How Do I Repair Volvo R60 Headlight Adjuster?

Car headlight adjusters provide a critical visibility assistance for Volvo drivers operating at night. The headlights on a Volvo R60 sedan, also known as the S60, work and adjust like most vehicles with horizontal and vertical adjustment mechanisms. These gears allow the headlight to be repositioned for safe driving and visibility at night. However, when these tools break, the headlight gets stuck in place until the adjuster assembly can be repaired or replaced. This requires the headlight assembly to be taken out and disassembled to access the necessary parts.

Instructions

1

Open the Volvo's hood. Use a socket wrench and crescent wrench to disconnect the headlight assembly. Unplug the headlight from the electrical sockets. Remove the headlight by pulling it forward.

2

Pull the top adjuster bolt out by pushing it up. Locate the horizontal adjuster on the side of the headlight cavity and pull it out with pliers.

3

Insert a flathead screwdriver into the various metal clips holding the glass part of the headlight together with plastic backing. Pry these clips to an "open" position. Catch the clip when it pops off and place it in a cup so as not to lose it. Pull the glass off the plastic backing.

4

Carefully pull the rubber O-ring off with the glass lens. Set it aside if it falls off. Place the glass lens on paper with the inside cavity facing downward to block contamination.

5

Locate the headlight gear mechanism inside the back of the headlight's plastic unit. Pull this off the unit carefully it is installed as a bayonet fitting with prongs. Examine the light reflector for white clips.

6

Separate the white clips from the reflector with the flathead screwdriver. Remove the remaining screws that move the reflector via the clips, using needle-nose pliers.

7

Open the repair kit and locate the new reflector-adjusting screws and clips. Insert the new screws into the backing unit. Attach the new white clips. Push the reflector back into the new clips until it pops into place. Plug in the headlight gear mechanism unit.

8

Reinstall the glass lens against the reflector and backing unit after reinstalling the rubber O-ring. Reattach the lens clips. Reinstall the horizontal and vertical actuator bolts into the headlight cavity after wiping them clean with a shop rag.

9

Push the headlight lens back into headlight cavity. Retighten all the lamp-unit securing screws. Reattach the electrical sockets. Turn on the car and test the headlight. Use the socket wrench to adjust the position of the headlight.