Removing headlamp mechanism

[BirkenNed]

Does anyone know how to remove a headlamp pop-up mechansm to replace the motor?
The Haynes manual is more a liability than a help. and I haven`t been able to find
anything on the forum except for changing a bulb !!

[glasgowjim]

The job is not too difficult but the drivers side is more awkward than the passenger side.

Read this how to thread first.....

http://www.volvo-480-europe.org/forum/v ... 24&t=34025

then you will get a feeling for what has to be done .

But before I can give you detailed instructions I need to know which side you are going to change.

[BirkenNed]

Hi Jim, it`s the passenger side. I`ve taken out the battery and tray and stopped there
Bill

[glasgowjim]

Whoa you dont need to remove the battery tray at all ever.

Passenger side motor

Raise the popups. open bonnet and switch off the ignition . You can now turn the rotary light switch off to save your battery.

remove battery and disconnect the motor.
Remove the front indicator cluster as shown in the how to thread in the post above.
Then remove the popup cover disconnect the headlamp bulb .

With a marker pen or screwdriver mark the junction of the support arm where it joins the arm connection to the motorarm connector. This way when you reassemble the headlamp will be correctly aligned.

Now be very careful about the hinges as they are very easily damaged.

I personally would remove the hinges (by unscrewing the allen key bolts on either side) and put them and the small bolts carefully aside.

Now to release the headlamp unit from the small suspension arm/unit put a slotted screwdriver in the flat part underneath the spring and twist / prise it away from the suspension arm body and the end will be pulled out from the ball head connector.

Remove headlamp unit.

using a 10mm spanner or small socket set remove the three bolts that hold the motor in place and manoeuver the motor unit out if necessary loosen the black headlamp frame to facilitate removal.

reassembly is the reverse of this procedure. except grease the hinge liberally before reinsertion.

Allow an hour or more for this job as its your first time .

good luck

[480-clone]

I remember my first time...........in my eagerness the whole nosecone was off

[BirkenNed]

That`s great, did all that and replaced the motor. Only problem is that the crank (if thats the right term) was put onto the new motor`s spindle; but the spindle was at a different point of rotation from the original, so now the headlamp movement is out of sync.
Also; do you know if these motor relays can be repaired ? mine`s not working on one side.

[glasgowjim]

adjuysting the sync is easy put up headlamps , loosen the maladjusted one push up into same position as the "good one" tighten up.

and you are done. Dont worry I changed mine one time and the headlamp was 180 degress out so it does happen once you have done this you get wise to it the next time uunless you rush and forget like I did

[glasgowjim]

Oh and if you are relying on the HBOL you know you are in trouble

always check the how to section first it can be very useful.

[BirkenNed]

Thats great thanks, I`ll get right on it. The end is in sight.

Is it true that the motor relays are no longer available ?
If so, what are the options ? repair - used units - adapt one from a different car etc.