How to repair the headlight switch on 1996 – 2000 Volvo S40 and V40

by: JSeaman


Whilst fault finding on my car I needed to rule out my headlight switch as a problem, whilst this is by no means a service item, a few people have commented about switch contacts causing issue so here’s how to get to it and clean it

Step 1

There are two posidrive screws that hold the base of the unit in place, remove the

Step 2

Gently ease the unit forward, there should be little/no resistance

Step 3

Note there should be a piece of plastic running from the tube you can see at the back to the little semi circle where my finger is pointing. This just slides out normally

Step 4

For the two multiplugs, simply lift the tab and pull the connector away

Step 5

Depress the 4 grey tabs and slide the switch mechanism out of the surround

Step 6

There are now 6 tabs that lock the unit together, very gently ease each one back and allow the inner piece to pop up a very small amount. Once you have released all 6, the unit will separate easily. Note that if you are forceful you will probably break the plastic, a flatblade screwdriver and gentle care or even a fingernail will suffice

Step 7

Remove the cover and you will have access to the switch contacts

Step 8

Clean up the two contacts on the switch itself

Step 9

Wipe off any signs of scoring where the contacts travel on the metal work. Also look for any signs of water ingress (green build up etc) which need to be gently removed

Step 10

Once clean you can use electrical contact grease for longevity or simply refit dry

Step 11

Refit into the surrounds and clip together the unit then pop the multiplug back on and afix with the two screws removed in Step 1

Original posted in Volvo Owners Club Forum

The instructions in this tutorial will work in the following models / years:

– 1995, 1996, 1997, 1998, 1999 and 2000 Volvo S40
– 1995, 1996, 1997, 1998, 1999 and 2000 Volvo V40