IPD sale XeMODeX - Experts in Volvo Electronics
Did you know? 🤔
Logged in users can get email notification of topic replies Log in or register (free).
Amazon Link Buy anything with this and it helps MVS!

S60 main beam replacement. Cramped!

Help, Advice, Owners' Discussion and DIY Tutorials on Volvo's stylish, distinctive "P2" platform cars.

2001 - 2007 V70
2004 - 2007 V70 R
2001 - 2007 XC-70
2001 - 2009 S60
2003 - 2007 S60 R

gcha8e
Posts: 38
Joined: Thu May 16, 2019 10:22 am
Year and Model: 2005 S60 2.5T AWD
Location: Kansas City, Missouri
Has thanked: 16 times
Been thanked: 2 times
United States of America
gcha8e

S60 main beam replacement. Cramped!

Post by gcha8e » Sat Apr 04, 2020 12:14 pm

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: 38
Joined: Thu May 16, 2019 10:22 am
Year and Model: 2005 S60 2.5T AWD
Location: Kansas City, Missouri
Has thanked: 16 times
Been thanked: 2 times
United States of America
gcha8e

Re: 2005 S60 main headlamp Xenon low beam replacement. Cramped!

Post by gcha8e » Sat Apr 04, 2020 1:15 pm

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.

User avatar
oragex
Posts: 4808
Joined: Fri May 24, 2013 6:20 am
Year and Model: S60 2003
Location: Canada
Has thanked: 95 times
Been thanked: 265 times
Contact:
Canada
oragex

Re: S60 main beam replacement. Cramped!

Post by oragex » Sat Apr 04, 2020 2:49 pm

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


Post Reply
  • Similar Topics
    Replies
    Views
    Last post