Auxiliary Lights, Installation Kit

Auxiliary lights, installation kit, S80




























Auxiliary lights, installation kit, S80

Preparations




Auxiliary lamps Alpha 175 with P/N 9166090 are recommended for this installation kit.
- Turn the ignition key to position 0.
- Remove the ignition key from the ignition switch.

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




- Detach the top edge of the grille by pressing in the centre of the eleven clips until a clicking noise can be heard. Remove the clips by pulling them straight up. The grille is fitted with six clips on cars from model year 2003.
- Pull the top edge of the grille forward and fold aside the rubber edge that is inside.




- Position something soft as a spacer to form a gap between the grille and the car's panel.

Installing the cable harness




- Thread in a wire between the headlamp and the grille and then on into the engine compartment.

Note! Do not damage the painted surfaces.

- Take the cable harness from the kit. Tape the shorter cable without connectors in along the long cable without connectors.
- Tape the long cable without connectors to the end of the wire in the engine compartment. Pull the cable out past the grille.




- Route the wire and cable past the rubber seal inside the radiator grille and out through the fifth hole from the left in the radiator grille. On cars from model year 2003 the wire must be routed out through the second hole from the left, furthest down in the radiator grille. The cable must be routed out exactly where the left-hand auxiliary light shall be fitted.
- Route the cable out through the hole.




- Remove the intake manifold (1).




- Lift up the air cleaner (ACL) module by detaching it from its three mountings: one at the rear, one in the front and one at the left-hand end face. Use a small socket with an extension to press the four catches on the clips together. Detach the air cleaner (ACL) module by pulling it straight up.




- Detach the vacuum hose at the front of the air cleaner (ACL) module by lifting it from the mounting.
- Move the air cleaner (ACL) module aside and secure it using a cord.
- Move the air cleaner so that the stainless bracket underneath is visible.




- Remove the screw in the bracket. Connect the cable harness ground cable by tightening it into the bracket with the screw. Tightening torque 24 Nm (18 lbf.ft.).




- Take the relay from the kit and connect it to the cable harness. Press it into the connector firmly.
- Plug the cable harness connector into the pre-routed cable harness connector. It is located between the air cleaner (ACL) module and the body, behind the left-hand headlamp.
- Thread a tie-strap through the relay mounting eyelet (2).
- Clamp the relay (1) with the connection downward, into the cable harness behind the left-hand headlamp (3).
- Reinstall the air cleaner (ACL) module, vacuum hose and intake manifold.

Installing the auxiliary lights bracket




- Remove the number plate by tapping the moulding at the bottom of the number plate to the side with a piece of wood. The moulding is firmly secured so do not damage any painted surfaces. Remove the number plate.
- Remove the screws (1) and the number plate holder.




- Take the auxiliary lights bracket (1) from the kit, and install it in the same holes (2) as the number plate (use the upper holes in the bracket).
- Mark out the drilling position of the two upper holes (3) for the auxiliary lights bracket.
- Drill using a - 7 mm (9/32") diameter drill bit in the centre of the holes (3), through the bumper cover and through the bumper rail that is approx.80 mm (3 5/32") inside.

Note! Keep the drill horizontal.

- Remove the screws and auxiliary lights bracket.




- Drill the holes (1) to the correct dimension with 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 that has the dimension - 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! Keep the drill horizontal. Check that the drill holes are free of plastic swarf by shining a torch into them.




- Check that the surface (1), which the socket shall support against, is free from plastic.
- Install the two spacer sleeves, with a length of approx. 81 mm (3 3/16"), into the holes.

Note! The spacer sleeves must protrude approx. 1mm (1/32") from the bumper cover.




- Install tie straps (1) in the holes in the auxiliary lights bracket, but do not tighten them yet.
- 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 in through the radiator grille.
- Tighten the tie straps.
- Tighten the two screws to 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 in the number plate holder.
- Install the number plate by pressing on the plastic moulding at the bottom, over the number plate and holder, until a number of clicking noises is heard. Press in along the full length of the moulding.

Installing and connecting the auxiliary lights




Always 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 gently.




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




- Route the cable harness through the rubber grommet (1).
- Install the cable terminals.




- 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.

Illustration A





Applies to cars up to and including model year 2005
- Open the cover to the fuse holder in the engine compartment.
- Look on the inside of the cover to determine the position for the fuse (position 2 or 10).
- Take a 20A fuse from the kit and install it in the correct position.
- Reinstall the cover.

Illustration B





Applies to cars from model year 2006
- Open the cover to the fuse holder in the engine compartment.
- Take a 20A fuse from the kit and install it in position 5.
- Reinstall the cover.




- Carefully prize away the gear lever panel (1) using a weatherstrip tool.




- Move the gear selector lever to the rear position.
- Pull the panel (1) with the gaiter backward, as far as possible.
- Remove the screws (2) from the dashboard environment panel (3).




- Angle out the dashboard environment panel so that there is space for a couple of fingers between the centre console and the short side of the dashboard environment panel.
- Detach the dashboard environment panel by pulling it downwards while maintaining the same angle. Some force is required because the panel is firmly installed.
- Detach the connectors on the back. Place the dashboard environment panel to one side. NOTE: If any of the outer hooks break off, these must be repaired. The method for this can be found in the Workshop Manual in the section covering the dashboard.




- Position the dashboard environment panel as illustrated.
- Detach the surround (1) by carefully pressing down the three catches (2) in the holes (3) using a small screwdriver, and at the same time prizing out the surround using a thin weatherstrip tool. Start at the 12V socket (4) and prize up one corner. The surround is firmly installed, so take care of the parts. NOTE: A surround with three button locations may need replacing with a surround with seven button locations. This is available for purchase separately.




- Remove the dummy button and install the new switch (1). The switch can be located in any available position.
- Reinstall the surround and the cigarette lighter.
- Plug in the connectors to the dashboard environment panel and reinstall the panel.
- Reinstall the gear lever panel.

- Align the auxiliary lights.
- Tighten the two screws.
- Install the protective caps on the screw heads.

Installing the top struts




- If the lights vibrate and this is distracting then top struts can be installed. They must be secured in the horn's mounting point (1). See steps 30-34.

Applies to cars up to model year 2002




- Detach the top edge of the grille by pressing in the centre of the eleven clips until a clicking noise can be heard. Remove the clips.
- Pull the top edge of the grille forward.
- Put your hand into the inside of the radiator grille. Press up the four catches that are evenly spaced in the top edge.
- Pull the radiator grille out at the top edge until the catches release.




- Detach the radiator grille at the bottom by inserting a small screwdriver in the openings and pressing the three catches down.
- Remove the radiator grille and place it to one side.




- Take the top struts from the kit.
- Unscrew the screws holding the horn and install the top struts using the same screws. Tighten to 10 Nm (7.3 lbf.ft.).
- Reinstall the radiator grille and grille.

Applies to cars from model year 2003




- Take the top struts from the kit. Cut or saw away material from one end so that the strut can be threaded onto a screw without unscrewing the screw completely. File off any unevenness and burrs. Repeat on the second top strut.
- Partially unscrew the two screws holding the horn. Thread an articulated wrench in through the holes in the radiator grille and turn with an adjustable spanner.
- Thread the cut-out ends of the struts through the radiator grille, and in beneath the unscrewed screws.
- Make sure that the struts are fitted firmly into position. Tighten the screws to 10 Nm (7.3 lbf.ft.)

Applies to all models

- Adjust the angle and length of the struts. Screw them into the auxiliary lights with screws from the kit.