http://www.volvoforums.org.uk/showthread.php?t=67584

 

Really interesting. I stumbled upon this thread in 2018 and see that you're referring to the same problem I have with a components manufacturer located in North Dakota where I live! Digikey. Ha, I'll be able to drive over and pick it up directly at the warehouse.

 

Just ordered the relays from Digi-Key. Will be doing this on my daughter's '03 S40 as soon as the parts come in.

The tickets she's received from having a headlight out are getting costly. haha

 

Plan B is to find a used CEM. On the gen1s they are not paired to the car so you can simply swap one in. I used car-part.com to find a local yard with an S40 and paid $65 for the CEM used. I need to look to see if I have the old one for somebody to practice a rebuild on..

 

Success.

About $8 in relays (I replaced both) and an hour of my time and she's back in business.