Volvo 240/740/760/780/940/960 1990-1998

Headlights

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REMOVAL & INSTALLATION



Replaceable Halogen Bulbs

See Figures 1, 2 and 3

  1. Open the vehicles hood and secure it in an upright position.
  2.  
  3. If so equipped, remove the headlight bulb and socket assemblys access cover.
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Bulbs with in-line sockets typically utilize separate locking rings, but those with angled sockets do not.

  1. If equipped with a locking ring, twist and remove the ring to expose the bulb and socket assembly. If there is no separate ring, simply twist the bulb socket, then withdraw the assembly rearward.
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  3. If necessary, gently pry the electrical connectors retaining clip over the projection on the socket (use care not to break the clip.) Remove the bulb and socket assembly from the vehicle.
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To install:
  1. Before installing a light bulb and socket, ensure that all electrical contact surfaces are free of corrosion or dirt.
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  3. Line up the replacement headlight bulb and socket assembly with the electrical connector. Firmly push the connector onto the socket until the spring clip latches over the sockets projection.
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WARNING
Do not touch the glass bulb with your fingers. Oil from your fingers can severely shorten the life of the bulb. If necessary, wipe off any dirt or oil from the bulb with rubbing alcohol before completing installation.

  1. To ensure that the replacement bulb functions properly, activate the applicable switch to illuminate the bulb which was just replaced. (If this is a combination low and high beam bulb, be sure to check both intensities.) If the replacement light bulb does not illuminate, either it too is faulty or there is a problem in the bulb circuit or switch. Correct if necessary.
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  3. Position the replacement headlight bulb; if applicable, secure the locking ring. Also install the access cover, if so equipped.
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  5. Remove all tools, then close the vehicles hood.
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Fig. Fig. 1: Remove the access cover to replace the headlamp bulb



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Fig. Fig. 2: Twist the angled bulb and socket assembly 1/4 turn counterclockwise and withdraw it from the lens ...



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Fig. Fig. 3: ... then release the tab and disengage the electrical connector

Sealed Beam Units

See Figure 4

  1. Disconnect the negative battery cable.
  2.  
  3. Release the headlight trim, using the applicable method. If equipped with plastic screws, rotate them 1 / 2 turn, then remove the trim. If equipped with a clip at the top center of the trim panel, squeeze the two sides together, and pull upward to release the trim.
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  5. Unfasten the 4 small screws holding the retainer, then remove the retainer and the headlamp.
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  7. Unplug the electrical connector from the rear of the headlamp.
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  9. Installation is the reverse of removal.
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Fig. Fig. 4: Remove the trim ring while supporting the headlight to prevent it from falling

AIMING THE HEADLIGHTS



See Figures 5, 6, 7, 8 and 9

The headlights must be properly aimed to provide the best, safest road illumination. The lights should be checked for proper aim and adjusted as necessary. Certain state and local authorities have requirements for headlight aiming; these should be checked before adjustment is made.


CAUTION
About once a year, when the headlights are replaced or any time front end work is performed on your vehicle, the headlight should be accurately aimed by a reputable repair shop using the proper equipment. Headlights not properly aimed can make it virtually impossible to see and may blind other drivers on the road, possibly causing an accident. Note that the following procedure is a temporary fix, until you can take your vehicle to a repair shop for a proper adjustment.

Headlight adjustment may be temporarily made using a wall, as described below, or on the rear of another vehicle. When adjusted, the lights should not glare in oncoming car or truck windshields, nor should they illuminate the passenger compartment of vehicles driving in front of you. These adjustments are rough and should always be fine-tuned by a repair shop which is equipped with headlight aiming tools. Improper adjustments may be both dangerous and illegal.

For most of the vehicles covered by this guide, horizontal and vertical aiming of each sealed beam unit is provided by two adjusting screws which move the retaining ring and adjusting plate against the tension of a coil spring. There is no adjustment for focus; this is done during headlight manufacturing.

Because the composite headlight assembly is bolted into position, no adjustment should be necessary or possible. Some applications, however, may be bolted to an adjuster plate or may be retained by adjusting screws. If so, follow this procedure when adjusting the lights, BUT always have the adjustment checked by a reputable shop.

Before removing the headlight bulb or disturbing the headlamp in any way, note the current settings in order to ease headlight adjustment upon reassembly. If the high or low beam setting of the old lamp still works, this can be done using the wall of a garage or a building:

  1. Park the vehicle on a level surface, with the fuel tank about 1 / 2 full and with the vehicle empty of all extra cargo (unless normally carried). The vehicle should be facing a wall which is no less than 6 feet (1.8m) high and 12 feet (3.7m) wide. The front of the vehicle should be about 25 feet (7.6m) from the wall.
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Fig. Fig. 5: The headlight aiming levels, as viewed from the top



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Fig. Fig. 6: Location of the aiming screws on most vehicles with sealed beam headlights



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Fig. Fig. 7: Example of headlight adjustment screw location for composite headlamps

  1. If aiming is to be performed outdoors, it is advisable to wait until dusk in order to properly see the headlight beams on the wall. If done in a garage, darken the area around the wall as much as possible by closing shades or hanging cloth over the windows.
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  3. Turn the headlights ON and mark the wall at the center of each light's low beam, then switch on the high beams and mark the center of each light's high beam. A short length of masking tape which is visible from the front of the vehicle may be used. Although marking all four positions is advisable, marking one position from each light should be sufficient.
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Fig. Fig. 8: Low beam headlight pattern alignment



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Fig. Fig. 9: High beam headlight pattern alignment

  1. If neither beam on one side is working, and if another like-sized vehicle is available, park the second one in the exact spot where the vehicle was and mark the beams using the same-side light. Then switch the vehicles so the one to be aimed is back in the original spot. It must be parked no closer to or farther away from the wall than the second vehicle.
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  3. Perform any necessary repairs, but make sure the vehicle is not moved, or is returned to the exact spot from which the lights were marked. Turn the headlights ON and adjust the beams to match the marks on the wall.
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  5. Have the headlight adjustment checked as soon as possible by a reputable repair shop.
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