenses on my 1991 240. From 1986 to 1993, there may be some variation. This will also work for replacing the entire assembly as it will have to come off the car anyway. Forgive me for I did not take any pictures. Everything is pretty straight forward though.

Tools needed:
• 10mm socket with ratchet
• Phillips head screw driver (torx head bits for some cars)
• Flat head screw driver
• Waterproof sealant of some sort
• Packing or masking tape

1. Lift the hood and remove the grill assembly.

2. Twist and remove the plastic headlight bulb retention clip from the rear of headlight assembly. Sit the bulb aside as not to damage it (unless you plan on replacing it).

3. Remove the 10 mm nuts from the rear of each headlight assembly. The driver’s side has 3 and the passenger side has 4.

4. Gently pushing from the rear, the headlight assembly, including the attached turn signal assembly, should fall forward. Be careful not to damage the aiming knobs as mine were pretty brittle.

5. Detach the turn signal assembly by removing the two Phillips head screws. (Some cars may have torx screws as the Swedish seem to love them.) (IMG:style_emoticons/default/tongue.gif) There is no need to unplug the turn signal assembly. I simply allowed mine to hang in the hole.

6. Preferably working from a table or work bench, unscrew the “chrome like” plastic trim piece from the top of the assembly by removing the two Phillips (torx) head screws.

7. Remove the black plastic trip piece from inside edge of headlight assembly by removing two Phillips (torx) head screws also.

8. This is the tricky part. Using a flat head screwdriver, gently pry the headlight lens away from the assembly. As stated in a previous post, the headlight lens is sealed from the factory unless someone has replaced it before. The sealant may have degraded over time though. Be gentle, but insistent.

9. After removing the lens, scrape away all remaining sealant from the assembly. You should notice the channel or groove in the assembly where the sealant was applied. Clean this as best you can so that you can apply a replacement sealant to adhere your new lens.

10. If you like, clean the assembly reflector. Be careful what you use as it scratches easily. After cleaning, cover the headlight bulb hole with tape to prevent dust or dirt from getting in after you install your new lens. Don’t remove it until the assembly has been re-installed onto the car and you are ready to insert the bulb.

11. Apply a continuous bead of sealant of your choosing to the channel of the headlight assembly to adhere the new lens. I used silicone only because I had some. Time will tell if this was a good choice.

12. Attach your new lens to the assembly and press it firmly into the bead of sealant.

13. Wrap tape around the assembly and lens to hold them firmly in place while the sealant sets up and cures. There may be a better way to hole everything together instead of using tape. Again, this is just what I did.

14. Once the sealant cures, re-install your headlight assembly and take a few years off the look of your beloved 240. (IMG:style_emoticons/default/banana.gif)

For those of you looking for comprehensive step by step instructions, I hope this helps. I’m not an expert but a tinkerer, so I may have left something out (IMG:style_emoticons/default/unsure.gif)

Regards…

[Doogwhan]

Good post. (IMG:style_emoticons/default/thumbsup.gif) Please update in a couple months on how the silicone holds up over time!

Might be time to seal mine up, as the lenses are only pressed on like the old ones.

But they look good.

[J Dubb]

Thank you very much! Yes… I’ll be sure to update everyone on how the silicone works.

[Doogwhan]

10. If you like, clean the assembly reflector. Be careful what you use as it scratches easily. After cleaning, cover the headlight bulb hole with tape to prevent dust or dirt from getting in after you install your new lens. Don’t remove it until the assembly has been re-installed onto the car and you are ready to insert the bulb.

Don't use Windex!!! It will pull the reflective coating right off the bucket!

Now I get to got to the bone yard for another one...

[J Dubb]

Don't use Windex!!! It will pull the reflective coating right off the bucket!

Yeah, I used alcohol and a soft towel... Or what I thought was soft. Even so, I got some hairline scratches from the towel. Maybe micro fiber would have been better. I don't see any ill affects in terms of light output though.

[NightSailor]

I put my 17 year old girl in a 240 so she could learn to drive a stick. Before getting a single lesson on how to use a clutch, she tried to drive it, and succeeded in putting a nearby boat trailer tongue through the grill. Among other things, it popped both headlight lenses off.

I cleaned the surfaces to be mated up with acetone, and mixed up a small amount of epoxy, thickened with fiberglass dust (any filler will do--even wood dust). The idea is to make the epoxy thick enough that it won't run. I masked off the front pumper area and painted it on with a popsicle stick and then taped it in place. I checked back to clean up any drips. It is on there permanently now.