There is nothing about the plastic US spec headlight that even remotely resembles the Euro spec (E-Code) headlights. The reflectors are massively different, the bulb attachment is different, the lens pattern is different, the thickness of the lenses is different, the trim is different. I'm not even sure the glass lens (which attaches to the E-Code assembly with metal clips) would fit well enough to glue it on the US spec headlight assembly (although simply having a glass lens instead of yellow plastic would be a huge improvement).

You can buy all the parts absolutely necessary to make a set of aftermarket E-Code headlights for about $250. You can get the headlight and turn signal assemblies from FCP (use your 10% off customer loyalty code) and some ceramic connectors and Hella H4 bulbs for next to nothing on Amazon.com. You can cut up your old "brow" trim (the long piece that goes above the headlight) and glue it on to the lens rather than buy the proper trim (which seems to be no-longer-available, even in the aftermarket).

I recently bought DJ Auto (re-packaged by Pro Parts Sweden) E-Code headlights and I was quite impressed with the quality of the headlight assembly. The turn signals were not as good, but still acceptable. The light, even with stock wattage bulbs and stock wiring, was noticeably better, and they look a LOT better than yellowed plastic. The beam pattern has a sharp cutoff and an upswing to the right, as they should, but there is some slight shadowing/splotchiness in the light field. If you want E-Codes, this is the cheapest way to do it.

If you want to improve lighting and don't care to maintain a stock look, check out what this creative 240 owner came up with: http://www.stanceworks.com/forums/showthread.php?t=51776

I would still love to find all of the parts to convert to 7" rounds from the heavy trucks(tractors) of the early '90s, but they seem to be exceedingly rare, and very expensive when found.

Good luck, keep dreaming (I mean this sincerely) and let us know what you come up with.

Sean

Actually, the rear parabolic reflector on the two lamps are not the same.

On my '93, I have the genuine Cibie/Volvo Euroheadlights (my daughter, a lawyer, had them shipped to me as a birthday present while on a business trip to Europe). I also had the much cheaper DJAuto headlights (just sold that car).

It's the parabolic reflector in relation to the spatial location of the bulb filament that makes most of the difference in the light output and direction [aside from the light shield (that makes the sharp upper cutoff for the European H4 low beam)] between the USA (plastic) and European (glass) headlights. The front lens only does some fine tuning.

The old USA-DOT specs from the era of the last 240s required most of the light from low beams to be directed to the ground a few yards in front of the car, and no amount of adjustment will correct for that (unless you want your high beams to shine on the tree tops instead of the road farther ahead -- and that's the reflector that you're leaving in your headlights.

You really need to get a set of Euroheadlights; there's no cheap alternative.