How do you remove the headlight assembly on a 2000 Volvo S40?

Answer 1

The following removal--install procedure is to be found in the Haynes publication #3569 for the Volvo S40 & V40, 1996--1999. I use this reference for my 2000 USA S40. The details are extracted from the above reference, page 12--13 [Chapeter 12, pg. 13, Body Electrical System]. 1. Disconnect the battery negative lead. 2. Apply the hand brake, and jack up the front of the vehicle, positioning the jack head underneath the braced underbody section situated behind the lower arm rear mounting, and support on it on stands under the side jack points. 3. Remove the top black plastic cover over the headlight area. 4. Remove the front direction indicator light by locating the retaining screw between the indicator and headlight unit, backing off the screw approx. one and one half turns. Slide the directional unit out of position, and disconnect the wire connector. 5. Remove the rubber cover from the rear of the headlight unit, and disconnect the wiring connectors, via the wire clips, frome the rear of the unit--Do not hand-touch the bulb itself. 6. Working under the vehicle, slacken and remove the two bumper mounting bolts [located directly behing the headlight unit] for the unit to be removed. 7. Undo the screw securing the relevant end of the front bumper to the wing, then free the bumper end and move it forwards slightly to gain the necessary clearance required for the headlight removal. 8. Slacken and remove the four retaining nuts, then carefully maneuver the headlight unit out of position. 9. Refitting a new headlight unit is the reverse of the removal procedure. 10. Headlight beam alignment is only possible using optical beam setting equipment and using the adjusters on the rear of the unit. Set the headlight switch to " O " before adjustment. The inner adjuster can be accessed through the hole in the hood lock crossmember.