Preparations

Preparations

• Turn the ignition key to position 0.

• Disconnect the battery negative lead.

  
  

  Note! Wait at least five minutes before disassembling the connectors or removing other electrical equipment.

  
  

• Remove the two screws (1) from the induction pipe of the air filter.

• Detach the hose clamp (2).

• Remove the connector (3) from the intake manifold to the turbocharger.

• Pull the air cleaner (ACL) from its mounting in the left-hand front member.

• Remove the intake manifold from the air cleaner (ACL) and place it to one side.

• Pull up the air cleaner (ACL), rotate it in the short hose and position it as illustrated. Depending on the design, more hoses or connectors may need detaching around the air cleaner (ACL).

• Detach the left-hand headlamp by pulling up the two locking pins and then carefully pulling away the headlamp forwards.

• Carefully prize up the catch on the connector for the headlamp using a screwdriver.

• Pull the catch up completely, detach the connector and place the headlamp to one side.

Installing the cable harness

Installing the cable harness

Illustration A

• Take the cable harness from the kit and position it with relay and relay holder where the air cleaner (ACL) was located.

• Now route the ends of the cable harness without cable terminals, along the left-hand side of the panel flange on the left-hand side member.

Illustration B

• Route the cable harness to the right of the top of the bumper rail and out through the third lower space in the air intake above the number plate holder.

Installation, auxiliary lights bracket

Installation, auxiliary lights bracket

Remove:

• the number plate.

• the screws (1) to the number plate holder.

• the number plate holder.

• Take the auxiliary lights bracket (1) from the kit and secure it in the holes for the number plate holder. Use the upper holes (2) in the auxiliary lights bracket.

• Drill with a Ø 7 mm (9/32") diameter drill bit in the centre of the holes (3), through the bumper cover and the bumper rail that is 39 mm (1 1/2") inside.

  
  

  Note! Keep the drill horizontal.

  
  

• Remove the screws and auxiliary lights bracket.

• Drill the holes (1) with the drill bit (P/N 8633152). Drill through the plastic with the thicker section of the drill bit, and through the bumper rail (2) with the thinner section of the drill bit, which has the dimension Ø 7.3 mm (19/64").

  
  

  Note! It is important that the tip of the drill bit meets the hole that was previously drilled into the bumper rail. The flat surface on the drill bit must drill out all plastic up to the bumper rail.

  
  
  

  Note! Hold the drill horizontally. Use a torch to check that there is no plastic swarf in the holes.

  
  

• Check that the surface (1), which the socket shall support against, is free from plastic.

• Install two spacer sleeves L = 44 mm (1 3/4") into the holes.

  
  

  Note! The spacer sleeves must protrude approx. 5.5 mm (7/32") from the bumper cover.

  
  

• Affix tie straps (1) in the holes in the auxiliary lights bracket, but do not tighten.

• Install the auxiliary lights bracket on the bumper using the screws (2) from the kit. Tighten loosely. The screws create their own threads in the drilled holes, which means that they may screw in stiffly.

• Guide in the two cable ends (1) in the three tie straps (2). Route the cables as illustrated.

• Adapt the length of the cable to the lamps. Press back any excess length of the cable outside of the front grille back in through the front grille.

• Tighten the tie straps.

• Tighten the two screws for the auxiliary lights bracket.

• Install a spacer washer (3) between the auxiliary lights bracket (4) and the expander nut (5) on both sides.

• Install the number plate and tighten it with the two screws.

Installation, auxiliary lights

Installation, auxiliary lights

Use auxiliary lights which are recommended by Volvo dealers.

• Remove the screw (1) and the cover.

• Press lightly on the lens (2).

• Fit a screwdriver (3) between the insert and the lamp housing, and prize carefully.

• Install the lamp housing on the auxiliary lights mounting with screw and nut. Tighten manually.

• Route the cable harness with the rubber grommet (1) into the holes in the lamp housing.

