How to replace the headlight on 1996 – 2004 Volvo S40 and V40

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 .

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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