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Headlight assembly replacement S80 2001

posted by  volvoloversince15 on  Sun Dec 11 11:47 CST 2005
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Like earlier posts, I have a headlamp that has moisture. I will make the "quick fix" on that lamp; however, my other lamp was pounded by a rock resulting in a crack in the glass. I had all good intentions to replace it myself, but after realizing that the bottom two bolts are impossible to get to from any angle using every posisble combination of swivel, extension, low profile socket wrench and/or crescent wrench, I have concluded that, YES, part of the bumper moudling has to be removed. Is this something I should tackle? If so, are there any secrets on how to remove the moudling without damaging it or the clips that hold it in?

I have a T-6 Executive model which has the body matched moulding under the headlight like in 2002 and later models. (not the black moulding)







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    Headlight assembly replacement S80 2001

    posted by  someone claiming to be n0v8or on  Wed Dec 14 12:51 CST 2005 [RELATED]

    These instructions were posted in 2001 on another forum. I saved them for future reference.

    ===========================================================
    The front bumper has to be partially removed on one side to replace a headlight assembly or glass.

    Start by removing the upper clips that retain the glass to the headlamp shell.
    Next, drill off the 4 plastic-headed rivets inside the wheel well (have new rivets and a rivet gun handy for re-installation).
    Remove the headlight wiper arm, the black plastic cover just below the headlight (heat with a hair dryer then pull off carefully), and the side marker lamp (which is attached to the black cover).
    Remove the turn signal lamp assembly (push down on the release tab from the top next to the headlight, then slide forward).
    Remove the 2 plug covers in the lower front area of the bumper, and remove the bumper retaining bolts. The bumper will now slide forward enough on one side to remove the remaining clips that retain the glass to the shell.
    ===========================================================






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