Preparations

Preparations

• Turn the ignition switch 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 intake manifold for the air cleaner (ACL)

• Disconnect the hose clamp (2)

• Remove the connector (3) from the intake manifold for the turbocharger (TC)

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

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

• Pull up the air cleaner (ACL). Turn the air cleaner (ACL) around in the short hose. Position as illustrated. Depending on the version more than one hose or connector may need to be detached from around the air cleaner (ACL).

• Remove the left-hand headlamp by pulling up the two cotter pins and then carefully pulling the headlamp forwards.

• Carefully pry up the catch on the headlamp connector using a screwdriver

• Pull up the lock completely. Disconnect the connector. Place the headlamp to one side.

Installing the cable harness

Installing the cable harness

Illustration A

• Take the cable harness from the kit. Position the cable harness with the relay and relay holder where the air cleaner (ACL) was positioned

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

Illustration B

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

Installing the bracket for the auxiliary lamps

Installing the bracket for the auxiliary lamps

Remove:

• the number plate

• the screws (1) for the number plate holder

• the number plate holder.

• Secure the auxiliary lamp bracket (1) (from the kit) in the holes for the number plate holder. Use the upper holes (2) in the auxiliary lamp bracket

• Using a 7 mm (9/32”) diameter drill bit, drill the centre of the holes (3). Drill through the bumper cover and the bumper rail which is positioned 39 mm (1 1/2”) inside.

  
  

  Note! Hold the drill horizontally.

  
  

• Remove the screws and the auxiliary lamp bracket.

• Drill the holes (1) using a drill bit (P/N 8633152). Drill through the plastic using the thicker section of the drill bit. Drill through the bumper rail (2) using the smaller section of the drill bit, the dimension of which is 7.3 mm (19/64”) diameter.

  
  

  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 of the drill bit must drill out all the plastic up to the bumper rail.

  
  

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

  
  

• Check that there is no plastic on the area (1) on which the spacers will rest

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

  
  

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

  
  

• Secure the tie straps (1) in the holes in the auxiliary lamp bracket. Do not tighten

• Install the auxiliary lamp bracket on the bumper using the screws (2) from the kit. Finger tighten. The screws are self-tapping so it may be hard to screw them in.

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

• Adjust the cable lengths for the lamps. Press any excess cable outside the grille back into the grille

• Tighten the tie straps

• Tighten the two screws for the auxiliary lamp bracket

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

• Install the number plate. Tighten the number plate with the two screws.

Installing the auxiliary lamps

Installing the auxiliary lamps

Use auxiliary lamps recommended by your Volvo dealer.

• Remove the screw (1) and cover

• Press lightly on the lens (2)

• Position a screwdriver (3) between the insert and lamp housing and pry gently.

• Install the lamp housing on the auxiliary lamp mounting. Use a screw and nut. Finger tighten.

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

• Press the rubber grommet into place in the hole

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

• Connect the blue (BL) cable to the lamp cable via a socket housing

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

• Assemble the auxiliary lamp as illustrated.

Installing the cable harness (continued)

Installing the cable harness (continued)

Illustration A

• Route the previously routed cable harness (1) as illustrated.

Illustration B

• Connect the connector (2) to the pre-routed connector (3).

Illustration C

• Press the relay (4) into place at the vertical panel, under the panel on which the headlamp rests. Twist up the relay so that the connector with the cable does not catch the panel underneath. Also see illustration for the location of the relay.

Illustration D

• Remove the existing screw (5) in the air cleaner bracket. Connect the ground lead. Twist the ground lead cable terminal downwards. Position the cable so that it does not catch the air cleaner (ACL) when it is reinstalled. Route any excess cable through the front grille. Secure the cable at existing wiring behind the headlamp using tie straps

• Reinstall the air cleaner (ACL) and intake manifold

• Connect the connector to the headlamp and reinstall it.

  
  

  Note! The longer of the cotter pins must be positioned on the outside of the headlamp.

  
  

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

• Reinstall the cover.

Installing the switch

Installing the switch

Illustration A

• Remove the blind cover plug from the 12V socket

• Take a scriber with an angled point. Insert the angled end of the scriber in the joint underneath, on one side of the surround for the switch unit.

Illustration B

• Carefully pull out the surround using the scriber. Pull along the underneath of the surround. It is securely positioned with three mounting lugs at the top and lower edges.

  
  

  Note! Do not damage the surround.

  
  

• Place the surround to one side.

  
  

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

  
  

• The switch can be installed in any location. Remove the switch blank. Install the new switch (1)

• Reinstall the surround and the blind cover plug for the 12V socket.

• Set the auxiliary lamps for optimal light distribution

• Tighten the two screws. See point

• Install protective caps on the screw heads.

Installing top stays

Installing top stays

• Take the top stay and slide one end in the gap between the two bumper sections. Position in line with the centre of the auxiliary lamp

• Make a mark for drilling a hole through the top stay and in the bumper, in the centre of the black edge (A)

• Drill out the hole. Use a 3 mm (1/8”) diameter drill bit

• Remove any swarf.

• Make a mark for drilling out the hole through the top stay and in the centre of the top edge/rear edge of the auxiliary lamp

• Drill the hole. Use a 4.5 mm (3/16”) diameter drill bit

• Remove any swarf

• Position the top stay between both drilled holes so that the stay (1) can be cut to the correct length

• Shorten the stay (1) to a suitable length

• Tighten the top stay to the bumper and auxiliary lamps using screws, nuts and toothed plate connectors.

  
  

  Note! Do not install a toothed plate connector on the screw for the bumper. There is a risk that the screw would rub against the paint on the bonnet.

  
  

• Bend the top stay down to the bumper using a screwdriver. This is to prevent the lower edge of the bonnet catching when closing.

• Clean the painted surfaces at the front and lower edges of the bonnet, opposite the points where the top stays are secured in the bumper. Use a mixture of 30% windscreen washer fluid and 70% water

• Wipe dry.

• Press the masking tape firmly into place at the front and lower edges of the bonnet, opposite the points where the top stays are mounted in the bumper.

• Turn the ignition key to position II

• Reconnect the battery negative lead.