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Burnt out headlight bulb - 09 S60 - how to change

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive P2 platform cars sold as model years 2001-2007 (North American market year designations).

2001 - 2007 V70
2001 - 2004 V70 XC (Cross Country)
2004 - 2007 XC70 (Cross Country)
2001 - 2009 S60
2003 - 2007 S60 R
2004 - 2007 V70 R

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Dave in Maine
Posts: 75
Joined: 8 June 2015
Year and Model: 2009 S60 2.5T
Location: Maine
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Burnt out headlight bulb - 09 S60 - how to change

Post by Dave in Maine »

Left front headlight on my 09 S60 burned out today.
Went to the parts store, got replacements. i figure I'll change both and be done with it.
Now, the fun part.
The gap between the air filter box and the front of the car is so narrow I cannot fit my hand in. I doubt there is enough room to withdraw the old bulb and insert the new. The obvious solution is to move the filter box.

But, before I do that, I need to know (a) is my deduction correct? and (b) how do I go about it? Without ruining everything? Is this one of those 15 minute jobs I should block off all day Saturday to accomplish? What tools do I need?

I know there are a couple videos out there. The ones I found were hosted by people I'll politely call blithering dimwits. I don't trust their advice.
1996 850 Turbo Gold Edition, 7 years' reliable service and >220k mi, sadly now gone
2009 S60 2.5T, sent away after taking me down Via Dolorosa. Happy to be rid of it.

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br0dy519
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Year and Model: 2004 XC70
Location: Windsor, ON
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Post by br0dy519 »

I'm able to fish my hands in there to change the H7 bulbs without issue. But I could see why someone would need to remove the airbox. It's deadsimple.

Take off the lid of it,move it off to the side with the MAF/turbo plastic hose still attached. Remove the TCV on the left side of the box,remove the brake booster switch on the front. Remove the plastic air dam that connects to the front of the car. Now just pull the box straight up in an even motion and it pops right out. Shouldn't take a first timer longer than 15 minutes. Look up videos of how to replace the lower radiator hose, or vaccuum pump, and you should find what you need. Just be gentle with everything (except pulling the airbox straight up) and you won't break anything. Especially that vacuum pump switch on the front, I actually broke that one.
04s60 2.4
04xc70 2.5t
prwood wrote:I wish I had a permanent car repair area that was covered, had a level surface, lighting and fans, a workbench, and tool cabinets. You know,like a garage. Much of my time during the job is spent hauling things up and down the stairs to the basement or in and out of the storage shed, or running back downstairs when I realize I need something else,or taking a break from standing out in the sun,or using flashlights or work lamps when it gets dark.

Dave in Maine
Posts: 75
Joined: 8 June 2015
Year and Model: 2009 S60 2.5T
Location: Maine
Has thanked: 8 times
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Post by Dave in Maine »

I wound up taking it to the mechanic. 15 minutes for him, but he's done a bunch of them over the years. Cost me the price of the replacement bulbs and a little vacation time from work. Had the right side changed, too. Just because.
1996 850 Turbo Gold Edition, 7 years' reliable service and >220k mi, sadly now gone
2009 S60 2.5T, sent away after taking me down Via Dolorosa. Happy to be rid of it.

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