Lens Headlamp, Replacing
Lens Headlamp, Replacing
Special tools: 999 7069,999 7066,999 7067
Removing the headlamp lens
NOTES:
- As the illustrations in this service information are used for different model years and/or models, some variation may occur. However, the essential information in the illustrations is always correct.
- If the entire headlamp housing is fragile, the housing should be secured in a mounting when removing/replacing the lens.
CAUTION: To protect the headlamp housing from adhesive residue, the edges of the housing and any other vulnerable areas must be covered using masking tape. The adhesive leaves strings which will stick to the base and are difficult to remove.
Hint: Read through the entire instructions before beginning work.
NOTE: These instructions apply only to the S60.
Removing the headlamp
- Remove the headlamp.
Using a mounting
- Secure the mounting in the vise. Use tool 999 7069.
- Secure the mounting on the top of the headlamp housing using the screws in the nuts (tighten carefully). Place a piece of wood (2) under the housing as support.
- Remove the trim strip.
- Remove the clips (1) holding the glass. Mark the position of the clips for reinstallation.
Using masking tape
- This protects the housing from adhesive residue when removing the lens (adhesive residue is difficult to remove).
- Tape around the housing, the black area in the illustration (1) towards the edges of the lens. Also tape the mounting points for the trim strip.
Preparation
- Tool 999 7067 for removing adhesive residue.
- Tool 999 7066 for spreading out the adhesive.
- Hot-air gun, knife, masking tape/paper as protection (the reflector).
- Protective goggles, leather gloves.
- Isopropanol cleaning agent (P/N 1161 721).
Removing the headlamp lens
NOTE: Do not heat the edge or groove on the housing; it may deform.
- Wear protective gloves.
- Begin by heating around the top of the lens towards the bonding in the housing. - Use a high heat setting so that the lens become very hot (the hotter it is, the easier it is for the knife to penetrate the adhesive).
- Insert the knife between the lens and the plastic edge. Carefully run the knife through the adhesive all the way around the housing a couple of times while heating the top of the lens. Do not damage the plastic edge with the knife.
NOTE: The adhesive leaves strings which will stick to the base and are difficult to remove.
- Pry the glass straight up approximately 5 cm. Start at the side of the outer end. Do not damage the plastic edge on the housing.
- Lift and hold up the lens.
- Using the knife, gradually remove the adhesive from the inside of the housing all the way around, ensuring that no adhesive residue gets on the black trim panel when the lens is lifted straight up from the housing.
Removing adhesive residue from the groove
- Use tool 999 7067.
CAUTION: Use protective goggles.
- Protect reflectors/black trim panel using paper and masking tape.
- Let the adhesive cool a little in the groove. This will make it easier to remove.
- Cut the adhesive along both sides using the tool. Then remove the adhesive residue from the groove using tool 999 7066 until there is an even surface in the groove. Remove the adhesive residue from the tool using a piece of paper.
- The groove does not need to be completely clean. Any remaining residue will be evened out using a hot-air gun and screwdriver.
- Remove the adhesive residue from the panel on the inside of the housing. Use denatured alcohol.
Preparations before bonding
- Insert the adhesive tube in the adhesive gun. Cut the tip of the adhesive tube at an angle.
- Treat the mating surface using glass activator (P/N 1161514) before bonding.
- Bonding adhesive P/N: 1161377 (BLACK)
- Glass primer 1161515
- Brush (10-15 mm wide)
- Isopropanol cleaning agent (P/N 1161 721)
- Window cleaner.
- Remove the backing and masking tape from the reflector/black trim panel
- Carefully blow clean around the reflector and in the housing if necessary
- Remove the clips. Compress the clips slightly using pliers.
- Re-tape the lower section of the housing if necessary.
Installing the headlamp lens
Lens bonding
- Fill the groove with adhesive all the way around so that it is about a millimeter lower than the height of the groove.
- Carefully smooth out the adhesive using a brush.
Installing the headlamps lens
- Apply glass primer all around the edge of the lens.
- Position the lens in the groove and press it into place
- Position and press the clips into place. A further 2 clips must installed at the serrated mountings at the marking
- Wipe away any excess adhesive from the housing.
- Remove the masking tape around the housing
- Position the headlamp housing with the lens upwards (leave it in the mounting if applicable) while it cures.
This takes approximately 12 hours because the adhesive is a one-part cure adhesive
- Clean the headlamp lens using denatured alcohol and window cleaner
- Reinstall the trim strip over the housing.
Installing the headlamp lens
- Remove the housing from the mounting.
- Install the headlamp.
- Check the light and align the headlamp.
Broken/cracked headlamp lens, removing
Preparation
- Position the housing in the mounting.
Taping
- To tape the housing, see (V27G30).
- If the lens is completely broken or cracked but the reflector is intact, tape the lens (2) as illustrated so that glass shards cannot damage the reflector.
Removing the glass
CAUTION: Leather protective gloves and protective goggles must be worn when carrying out the following operations.
NOTE: Do not heat the edge or groove on the housing excessively so that it deforms.
- Take a hot-air gun and a flat-nosed pliers.
- Heat the lens and the groove where the lens is bonded using a hot-air gun.
NOTE: Be careful when removing pieces of glass and splinters.
- Turn the headlamp housing downwards so that pieces of glass do not fall into the housing and damage the reflector.
- Pull the pieces of glass straight out using the flat-nosed pliers. Work the lens and the adhesive out of the groove and housing.
- The adhesive leaves strings which will stick to the base and are difficult to remove.
- Shake out any pieces of glass and splinters that may have got into the housing. Take care!
Removing
- Remove the housing from the mounting.
Installing the headlamp
- Install the headlamp housing in the car.
- Check the light and align the headlamp.