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Forum Mark Specific Garages Astra Mk4/G 1998-04 Bodywork and Exterior Removing headlight glass

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Thread: Removing headlight glass Tweet

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02-12-2005, 21:27

Removing headlight glass

I've done a search and couldn't find anything relating to this although I know it's possible.

Here's the problem, decided to work on the GSi Xenon headlights, I was fitting the new HID H7 bulbsin the main beam holder. The HID bulbs base is slightly too thick for the catchs to lock in in place, Ifiled down the base a bit and was test fitting it. I seemed to have it almost perfect but I needed alittle more pressure to get one clip to lock, gave a push and it's popped the reflector lens off it'sinside edge mounting point. It appears to be a sort of ball and cup affair but I can't seem to get itback into place. Looks like I'll need to remove the glass in order to push it back into place from thefront. Now I know the glass is held in place by clips and glue. The glue needs to be heated in order tosoften it sufficently to get it to unstick. How hot should I set the oven in order not to melt theplastic only enough to melt the glue.

Anyone done this, I know someone has as they sprayed their silver edging black in order to copy thecoupe look, if you have can you let me know all the in and outs and little tricks that help.

Cheers.

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02-12-2005, 21:29

Keif is the master at taking lights apart, so it might be worth giving him a quick PM.

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02-12-2005, 21:33

Keif is the master as Ffoeg states - it involves an oven so make sure you have a grown up helper.

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why do today what you can...... I'll finish this later

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02-12-2005, 21:43

I'll PM Keif and ask him to post his reply on this thread. That way anyone else searching for the infowill find it.

Cheers guys.Need to find a grown up now though

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02-12-2005, 22:43

Hello! .

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02-12-2005, 23:03

O.K. i had a quick seach, is i thought i'd put this up somewhere. But alas no.

Here go's

Tools required.Oven (Electric) fan assisted is also helpful!Screwdriver - 2x flat bladed.Scissors

KettleTeabagMilk - optionalSugar - optional

The idea is to soften the sealant with heat, this then makes it plyable enough to pull the "glass"away from the headlight body.

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I have also done this with a hairdryer, but it is VERY time consuming.

1. Put oven on at 70degC and wait for it to warm up.2. Remove rubber seal around the unit

3. Place headlight in the oven for approx 15mins.4. With the headlight on a bench/kitchen side. Unclip one of the clips and using the two screwdriversto slowly work around the glass pulling the sealant apart. (undoing the clips as you go)

The sealant is amazingly strong. you may have to cut it with scissors when it stretched out.

If the sealant is proving to be tough, it may well do. Put the headlight back in the oven for a further15mins. At this point

5. Fill kettle with water and put on to boil.6. Place Teabag in Mug.7. When the kettle has boiled, pour the Hot water into the mug and stir.8. Remove Teabag.9. Add milk/sugar to taste

Once the "glass" is off the unit try to remove some of the remaining sealant, as when you come toseal the unit back together, it will be hindering progress.

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(Dont forget to drink your tea)

To reseal the unit, fill the sealant channel with silicone sealant and press together. If you've not removed enough of the original sealant it'll be very difficult to get the clips back overthe retaining lugs.

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03-12-2005, 00:35

Cheers Keif. Only possible problem I can forsee is that the GSi Xenon headlights have a lot of internalwiring. As these are small and thin I'm slightly concerned that they will melt but maybe the plasticdoesn't get that hot.

Will coffee be ok as a substitute for tea? I'll ask me Mum to come round and supervise me

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03-12-2005, 07:05

After an initial softening in the oven you could use a hair dryer to warm the sealant as you moveyour way around the light. Keep some blocks of wood or similar handy to wedge into the sections ofthe light that you have already seperated.

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03-12-2005, 08:37

You can drop the temperature of the oven, but you'll have to increase the warming time. TBH 70degsshouldn't melt the wiring insolation anyway.

Coffee is fine. You can add cream (to taste) instead of milk.

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Keif Originally Posted by Oddjob

Cheers Keif. Only possible problem I can forsee is that the GSi Xenon headlights have a lot of internalwiring. As these are small and thin I'm slightly concerned that they will melt but maybe the plasticdoesn't get that hot.

Will coffee be ok as a substitute for tea? I'll ask me Mum to come round and supervise me

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17-03-2006, 22:22 #10

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Keif mate your a star. I finally plucked up the courage to put my Gsi Xenon headlight in the oven, notsomething you want to do with a headlight which you have little chance of finding a replacement forif it goes wrong. 15 mins later I removed it and the glass came off no problem. Didn't even need towork hard at it. Sealant is like snot but comes off ok with a little work.

Now here's a question you may be able to answer. Whilst I have the light apart I thought I'd take theoppurtunity to remove the orange lens from the inside of the indicator holder. Removed the holder viathe 2 torx screws inside the lens area and finally got the clear plastic lens off the front, underneaththat is an orange bubble type lens which I've now removed. I thought I'd try and see which type ofbulb fits in the holder now, straight pin or staggered pin and it's none of them. I've only just realisedthe bulb holder bears little relationship to the normal Astra Headlight, the bulb goes in from theoutside but the hole is smaller than a normal bulb so it must take something like a 501. Any idea whatbulb the Gsi Xenon headlight uses in the indicator slot as it's no use me removing the orange lens ifthe only bulb that fits only comes in a clear form.

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