Single to Dual Headlight Conversion

Tools Needed:
Special Thanks to: NA850
2 DUAL Bulb headlights 2 Corner Lights
2 Trim Pieces Wiring Harness from 95+ Volvo 850
Sockets
Dremel and Bits

Here's the wiring harness. No you do not have to get the ENTIRE thing but I like to be careful.(The only plugs you will use are the grey ones)

Dual Headlight Wiring Harness

Start by removing 2 bolts that hold in the hood latch on the driver side. You need to do this so you can reach 2 bolts that hold in the headlight.

Right headlight

With the hood latch unbolted carefully move it out of the way.   

Hood Release

Then start removing the bolts that hold in the headlight housings.

Conversion headlight

Once you have everything unbolted. Remove the Corner lights. Then take out the headlight housing.

Wiring

Now take the headlight wiring and cut the wires so you can attach the new harness.

Dual headlight wires

Now take your new plug(The grey one). And match up the wires and solder them together. Once done with that put a generous amount of electrical tape over each individual wire. Then tape all the wired together.  

New Harness

Now you can remove the trim piece. When installing the new trim piece(if u have the wipers installed) the shaft for the wiper is to low to pass through the hole on the trim.

Trim Piece

The easiest fix for this is to drill a new hole below the orginal opening.  Now the side of the trim will need to be trimmed to allow clearence.  

Cut Trim

After modding the trim pieces you can now put in the new headlight. Rebolt the 3 bolts that hold the headlight housing in. Then Plug in your new socket to the headlights. Install your corner light. And put on your trim and assemble your wiper.

Install trim

Make sure that when you bolt back up your hood latch that it is set at the right height.
Being to low and the latch wont catch your hood and it will not lock down.

Left Side

The passenger side will just require you to take out a few more pieces.

Start by taking out some tubing(circled in yellow). And a black box(fault computer) with some wires going into it.(circled in white) You can see where I took it off of(look at the ballast then a little to the right)

12

Pull it out and you can swing it over to the right(look above the spark cover). To take the black box off just pull up and place it below everything.

Next pull out another tube that is below where the black box was.(circled in green)

Finish up

It easily pulls straight out.

Finally remove the Windshield Fluid tube.(circled in red)
After you get all of that removed begin the same process that you did for the other side. Then reinstall and check your lights then enjoy the excellent upgrade.
Project S60
Message Board
Join Volvospeed
VS Deals
Cosmetics & Performance
Repairs & Maintenance
Reviews
Gallery
Dealerships
Reference
Search


  
Sponsored Links: