I have 2000 S80, which has identical body styling. The job is not too daunting, though I must rant that whoever designed the headlight assembly was an idiot for not designing an easy way to access it without having to partially remove the bumper cover. I did this job just last weekend on my own car and it took me about an hour. I'll try to be very descriptive, but don't worry, the job sounds worse than it is. The way I see it, you have two options:

OPTION ONE
1. Before you start, make sure you have a pop rivet tool and some replacement rivets so you can reattach the bumper to the inside of the fender well cowling -just inside the fender well. Look at the bumper where it attaches to the wheel well at the front tire to see the rivets. These four pop rivets just inside the wheel well will need to be drilled out - a 1/8" drill bit will do the job and you may need to remove the front tire for clear access. You can buy a whole box of replacement pop-rivets and some thin flat 1/2" fender washers with the right size hole at Home Depot for a few dollars - or the dealer will sell you four genuine Volvo replacement pop-rivets for about $1 each - your choice. A pop rivet gun is less than $20 and you'll need this regardless of where you buy your rivets.

2. Also, before you start, you will also need to get 6 replacement plastic snap-type trim rivets to replace the six located on the top of the grill/bumber assembly where te bumper cover/grill connects to the frame at the top of the radiator - when the hood is closed, these are just under the leading edge of the hood. These can be found at any auto parts store. Remove one ahead of time, so you can know what to look for at the auto parts store and for $3 you can buy a whole box of them - or the dealer will sell them for $1.50 each. They will get destroyed by removing them. Just plunge the center pin through the plastic trim rivet, and then lift up the outer ring part to release the bumper cover from the frame.

2. The black plastic wraparound trim piece just below the headlight snaps in place. If you have headlight wipers that protrude though this part, you will have to remove the wiper arms. Remove this trim and take the side marker light out so you can set it aside.

3. You now have access to the side turn signal light. Remove the bolt from the side. Use a flat screwdriver from the top to release the catch that holds it in place. Slide it forward.

4. In the front of the bumper, there are two bolts holding the bumper cover to the bumper frame. One is hidden behind a small rectangular access plate that is maybe 1-1/2 x 2 inches in dimension. The other, I think can be seen through an opening in the bumper cover - I think where the wraparound trim piece covered it. Remove these.

5. Pull gently on the front of the bumper cover to slide it forward out of its underside guide/holding bracket on the side near the fender. This should give you enough access in front of the headlight assembly to get to the 8 snap clips that hold the headlight lens to the reflecter - three on top, three on bottom, and one on each end. Remove these clips by lifting in the center of the clip with a screwdriver - they will snap right out.

6. Remove the broken lens, blow out any glass debris that is in the reflector assembly and allow it to air dry if water was trapped inside. Do not try to wipe out the reflector or clean it with a solvent as this will rub off the silvery reflector surface.

7. Your replacement lens probably came with a replacement gasket and new clips. If so. use them. Otherwise carefully remove the old gasket (so it doesn't tear) for reuse. Installing a new gasket requires a third hand at least, so ask a friend to help you postion/hold the gasket in place in the groove on the reflector part, while you align the new lens onto the gasket. Holding it there, begin snapping the holding clips back on. You may need to press the lens and relector assembly together pretty hard to compress the gasket enough to snap the new clips on.

8. Rebolt the bumper cover back on - be sure you remember to slide the bumper cover back into the slide guide holding bracket on the underside near the fender or it won't realign with the pop-rivets in the fender well. Pop-rivet the side of the bumper cover back to the inside of the fender well. Replace snap rivets at the top of the radiator, and re-install the turn signal light assembly and bumper cover trim piece.

9. Cuss the engineer who designed the @#$*^%& thing this way -- and you're done!


OPTION TWO -
The dealer will do all this for you for about $200-$250 labor, plus parts - highway robbery in my opinion.

Best of luck!

