Replacing Volvo 940 headlight lens

haymitch · Mar 1st, 2018, 16:13

Last weekend another car speeding around a corner overtaking threw up a load of gravel and dust. I didn't realise that a stone has punched a hole in my 1995 Volvo 2.3 LPT 's offside headlight lens until I stopped. I reckon I can remove the headlight okay (I've done it once before on a Volvo 960), but I have a few questions if anyone could help please? The hole is around 1.5 to 2 inches in diameter.

As the headlight is on the offside it looks like I'll have to remove the air filter box and the washer fluid pipe to remove the headlight. Has anyone managed to do this before without moving the airfilter box?

I notice that you can buy the whole headlight unit online. This seems the simplest option but then I'll be stuck with a spare headlight. I've found plastic versions of the lens online but how do these compare to the glass versions? They look a bit crap from the pictures.

Is there anything else I need to look out for when doing this?

loki_the_glt · Mar 1st, 2018, 18:08

I've replaced headlamps twice on my 1997 car; if you have suitably small but strong fingers and appropriate tools you probably could do it with the bits in-situ.

Removing the air-filter box is really all that needs to be done to make the job easy; removing the screen-wash reservoir will let you clean up the chassis leg and give it a coat of rust-killer.

Forrest · Mar 1st, 2018, 18:19

I do not recall it being necessary to remove the airbox or screenwash reservoir. You can remove the indicator and side-lamp by pushing in the locking tab from inside the car and pulling that part of the assembly forward. You can then gain access to the bolts behind it. The bolts on the other side can be accessed by removing the radiator grill (very easy) and the plastic baffle which is held on by a few self-tapping screws.

Best route to obtain a replacement lens is to buy a sound secondhand complete unit. It comes with spare securing clips included.

If you carefully line up the dirt marks with the bolt holes on the grill side when you reinstall your original unit the beam alignment will not be far off. If you swap in a whole new assembly you’ll need to realign the headlamps.

mjk164 · Mar 1st, 2018, 19:48

Haymitch, I have just had to do the same on the near side lamp on my 1993 960 for a stone hole in the glass. Replaced the lamp with a new one as, in addition to the stone chip, the reflector was original from 1993 and seen better days. I got my new one from carpartssaver for £116 and the alignment is easy. Place the car about 5 mtrs from a garage door or similar, switch on the lights and mark the door where the dipped beams are. Change the lamp and then you can switch on the lamps and see where the new beam is and adjust accordingly. You have to screw the adjusters quite a lot to get beam movement.

haymitch · Mar 2nd, 2018, 09:43

Excellent - thanks all

I'll have a look at ordering the parts today and have a crack at this once the weather improves next week!

jor · Mar 2nd, 2018, 09:57

Just get one from a breaker, give Lakes a call they are only 30 mins away from you

jor

haymitch · Mar 2nd, 2018, 10:01

Thanks jor - I've never been to Lakes but I thought I'd read somewhere that it had closed down?

Laird Scooby · Mar 2nd, 2018, 10:34

Quote:

Originally Posted by haymitch

Thanks jor - I've never been to Lakes but I thought I'd read somewhere that it had closed down?

Last time i was there was about 4 days before they were originally going to close. Barry (one of the brothers) said they weren't closing as soon as originally intended so it's worth giving them a call to see if they're still open.

Someone mentioned carpartssaver, that's one of the ebay names for EuroCarParts, they have one of their promos on at the moment (code is "WEEKEND35") and brings the price down to £121.54 from £186.99 :

https://www.eurocarparts.com/ecp/c/V...c75bc27&000176

If you can find their listings on ebay (carpartssaver, carparts4less) you may find it cheaper.

https://www.ebay.co.uk/itm/Volvo-940...cAAOSwALtaZiYk

https://www.ebay.co.uk/itm/Headlamp-...wAAOSw37BaZs23

Couple of options there for you.

Rversteeg · Mar 2nd, 2018, 13:02

Spare securing clips are also excellent for securing the cover on the airfilter box!

haymitch · Mar 2nd, 2018, 17:01

I gave Lakes a call and was told they are closing in around a year's time, but that things will be winding down a little while before that).

I think I will go with the Lakes option - if anything to have a look at all the Volvos!!

