WWW Astraownersclub Com

User Name
Passw ord
Log in
Forgot Password?
Register
Remember Me?
Forum
Club Info
Garage
Join the AOC Community! Forum Actions
Forum
Mark Specific Garages
Registry
Quick Links
AOC - Shop
Contact Us
Advanced Search
Calendar Forum Rules & FAQ
Astra Mk4/G 1998-04
Bodywork and Exterior
Removing headlight glass
Welcome to the Astra Owners Club Forums, the UK's largest Astra and Zafira community.
You are currently viewing our boards as a guest which gives you limited access to the forum's features. By joining our free community you will have access to post topics, communicate
privately with other members (PM), respond to polls and access many other special features. Registration is fast, simple and absolutely free so please, join our community today!
If you have any problems with the registration process or your account login, please contact us. Start posting and be a part of the largest Astra and Zafira community in the UK!
Astra Owners Club uses cookies; they are essential for the correct operation of both the site & forum.
Cookies are files stored in your browser and are used by most websites to help personalise your web experience. EU law states that we must inform you of our use of cookies. By closing
this notice and continuing to use this forum without changing your browsers cookie settings for this website/forum, you are agreeing/consenting to our use of cookies. Please note that
only anonymous information is held in the cookies, we explicitly do not share personal identity information with any third party websites or organisations.
Results 1 to 10 of 20
Page 1 of 2 1 2
Last
Thread: Removing headlight glass

0
Tweet
Thread Tools
#1
02-12-2005, 21:27
Status
Offline
Oddjob
I've done a search and couldn't find anything relating to this although I know it's possible.
AOC Obsessed
Join Date:
Posts:
Mentioned in:
Quoted:
Removing headlight glass
May 2003
5,213
0 Post(s)
0 Post(s)
Here's the problem, decided to work on the GSi Xenon headlights, I was fitting the new HID H7 bulbs
in the main beam holder. The HID bulbs base is slightly too thick for the catchs to lock in in place, I
filed down the base a bit and was test fitting it. I seemed to have it almost perfect but I needed a
little more pressure to get one clip to lock, gave a push and it's popped the reflector lens off it's
inside edge mounting point. It appears to be a sort of ball and cup affair but I can't seem to get it
back into place. Looks like I'll need to remove the glass in order to push it back into place from the
front.
Now I know the glass is held in place by clips and glue. The glue needs to be heated in order to
soften it sufficently to get it to unstick. How hot should I set the oven in order not to melt the
plastic only enough to melt the glue.
Anyone done this, I know someone has as they sprayed their silver edging black in order to copy the
coupe look, if you have can you let me know all the in and outs and little tricks that help.
Cheers.
52 Astra G 1.8, 18" Mille Miglia alloys, 325mm Brembo 4 pot conversion, Coupe leather interior, Raid strut
brace, Whiteline rear ARB, Irmscher bits (skirts, Carbon steering wheel, Bonnet extension, M3 mirrors, boot &
roof spoiler), Reiger Rear Diffuser & Front Bumper, Koni Adj. dampers, 35/30 Vogtland springs, Duplex quad
exit ASCAR stainless exhaust.
Reply With Quote
#2
02-12-2005, 21:29
Status
Offline
Keif is the master at taking lights apart, so it might be worth giving him a quick PM.
Ffoeg
2170:01:06
Join Date:
Jun 2003
converted by W eb2PDFConvert.com
Posts:
Mentioned in:
Quoted:
34,591
2 Post(s)
0 Post(s)
Reply With Quote
#3
02-12-2005, 21:33
Status
Offline
Keif is the master as Ffoeg states - it involves an oven so make sure you have a grown up helper.
kitchpoo
why do today what you can...... I'll finish this later
AOC Gold Member
Join Date:
Posts:
Mentioned in:
Quoted:
2958cc was 175BHP @ 4000rpm, 370Nm (273lb.ft.) @ 1900rpm NOW 230BHP/469Nm (344.9lb/ft)!!
May 2003
6,322
0 Post(s)
0 Post(s)
www.IUsedToOwnTwoAstras.com
Reply With Quote

#4
02-12-2005, 21:43
Status
Offline
Oddjob
I'll PM Keif and ask him to post his reply on this thread. That way anyone else searching for the info
will find it.
Cheers guys.
Need to find a grown up now though
AOC Obsessed
Join Date:
Posts:
Mentioned in:
Quoted:
May 2003
5,213
0 Post(s)
0 Post(s)
Reply With Quote
#5
02-12-2005, 22:43
Status
Offline
Hello! .
Keif
Going Topless!
Join Date:
Jun 2003
Drives:
Astra 1.8 Twintop,
Lotus Carlton, Meriva VXR and Nova
Posts:
11,702
Mentioned in:
1 Post(s)
Quoted:
4 Post(s)
Reply With Quote
#6
02-12-2005, 23:03
Status
Offline
Keif
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
Going Topless!
Join Date:
Jun 2003
Drives:
Astra 1.8 Twintop,
Posts:
11,702
Mentioned in:
1 Post(s)
Quoted:
4 Post(s)
Kettle
Teabag
Milk - optional
Sugar - 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.
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 screwdrivers
to 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 further
15mins. At this point
5.
6.
7.
8.
9.
Fill kettle with water and put on to boil.

