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S60 main beam replacement. Cramped!

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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gcha8e
Posts: 45
Joined: 16 May 2019
Year and Model: 2005 S60 2.5T AWD
Location: Kansas City, Missouri
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S60 main beam replacement. Cramped!

Post by gcha8e »

Hello again. What a great day to be forced to be at home, doing headlights!

Darn the luck, BOTH of the main beams have failed in the same week. I was able to do the daytime head lights last year with no issues, but the main low beam light is insanely cramped. A brief search provided mixed results. This guy makes it look fairly simple,
https://www.youtube.com/watch?v=c2ZcowAW7ts

but.... I'm concerned about pulling out the air box. If I yank that thing off, I fear that the "christmas tree" clips that keep it secured will be mangled and then the darn thing is going to rattle around for the rest of the cars life.

is there a handy way to get access to the light? It seems doomed to be painful, on the car, and on me. :x

gcha8e
Posts: 45
Joined: 16 May 2019
Year and Model: 2005 S60 2.5T AWD
Location: Kansas City, Missouri
Has thanked: 20 times
Been thanked: 2 times

Post by gcha8e »

Ok, after a lot of cursing and scraping up my hands I was able to remove the casing around the control module to get a bit more room on the passenger side and wriggle my hand in there to undo the clip and pull loose the Xenon headlight assembly. I didn't unclip the wire, therefore it's free in there but cannot move it's way out because it's too large to come out of the opening.

At this point I'm going to begin with the bumper removal, and slide out the whole headlight assembly and work that way. will update soon.

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oragex
Posts: 5347
Joined: 24 May 2013
Year and Model: S60 2003
Location: Canada
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Post by oragex »

The air filter box has three bottom clips - use a long extension with a socket at the end - perhaps a 3/16 or alike, to press down on the plastic pins of each clip while pulling on the box at that place. For the headlights on 2005- I would certainly use a pliers to undo the bulbs


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