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Hi:
I have done this multiple times, to different 240's that I have owned, and have only had to do it one time per lense, so far.
I use a wire Dremel attachment to get all of the old sealant off of the lense and the mounting surface. If you don't have a Dremel type tool, then you can always use a small flat head screw driver as an alternative.
>>>Do not touch or clean the reflector of the headlight. It is very easy to scratch it. If you have compressed air, that is okay, if you want blow dust off of the lense, otherwise, it is very easy to ruin it.<<<
When both surfaces are clean, I then use GE brand silicone sealant, available in a small tube at Home Depot. I lay down a good bead of the sealant in the headlight groove and then insert the lense. I then use several large rubber bands to hold them together overnight. When 12 hours or so have passed, I simply cut the rubber band and remove the cut rubber band.
I have not had a lense come apart and I also have not had a seal break on a light that I have re-glued using this method.
Good luck with your project.
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If it needs to be maintained, repaired or replaced on a 1990 240, I've probably done it. '90 240DL, 327,610 miles, will she make it to 400K ?? >>You haven't really worked on a car until you draw blood<< :-}
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