Headlight Assembly Replacement - 2003 S40

[Navyguy2]

Hi,
I was hoping someone could post replacement instructions for a 2003 S40 drivers side headlight assembly. A rock cracked the lens and I got quotes of $300+ from mechanics I normally use. I think I'll try this myself if it's not that bad.

Thanks! Chris

[cn90]

Wrong forum (this is 1993-2000 forum) but anyway I just did the same HL lens on my 98 S70.
I bought it from this ebay seller below, the lens is made by "TTY" company, made in Taiwan but the quality is good.
Yours is here (driver's side lens):
http://www.ebay.com/itm/Volvo-S40-V40-H ... 0939828523

- Use 10-mm socket and remove the 3 bolts holding the HL assembly.
Some bolts are long, some short, so make a note which bolt is which.
- I left the HL resting on the front bumper (i.e. I did not disconnect any wiring).
- Note the locations of the clips (take photo)
- Undo the clips. I re-used the factory clips as they are somewhat better than the clips that came with the new lens.
- I liked the OEM seal so I kept the original seal.

In other words, I only used the lens (package included lens, seal, and clips).

Got it done in 15 min, easy job.

As long as you don't disturb the adjusters, you don't need to align your beams.