So the glue attaching the lens to the headlight assembly is falling apart and the lens sometimes falls off. what should i use to glue it back on to make it water tight.

My tall tale sign of needing the lens re-glued is that the lamps burn out quicker.

I would have used RTV silicone but there was a warning in the FAQ that curing fumes would damage the silver coating.

I used Super PL Polyurethane adhesive. A calking tube is about $5. It is similar to Gorilla Glue but it does not expand as much. I had to glue on both head lights lenses on the wife's 940 within a year of of each other. Water proof? I use this as GP adhesive indoors and out and sealing rain barrel spigots. Some boat builders are using it too.

Don't try to remove the lens later, you could never budge it.

Tom

Hi:

I have done this multiple times, to different 240's that I have owned, and have only had to do it one time per lense, so far.

I use a wire Dremel attachment to get all of the old sealant off of the lense and the mounting surface. If you don't have a Dremel type tool, then you can always use a small flat head screw driver as an alternative.

>>>Do not touch or clean the reflector of the headlight. It is very easy to scratch it. If you have compressed air, that is okay, if you want blow dust off of the lense, otherwise, it is very easy to ruin it.<<<

When both surfaces are clean, I then use GE brand silicone sealant, available in a small tube at Home Depot. I lay down a good bead of the sealant in the headlight groove and then insert the lense. I then use several large rubber bands to hold them together overnight. When 12 hours or so have passed, I simply cut the rubber band and remove the cut rubber band.

I have not had a lense come apart and I also have not had a seal break on a light that I have re-glued using this method.

Good luck with your project.
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If it needs to be maintained, repaired or replaced on a 1990 240, I've probably done it. '90 240DL, 327,610 miles, will she make it to 400K ?? >>You haven't really worked on a car until you draw blood<< :-}

Third the silicone. Clear silicone (NOT caulk) is a kind of wonder adhesive, sticking to almost anything well, costs next to nothing, is non-toxic when cured, etc., etc. I like to keep a few tubes around for exactly this kind of repair. Clean surfaces are the key.

Having had my 92 wagon only 5 weeks I'm obviously still getting to know it but I have been researching the lamps. Mine both have a bit of the "normal" reflector "rust" on the bottom part. To help it out a bit I'm going to add some chrome tape for the time being. reflectors are expensive! Yes it looks as if the lens is glued to the reflector but the lens is also held in place by a bunch of metal clips. These need to be removed before you can get the lens off so the lens can't just fall out, or can it?

I'm in the UK and have been reading this useful how-to.
http://www.volvoforums.org.uk/showthread.php?t=54565

second the silicone
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89 240 wagon, 94 940, 200K, 94 940, 135K

Hi,

I have used Automotive Goop to glue them back on in the past without problems, it's in a red tube that I think you can pick up at Walmart.

Travis