How to Assemble the Headlight Lens on a 1987 Saab 900 SE

If you have a broken or foggy headlight lens on your 1987 Saab 900 SE, you can replace it on your own. The process for assembling a replacement headlight lens or simply taking the lens out of the headlight assembly in order to restore it is a simple and straightforward process. No special tools are required. Purchase replacement headlight lenses through your local Saab dealership or online vendors. Expect the assembly process to take about 30 minutes for each headlight.

Tools Used: Socket wrench set, Screwdriver, Restorative polish, Silicone caulk and caulking gun, Spring-loaded clamps

Assemble Headlight Lens

Turn off your 1987 Saab 900 SE. Prop open the hood.

Unplug the two wiring harnesses from the rear of the headlight assembly.

Use your socket wrench set to remove the bolt on top of the turn-signal assembly. Pull the turn signal assembly away from the headlight assembly but not completely out of the fender, as it is still plugged in.

Remove the two bolts on top of the headlight assembly with your wrench.

Pull the headlight assembly toward you with both hands. If it gives but does not come out completely, pry it out on one side and then the other with your screwdriver.

Insert the flat end of your screwdriver through the crevice between the headlight lens and the headlight housing. Pry the headlight lens off of the headlight housing.

Clean the headlight lens with restorative polish or set it aside if it is broken. With your caulking gun, lay a bead of silicone caulking over the headlight lens mating surface on the headlight housing. Press the restored or new headlight lens against the prepared surface of the headlight housing. Clamp the two together with your spring-loaded clamps. Let the caulk cure for as long as is recommended in the product instructions. Follow the previous steps in reverse to mount the headlight housing with its restored or replaced headlight lens onto the Saab.

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