Place Teabag in Mug.
When the kettle has boiled, pour the Hot water into the mug and stir.
Remove Teabag.
Add milk/sugar to taste
Once the "glass" is off the unit try to remove some of the remaining sealant, as when you come to
seal the unit back together, it will be hindering progress.
(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 over
the retaining lugs.
Reply With Quote
#7
03-12-2005, 00:35
Status
Offline
Oddjob
Cheers Keif. Only possible problem I can forsee is that the GSi Xenon headlights have a lot of internal
wiring. As these are small and thin I'm slightly concerned that they will melt but maybe the plastic
doesn't get that hot.
Will coffee be ok as a substitute for tea? I'll ask me Mum to come round and supervise me
AOC Obsessed
Join Date:
Posts:
Mentioned in:
Quoted:
May 2003
5,213
0 Post(s)
0 Post(s)
Reply With Quote
#8
03-12-2005, 07:05
Status
Offline
Shahid
After an initial softening in the oven you could use a hair dryer to warm the sealant as you move
your way around the light. Keep some blocks of wood or similar handy to wedge into the sections of
the light that you have already seperated.
AOC Fanatic
Join Date:
Posts:
Mentioned in:
Quoted:
Apr 2005
475
0 Post(s)
0 Post(s)
Reply With Quote
#9
03-12-2005, 08:37
Status
Offline
Keif
Originally Posted by Oddjob
Cheers Keif. Only possible problem I can forsee is that the GSi Xenon headlights have a lot of internal
wiring. As these are small and thin I'm slightly concerned that they will melt but maybe the plastic
doesn't get that hot.
Will coffee be ok as a substitute for tea? I'll ask me Mum to come round and supervise me
Going Topless!
Join Date:
Jun 2003
Drives:
Astra 1.8 Twintop,
Posts:
11,702
Mentioned in:
1 Post(s)
Quoted:
4 Post(s)
You can drop the temperature of the oven, but you'll have to increase the warming time. TBH 70degs
shouldn't melt the wiring insolation anyway.
Coffee is fine. You can add cream (to taste) instead of milk.
Reply With Quote

17-03-2006, 22:22
#10
Status
Offline
Oddjob
AOC Obsessed
Join Date:
Posts:
Mentioned in:
Quoted:
May 2003
5,213
0 Post(s)
0 Post(s)
Keif mate your a star. I finally plucked up the courage to put my Gsi Xenon headlight in the oven, not
something you want to do with a headlight which you have little chance of finding a replacement for
if it goes wrong. 15 mins later I removed it and the glass came off no problem. Didn't even need to
work 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 the
oppurtunity to remove the orange lens from the inside of the indicator holder. Removed the holder via
the 2 torx screws inside the lens area and finally got the clear plastic lens off the front, underneath
that is an orange bubble type lens which I've now removed. I thought I'd try and see which type of
bulb fits in the holder now, straight pin or staggered pin and it's none of them. I've only just realised
the bulb holder bears little relationship to the normal Astra Headlight, the bulb goes in from the
outside but the hole is smaller than a normal bulb so it must take something like a 501. Any idea what
bulb the Gsi Xenon headlight uses in the indicator slot as it's no use me removing the orange lens if
the only bulb that fits only comes in a clear form.
Reply With Quote
Page 1 of 2 1 2
Quick Navigation
Last
Bodywork and Exterior
Top
Previous Thread | Next Thread

Similar Threads
Headlight glass
Replies: 1
By Rickz in forum Bodywork and Exterior
Last Post: 21-07-2012, 10:08
rem oving the m irror glass ?
Replies: 16
By 5853moore in forum Bodywork and Exterior
Bookmarks
Facebook
Google
Digg
Last Post: 08-01-2010, 20:40
Posting Permissions
You
You
You
You
m ay
m ay
m ay
m ay
not
not
not
not
post new threads

post replies
post attachm ents
edit your posts
del.icio.us
BB code is O n
Smilies are O n
[IMG] code is O n
[VIDEO] code is O ff
HTML code is O ff
Forum Rules
Stum bleUpon
-- AOC Modern
Contact Us Astra Owners Club Archive Privacy Policy Forum Rules Top
All times a re GMT +1. The time now is 11:14.
2006-2015 Astra Owners Club
Des igned by Loud Webdes ign
Powered by vBulletin. Copyright 2013 vBulletin Solutions , Inc.

WWW Astraownersclub Com

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

WWW Astraownersclub Com

Uploaded by

Copyright:

Available Formats

User Name

Join the AOC Community! Forum Actions

Mark Specific Garages

Calendar Forum Rules & FAQ

Astra Mk4/G 1998-04

Bodywork and Exterior

Removing headlight glass

Thread: Removing headlight glass

Removing headlight glass

Reply With Quote

3. Place headlight in the oven for approx 15mins.

Fill kettle with water and put on to boil.

(Dont forget to drink your tea)

Originally Posted by Oddjob

Reply With Quote

Bodywork and Exterior

Previous Thread | Next Thread

By Rickz in forum Bodywork and Exterior

Last Post: 21-07-2012, 10:08

rem oving the m irror glass ?

By 5853moore in forum Bodywork and Exterior

Last Post: 08-01-2010, 20:40

post new threads

You might also like