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S60 & V70 Projector Retrofit

Published on August 1, 2011 by Teh Volvo

Needed items:
-All necessary tools (flat head screwdriver, many size hex keys, 10mm socket, 13mm socket)
-Morimoto Mini H1
-Heatgun
-H1 Hid Kit Example: Kensun 6000k Slim H1 Kit
-Projector Shrouds
-Dremel

1. Disassemble the front end to get out the headlights
a. There is a thread to remove headlights, but it is VERY simple.

2. Remove headlights (be sure to disconnect and plugs going to the headlights.

3. Remove all of the bulbs inside of the headlight.

4. On your low beam spot, there is a prong that is used to hold your bulb in, on that metal piece, there is two torx bolts holding in the bulb shroud. Remove that, so your projector back can fit through the back of the headlight.

5. Now on to remove the lenses: Lens removal instructions

6. Once you have removed the lens, it is time to test fit your projector in the housing.
a. Keep in mind, that the back of the projector needs to be center in the whole the low beam bulb was in.
b. In the projector kit you buy, it should have some adapters and vibration resistant washers.

The one you will need are H7.

Washers
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c. Once you have tested the fit of your projector, you will have to do some cutting for clearance.

7. On to making clearance for your projectors by cutting here:

Lens Retrofit
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8. Once you have your projector fitting well, you need to make your fit your shroud.

a. Use e46 shrouds which look like this:

Test fit projector in lens
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b. Due to the size of the shrouds, you need to cut the shrouds to fit in the headlight.

Projector retrofit
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9. Once you have your projector and shrouds fitting in the headlight, you need to mount your projector into the headlight.
a. Insert your projector into the spot you made for it in the headlight.

IMPORTANT: MAKE SURE WHEN YOU MOUNT YOUR PROJECTOR THAT THE BACK OF THE PROJECTOR LABELED TOP IS SITTING UP. THIS MAKES YOUR BEAM.

Wiring and mount
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b. After the projector is sitting in your headlight correctly put the H7 adapter on the back of the headlight, aligning the projector.

Projector before chroud
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c. Once you have put your adapter in, use the retaining nut to secure the projector in the headlight.
d. Once that is done, find a way to mount your modified shroud to your projector. (Mine had a retaining ring that fit inside the shroud, and sandwiched it to the projector.)

10. Once you have all of that done, you essentially are done. All that is left is to properly align your cutoff from your light, and then put your lenses back together.

Final steps
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Thanks for reading. Remember, DO NOT TOUCH THE LENS OF THE PROJECTOR OR THE BULB YOU PUT IN THE PROJECTOR!

Light cut off
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Again a special thanks to Teh Volvo for this review.

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