Although this tutorial was made based on a Phase 1 (1995 – 2000) Volvo V40, it’s the same procedure for Phase 2 (2001- 2004) Volvo S40 / V40 .
If you are looking on How to upgrade your Phase 1 Volvo S40 /V40 to phase 2 dual headlights, clik Here
Step 1
Pop the bonnet and we’ll start work on removal
Step 2
Between the headlight and indicator you will find a posidrive screw, slacken this off (it clamps the indicator in place but only needs to be slackened to let the unit slide out, no need to take the screw out completely)
Step 3
Now simply slide the indicator unit outwards and shown
Step 4
Pull the light (gently) right out and then slide the connector off by lifting the tab, you can’t see it on the first picture as it is on the underside so I took another one to show the tab
Step 5
Remove the indicator from the car
Step 6
You have now revealed two 10mm nuts that hold the light in, remove these completely
Step 7
A further two 10mm nuts hold the light in place from behind, these can be accessed already in the engine bay as shown
Step 8
Removing the light is a bit awkward, the corner of the lens likes to hit the bumper so you need to force this down at the corner with one hand whilst wriggling the light out. It will come nad is probably easier if you can get two people on it. You need to pull forwards first then slide the unit towards the middle of the car to come off the 4 studs you removed the nuts from in Steps 6 and 7
Step 9
Squeeze and remove the 3 pin connector for the headlight level adjuster
Step 10
Twist and remove the black cap so you can get to the bulbs and then remove the 3 pin multi plug and 2 pin connector for the sidelight
Step 11
You can now remove the lamp
Step 12
If you need to disassemble the unit, simply remove the clips (3 at the top, 3 at the bottom and one either side) as shown with some pliers/a screwdriver. You can then remove the glass (second picture) and set to work on any repairs
Step 13
Repeat the process on the other side, it is exactly the same
The instructions in this tutorial will work in the following models / years:
– 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 and 2004 Volvo S40
– 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003 and 2004 Volvo v40
Tara says:
Thank you for the excellent tutorial. I was able to successfully perform my first auto repair all by myself because your instructions and photos were so clearly presented.
Alexandar Todorov says:
Excellent Tutorial how to replace the lights but, I have a question can you also show me how to remove/replace the front bumper? Because I am having problems removing it and I would be greatfull if you can show me so detailed how to remove it!
Alexandra M. says:
Hi Alexander! you can find tutorial on how to replace front bumper here: http://www.volvohowto.com/how-to-remove-front-bumper-on-volvo-s40-v40-1995-to-2004/
Best Regards!
Thomas Klimchuk says:
Any ideas of what kind of tool or wrench i need in order to remove the bottom screw on the headlight-housing on an s-40 drivers side the early additionmodel I can”t get a socket wrench and socket to get onto the screw because there isn”t enough room Any suggestions Thanks Tom
Alexandra M. says:
Yes, it’s very tight. You can do it with a 10mm socket and some long extensions.
Dee says:
That is super helpful. I wonder, can you offer any advice on what headlights I can buy to replace the standard ones? I have put in new bulbs which claim to be 180% brighter but they are still really weak. I’d say dangerously so.
Alexandra M. says:
You can install the dual headlights from the later models, they are much better. Check this post: http://www.volvohowto.com/how-to-upgrade-to-phase-2-dual-headlight-conversion-on-1995-2000-volvo-s40-and-v40/