• Press the rubber grommet into the hole.

• Install the cable terminals from the kit on the two cable ends.

• Connect the blue (BL) cable to the lamp's cable, with a connector socket housing in between.

• Connect the black (SB) cable to ground on the light insert.

• Assemble the auxiliary light, as illustrated.

Installing the cable harness (contd.)

Installing the cable harness (contd.)

Illustration A

• Take the previously routed cable harness (1) and route it as illustrated.

Illustration B

• Plug the connector (2) into the pre-routed connector (3).

Illustration C

• Press in the relay (4) at the vertical panel, under the panel that the main headlamp rests on. Rotate the relay up so that the connector with the cable does not make contact with panel underneath. See also illustration 6 for the location of the relay.

Illustration D

• Detach the existing screw (5) in the air cleaner (ACL) bracket and connect the ground cable. Turn the ground cable terminal down and position the cable so that it is not trapped by the air cleaner (ACL) when this is reinstalled. Pull any excess length of the cable through the front grille and clamp it with the existing cables behind the headlamp using tie straps.

• Reinstall the air cleaner (ACL) and the intake manifold.

• Plug in the connector to the headlamp and reinstall the headlamp.

  
  

  Note! The longer of the locking pins must be located on the outside of the headlamp.

  
  

Illustration A

Applies to cars up to and including model year 2004

• Remove the cover from the fuse box in the engine compartment. Install a 20A fuse in position 2 (1).

• Reinstall the cover.

Illustration B

Applies to cars of model year from 2005-

• Remove the cover from the fuse box in the engine compartment. Install a 20A fuse in position 5.

• Reinstall the cover.

Installing the switch

Installing the switch

Illustration A

• Remove the cover plug to the 12V socket.

• Insert a scriber with an angled tip into the joint on the underside, at one side of the keypad surround.

Illustration B

• Carefully pull out the surround using the scriber, pull along the underside of the surround. It is secured with three mounting lugs in the top and bottom edges.

  
  

  Note! Do not damage the surround.

  
  

• Place the surround to one side.

  
  

  Hint The surround with three button places must be replaced with a surround with seven button places if necessary. This can be purchased separately.

  
  

• The switch can be located in any available position. Remove the dummy button and install the new switch (1).

• Reinstall the surround and cover plug to the 12V socket.

• Align the auxiliary lights for optimum beam pattern.

• Tighten the two screws, see step 14.

• Install the protective caps on the screw heads.

Installing the top strut

Installing the top strut

• Take the top strut and insert one end in the space between the two bumper sections. Position it in line with the centre of the auxiliary light.

• Mark out for drilling the hole through the top strut and in the bumper, in the centre of the black edge (A).

• Drill out the hole using a Ø 3 mm (1/8") diameter drill bit.

• Remove any swarf.

• Mark out for drilling the hole through the top strut and in the centre top/rear edge of the auxiliary light.

• Drill out the hole using a Ø 4.5 mm (3/16") diameter drill bit.

• Remove any swarf.

• Take the top strut and locate it between both of the drilled holes for cutting the strut (1).

• Shorten the strut (1) to a suitable length.

• Tighten the top strut to the bumper and auxiliary light with screws, nuts and toothed washers.

  
  

  Note! The toothed washer must not be fitted on the screw to the bumper, as there is otherwise a risk that the screw may chafe against the bonnet's paintwork.

  
  

• Bend the top strut down to the bumper using a screwdriver. This is so that the lower edge of the bonnet does not catch when it is closed.

• Clean the painted surfaces in the front and lower edges of the bonnet opposite where the top struts are mounted in the bumper. Use a mixture of 30% washer fluid and 70% water.

• Wipe dry.

• Firmly press the protective tape into place in the front and lower edges of the bonnet, opposite where the top struts are mounted in the bumper.

• Turn the ignition key to position II.

• Reconnect the battery negative lead.