Instructions for Replacing a Volvo S40 Headlight Assembly

The Volvo S40's headlight assembly is more than just the housing for the headlights. This single unit also holds the parking light, turn signal, side-marker light and high beams. Removing this unit from the vehicle is simple, but a bit of work is required to remove the individual bulbs and transfer them to the new unit, as you'll likely want to do. If the old bulbs are dead, don't remove the from the old unit and transfer them. Simply install new bulbs into the new assembly.

Instructions

1

Turn the engine off and let the compartment cool for at least 10 minutes. Verify that the the headlight control next to the steering wheel is on position "0." This is the off position. Open the S40's hood.

2

Pull up the pin behind the headlight assembly that you want to replace. This pin has a handle-like top; you should be able to pull it up with your hands.

3

Move the headlight assembly out by pushing the back part of the assembly forward. Unplug the single electrical connection from the rear. Bring the assembly to a table.

4

Push together the two clamps on the back of the assembly. Pull the small cover off. This lets you view the bulb. Push the bulb's metal wire to the side and pull the bulb out. Repeat this for the four other bulbs. Each bulb has a separate small cover. If necessary, note the location on the assembly for each bulb to make it easier to install the bulbs into the new assembly.

5

Install the bulbs into the new headlight assembly. Simply push together the clamps on each cover, and then push each bulb into place and push back the metal wire to secure it. Push the individual covers back into place to snap them back on.

6

Plug the S40's electrical connection into the back of the new headlight assembly. Insert the new headlight assembly into the corner of the S40. Grab the retaining pin and push it down into place.