Mar 1st, 2018, 16:13	#1
haymitch Member Last Online: Jan 24th, 2024 09:34 Join Date: Nov 2015 Location: Newmarket	Replacing Volvo 940 headlight lens Last weekend another car speeding around a corner overtaking threw up a load of gravel and dust. I didn't realise that a stone has punched a hole in my 1995 Volvo 2.3 LPT 's offside headlight lens until I stopped. I reckon I can remove the headlight okay (I've done it once before on a Volvo 960), but I have a few questions if anyone could help please? The hole is around 1.5 to 2 inches in diameter. As the headlight is on the offside it looks like I'll have to remove the air filter box and the washer fluid pipe to remove the headlight. Has anyone managed to do this before without moving the airfilter box? I notice that you can buy the whole headlight unit online. This seems the simplest option but then I'll be stuck with a spare headlight. I've found plastic versions of the lens online but how do these compare to the glass versions? They look a bit crap from the pictures. Is there anything else I need to look out for when doing this? Last edited by haymitch; Mar 1st, 2018 at 16:16.

Mar 1st, 2018, 18:08	#2
loki_the_glt Torquemeister Last Online: Today 08:32 Join Date: Dec 2004 Location: Asgard, Cheshire	I've replaced headlamps twice on my 1997 car; if you have suitably small but strong fingers and appropriate tools you probably could do it with the bits in-situ. Removing the air-filter box is really all that needs to be done to make the job easy; removing the screen-wash reservoir will let you clean up the chassis leg and give it a coat of rust-killer. __________________ loki_the_glt - Skipper of the Exxon Valdez, driver of Sweden's finest sporting saloon - and pining for another Slant-4.

Mar 2nd, 2018, 09:57	#6
jor VOC 20573 Last Online: Jul 10th, 2023 22:14 Join Date: Mar 2007 Location: wembley	Just get one from a breaker, give Lakes a call they are only 30 mins away from you jor __________________ Volvo 940 SE 1994 D24Tic. BMW C1 85 mpg

Mar 2nd, 2018, 13:02	#9
Rversteeg Master Member Last Online: Today 08:31 Join Date: Feb 2006 Location: Amersfoort (NL)	Securing clips Spare securing clips are also excellent for securing the cover on the airfilter box!

Mar 1st, 2018, 18:19	#3
Forrest VOC Member Last Online: Yesterday 20:34 Join Date: Feb 2008 Location: Gloucester	I do not recall it being necessary to remove the airbox or screenwash reservoir. You can remove the indicator and side-lamp by pushing in the locking tab from inside the car and pulling that part of the assembly forward. You can then gain access to the bolts behind it. The bolts on the other side can be accessed by removing the radiator grill (very easy) and the plastic baffle which is held on by a few self-tapping screws. Best route to obtain a replacement lens is to buy a sound secondhand complete unit. It comes with spare securing clips included. If you carefully line up the dirt marks with the bolt holes on the grill side when you reinstall your original unit the beam alignment will not be far off. If you swap in a whole new assembly you’ll need to realign the headlamps.

Mar 1st, 2018, 19:48	#4
mjk164 VOC Member Last Online: Apr 12th, 2024 13:08 Join Date: Aug 2006 Location: Hounslow West London	Haymitch, I have just had to do the same on the near side lamp on my 1993 960 for a stone hole in the glass. Replaced the lamp with a new one as, in addition to the stone chip, the reflector was original from 1993 and seen better days. I got my new one from carpartssaver for £116 and the alignment is easy. Place the car about 5 mtrs from a garage door or similar, switch on the lights and mark the door where the dipped beams are. Change the lamp and then you can switch on the lamps and see where the new beam is and adjust accordingly. You have to screw the adjusters quite a lot to get beam movement.

Mar 2nd, 2018, 09:43	#5
haymitch Member Last Online: Jan 24th, 2024 09:34 Join Date: Nov 2015 Location: Newmarket	Excellent - thanks all I'll have a look at ordering the parts today and have a crack at this once the weather improves next week!

Mar 2nd, 2018, 10:01	#7
haymitch Member Last Online: Jan 24th, 2024 09:34 Join Date: Nov 2015 Location: Newmarket	Thanks jor - I've never been to Lakes but I thought I'd read somewhere that it had closed down?

Mar 2nd, 2018, 17:01	#10
haymitch Member Last Online: Jan 24th, 2024 09:34 Join Date: Nov 2015 Location: Newmarket	I gave Lakes a call and was told they are closing in around a year's time, but that things will be winding down a little while before that). I think I will go with the Lakes option - if anything to have a look at all the Volvos!!

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