Auxiliary Headlights, Pictures and Instillation Guide.

**slalomskier** · 12-06-2011, 07:40 PM

Hey Guys, Check out the attached pdf for the volvo instructions, and my notes for extra info on the install. There will be a second post with more photos. The mount is designed for Hella lights, which use either an 8mm or 10mm mounting bolt. The holes in the bracket are 10mm. KC headlights use a 1/2 inch bolt (13mm). I just drilled the holes out to accept the ones I purchased. I am using KC daylighter #634 driving lights purchased from Amazon.com . From all the reviews I have seen, paying a little bit more for the KC's is worth it in terms of quality.

Attachment 3402

I purchased the wiring harness and attachment kit, which was part number 30772053. It cost about $180 from Gengras volvo of Meriden, CT. They were great and mailed it to me, with free shipping. There are two kits, one for pre-2003 and one for post 2003. The only difference is the color of the switch, charcoal vs black, and the one I got was $20 cheaper and the color was only a little different.

You begin by turning your key to position I (for manual transmission, turn it off and take it out). This is important as I believe the steps involving key positions are required for the computer to recognize the switch for the lights.

Disconnect the battery (negative lead). Wait 5 minutes to touch any of the electrical components.

Pop the hood, and remove the 6 plastic pins that hold in the front of the bumper. You push in the center part until it clicks, then pull them up.

Pull the bumper forward and slide your hand underneath. Push down the center of the clips holding the grill in and pull the top of the grill forward and wiggle it out.

Reach down to the right side of the air filter box and feel around to find the connector that we will be using. Then attach it to the wiring harness you purchased. Make sure you push it together enough that it clicks shut. Attach the relay to the harness as well, and clip it to the tab that is to the right of the air box (all directions looking at the hood from the front of the car). Feed the wires around the airbox, right next the the headlights, and sliding it forward through the grill. use the hole in the bottom of the gril, second from the left.

Replace grill, reattach bumper

Remove the licence plate

Remove the licence plate bracket with a torx wrench.

Screw the mounting bracket to the car without any spacers. Use the lower holes for the xc70.

Drill out the mounting holes (the top pair) with 9/32nd bit. Make sure this is all level. You will drill through about a quarter inch of plastic, and then about 2 inches of air, before hitting the metal bumper. Drill through the bumper as well. Make sure put the bit through a few times to make sure the hole is very clean.

Attachment 3398

Remove the bracket, and re-drill the plastic outer bumper with a 15/32nd bit. Drill until the bit just grazes the metal bumper. DO NOT DRILL INTO THE METAL with the larger bit. Also make sure that this is a clean hole.

Put the metal spacers in the hole. Choose the set that sticks out 9mm, or about the width of a 3/8th inch bit from your set.

Very loosely attach the bracket using the holes and bolts for the licence plate mount. You are going to use the spacers at this point. The order of things goes like this, from away from the car to the metal bumper. The metal plate mount, the headlight bracket, the plastic spacer, then the bumper.

Now it is time to finish mounting the bracket. Use the two bolts that come with the kit. they are tapered so that they thread their own holes. they start pretty hard to turn, but it gets easier.

Attachment 3400

Now you are done mounting the bracket. Bolt the lights on. Complete the wiring (blue is positive).

Put a fuse in slot 2 while you have the hood open (for 2001 to 2004 year cars). I think it is slot 5 for 2005-, but check your user manual.

Now this stuff just applies to 2001-2004 models. The attached manual explains other years/models.

Though I did, I do not think it is necessary to remove the radio.

Put the parking brake on, move the gear selector into drive.

Use a plastic tool, or very small screw driver, to pull out the sides of the plastic pen holder below the false buttons.

Then use the same tool to pull out the oval with the false buttons that
surrounds the 12v socket.

Attachment 3401

Install the new button and replace the cover

Turn the key to position II

Reconnect the battery

Note, the aux lights will only work when the high beams are on.

Enjoy!

Attachment 3405

http://accessories.volvocars.com/Acc...ar=XC70%202002

**ifnt420** · 12-06-2011, 09:03 PM

Love the Java Brown.

**Ocean Racer** · 12-06-2011, 11:47 PM

Nice!
A few locals are running these - with great results.

9-32v 60 x 3w SUPER HIGH POWERED LED LIGHT BAR
Lumens 12,000
Colour 6000K

**brianblank** · 12-07-2011, 04:55 PM

Nice, I am very interested in doing this. Looking forward to your additional pictures, hopefully some of the wire harness installation (that is the part that I am worried about most)

**slalomskier** · 12-09-2011, 10:18 AM

Hey Brian,

The wiring harness is so easy to install that I don't know what I would have photographed. If you have an requests for a specific shot, let me know. I will write another description below.

The wiring harness has 4 ends to it. One end goes to the lights, one end is a ground that can be bolted anywhere on any metal in the car (there are three such bolts right next to the air filter box). One end goes to the relay provided in the kit, which can be put anywhere in the car (there is a little metal tab it can clip on to between the air filter box and the side of the car). The only thing that is connected to the wiring system of the car is one plug, the fourth part, that connects to a plug that is unused and already in the vehicle. It is located at the bottom of the air filter box, between it and the side of the car, and you can reach down and grab it, pull it up a little bit, and then connect the proper plug from the wiring harness. Then all that is left is to install the switch in the car. The switch is not attached to the harness in any direct way. It is completely separate, and just tells the computer what to turn on. the computer is already programmed to know that one of those options are the auxiliary lights, which just were never installed. Put the switch in, put the proper fuse in, and you are all set!

**brianblank** · 12-09-2011, 04:22 PM

Thanks slalomskier, your description was helpful. I was concerned about running the harness into the switches on dash, but it sounds like that is not necessary.

**Ozzie** · 12-09-2011, 04:34 PM

Great write-up. Thankyou.

oz

**squirrel_master** · 12-30-2011, 07:07 PM

if you have the aux lights on and you turn off the high beams(both aux lights and high beams are off), do you need to turn the aux lights back on with the supplied switch or do they come back on with high beam operation?