Removing A Broken/Cracked Headlamp Lens

Removing loose pieces of glass

Fig 1: Removing Loose Pieces Of Glass

Courtesy of VOLVO CARS OF NORTH AMERICA.

WARNING: Use protective goggles and protective gloves.

If the lens is broken or cracked but the reflectors seem to be intact, hold the headlamp with the lens facing down to prevent bits of glass from damaging the reflectors. Remove all loose pieces of glass using pliers.

Heating and removing the glass

Fig 2: Heating And Removing Glass

Courtesy of VOLVO CARS OF NORTH AMERICA.

Place the headlamp mounting in the vice and use the hot air gun.

CAUTION: Heat carefully to prevent damaging the edges of the headlamp housing.

Heat the lens towards the bonding, around in the housing. Use a high heat setting so that the lens becomes very hot. Remove all pieces of glass using pliers.

NOTE: Pull upwards/outwards to prevent adhesive residue sticking to the black trim panel.