940 headlight housing replacement

Volvo1man · Post by **Volvo1man** » 24 Feb 2013, 07:26

Hi, I have a 1994 940 turbo wagon with the base-style headlights (no integrated fog lamps). My headlights are very opaque and I would like to change them for new units. I know that I can get the new headlight units from the dealer ($$) of from any number of third-party suppliers ($). I don't however, know how to remove the old headlight units, and of course install the new ones. I have a Chilton's manual but it is pretty light on most details and doesn't even discuss headlight unit removal.

I searched the forum but couldn't find any previous answer on how to replace the headlight assemblies on a 1994 940. I also Googled it but found only either the parts or instructions for other Volvo models. This must have been done by someone in the past. Is it so easy that instructions aren't really necessary and I'm making it a bigger deal than necessary?

If someone could provide a bullet list or write-up on how to do it I would be very grateful.

Thank you.

lummert · Post by **lummert** » 24 Feb 2013, 08:19

The first step in removing the headlamp including the mounting frame is to remove the park lamp. You will find attaching bolts behind those park lamps.

Volvo1man · Post by **Volvo1man** » 24 Feb 2013, 10:34

OK thank you, that makes sense, I can follow that, as I have replaced the side marker lights before. That would seem to make available the outside bolts for the headlight frame/unit/assembly. Are there bolts on the grill side, and if so how do I get to those?

Thanks in advance.

JerryC · Post by **JerryC** » 24 Feb 2013, 11:56

Replacing the headlight only is difficult without breaking the adjuster screws, which are plastic. It's far easier to replace the hl and the mount. In either case, there are screws under the corner light, and sideways behind the grille. The latter are usually Torx.
I have changed or cleaned about 50 on various cars. It's not a big deal to clean the ones you have, which gives pretty good results. I take them off, wet sand with 1500, then some plastic polish or even red Turtle wax polish, and clean the inside with a mix of water, a drop of dish liquid, and some alcohol. Let it dry before reinstall.

Volvo1man · Post by **Volvo1man** » 24 Feb 2013, 16:52

Thank you everyone very much! To summarize, I take off the side marker lights to get to the outside headlight assembly bolts, then remove the grill to get to the inside headlight assembly bolts. I will check it out tomorrow during the daylight.

You guys are great!

timmyc · Post by **timmyc** » 18 Mar 2013, 21:45

If you are taking the time to pull the headlights and sand them, take them to a body shop and have them clear the lenses. They will not go bad again. If you just polish them, the haze will return in 6 months or so if it is outside often. Just did my parents 240 and they can't believe the difference in the light output! Also did my 328i about 2 years ago and they look like new.