I have 2000 S80, which has identical body styling. The job is not too daunting, though I must rant that whoever designed the headlight assembly was an idiot for not designing an easy way to access it without having to partially remove the bumper cover. I did this job just last weekend on my own car and it took me about an hour. I'll try to be very descriptive, but don't worry, the job sounds worse than it is. The way I see it, you have two options:

OPTION ONE
1. Before you start, make sure you have a pop rivet tool and some replacement rivets so you can reattach the bumper to the inside of the fender well cowling -just inside the fender well. Look at the bumper where it attaches to the wheel well at the front tire to see the rivets. These four pop rivets just inside the wheel well will need to be drilled out - a 1/8" drill bit will do the job and you may need to remove the front tire for clear access. You can buy a whole box of replacement pop-rivets and some thin flat 1/2" fender washers with the right size hole at Home Depot for a few dollars - or the dealer will sell you four genuine Volvo replacement pop-rivets for about $1 each - your choice. A pop rivet gun is less than $20 and you'll need this regardless of where you buy your rivets.

2. Also, before you start, you will also need to get 6 replacement plastic snap-type trim rivets to replace the six located on the top of the grill/bumber assembly where te bumper cover/grill connects to the frame at the top of the radiator - when the hood is closed, these are just under the leading edge of the hood. These can be found at any auto parts store. Remove one ahead of time, so you can know what to look for at the auto parts store and for $3 you can buy a whole box of them - or the dealer will sell them for $1.50 each. They will get destroyed by removing them. Just plunge the center pin through the plastic trim rivet, and then lift up the outer ring part to release the bumper cover from the frame.

2. The black plastic wraparound trim piece just below the headlight snaps in place. If you have headlight wipers that protrude though this part, you will have to remove the wiper arms. Remove this trim and take the side marker light out so you can set it aside.

3. You now have access to the side turn signal light. Remove the bolt from the side. Use a flat screwdriver from the top to release the catch that holds it in place. Slide it forward.

4. In the front of the bumper, there are two bolts holding the bumper cover to the bumper frame. One is hidden behind a small rectangular access plate that is maybe 1-1/2 x 2 inches in dimension. The other, I think can be seen through one of the openings in the bumper. Remove these.

5. Pull gently on the front of the bumper cover to slide it out of its guide bracket on the side near the fender. This should give you enough access in front of the headlight assembly to get to the 8 snap clips that hold the headlight lens to the reflecter - three on top, three on bottom, and one on each end. Remove these by lifting in the center of the clip with a screwdriver - they will snap right out.

6. Remove the broken lens, blow out any glass debris that is in the reflector assembly and allow to air dry if water was trapped inside. Do not try to wipe out the reflector or clean with a solvent as this will rub off the silvery reflector.

7. Your replace ment lens probably came with a replacement gasket and new clips. If so. use them. Otherwise carefully remove the old gasket (so it doesn't tear) for reuse. Installing a new gasket requires a third hand at least, so ask a friend to help you postion hold the gasket in place in the groove on the reflector part while you align the new lens onto the gasket. Holding it there, begin snapping the holding clips back on. You may need to push pretty hard to compress the gasket enough to snap them on.

8. Reassemble and rebolt the bumper cover back on - be sure you remember to slide the bumper cover back into the slide guide holding bracket on the underside near the fender or it won't realign with the pop-rivets in the fender well. Pop-rivet the side of the bumper cover back to the inside of the fender well. Replace snap rivets at the top of the radiator, and re-install the turn signal light assembly and bumper cover trim piece.

9. Cuss the engineer who designed the @#$*^%& thing this way -- and you're done!


OPTION TWO -
The dealer will do all this for you for about $200-$250 labor, plus parts - highway robbery in my opinion.

Best of luck!

I cannot help you with repair instructions, but I can tell you, DO NOT touch the reflector.

I have read several tales of woe written by owners who have tried to clean their headlight reflectors, the reflective coating comes off!
--
'96 855R,'64 PV544, '67 P1800, '95 855, '95 854, the first three are mine, heh, heh, 405,000 miles put on 8 bricks