Volvo Repair: headlamp replacement, reflector surface, blind rivets


Question
1999 S80 T6
A stone shattered the drivers side headlamp glass.  I ordered a replacement for the headlamp assembly.  Do you know of installation instructions?

Answer
Hello Mark,
You can finf following the instructions that you need.

Removal
Headlamp lens
-Remove the headlamp. (See Headlamp / bulb, replacing )
(*Headlamp / bulb, replacing
-Switch off the ignition
-Set the switch for external lighting to zero
-Remove the front indicator lamp.
-Remove the headlamp wiper arm and the headlamp wiper motor.
-Remove the bumper casing on the relevant side. Remove the clips above the grille. (See Casing, bumper front, replacing)
((*Casing, bumper front, replacing
Remove:
-headlamps x 2, nuts x 2
-the 6 screws
-8 blind rivets.
Drill out
-11 clips.
Press down the centre section
-the metal strip.
Remove the bumper.
Separate the connector on the left-hand side.
Remove the casing.
Installation
In reverse order.
Note! Locate the casing in the guide channels))

-Carefully pry the casing down and out. Remove the innermost and the outermost screws for the headlamp
-Remove the uppermost screws from the headlamp
-Remove the headlamp.
Note! Completely remove the bumper cover when removing both headlamps.
-Remove the headlamp wiper arm stops (x3)
-Release the 7 clips holding the lens
-Remove the lens and seal.
Note! Do not touch the reflector surface.

Installation

Headlamp lens
In reverse order. Replace the seal. Check that the seal is positioned correctly in the frame.

Regards...