remove the battery(drivers side) or coolant reservoir(passanger side) to see the bulb holders twist and pull to reveal the bulbs
1.) Open the hood 2.) Look directly behind the headlight housing inside of the engine compartment 3.) There should be a black plug plugged into the back of the headlight. The back of the headlight should be a grey cone shaped object and should NOT come out i this process. 4.) There is a black ring around the plug which secures the plug onto the headlight housing, turn it counter clockwise to loosen it until it slides back behind the plug. 5.) Pull out the plug and the bulb should be attached to it. you should be able to pop it right out and put in a new one. *NOTE: this might require a little coercion as 20 year old plastic parts tend to be a bit difficult. Volvo used pretty quality plastic parts on the 240 so you shouldn't worry too much about breaking anything but you should be careful as parts can be hard to find. Hope this helps, i own an 89' 240 dl sedan so it should be the same as yours.
You did not say what year. On the 1989 Volvo 240 GL, the headlight relay is mounted on the drivers side front fender just back from the battery box. The relay has two plugs going into the bottom and I would say about 1 inch wide, 2 inches long and about 1.5 inches deep. The relay that you're referring to is the high beam relay. The headlight relay switch is located in the cab of the car behind the brake and gas pedals. You pull back the carpeting and it is mounted to the firewall.
== == One of 4: First Choice: The Side light (first click on rotating switch). 5w capless. 90114440. (though now has changed number). cheap. About £0.60. Second & third Choice: Second click on rotary headlamp switch: Dipped beam, Choice of 2. If you are lucky, 91149650. (again changed part no, twice) about £7. If unlucky, it's a Xenon Headlamp. Number unknown. About £120. (Ouch!) or the control unit, about the same price, or both. Double Ouch. £240 for a blown bulb! Forth: the main beam bulb. (blue indicator light on dash), seem to last forever, can't remember when I last sold one, or price, but I think less than £10.
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