My 2004 S60 2.5T, 167,000 miles has a headlight issue on the driver's side. High beams work, low beams do not. All lights are functioning normally except my driver's side low beam bulb.

• I've replaced the both sets of bulbs two times for good measure making sure that I'm using the correct part. These are standard bulbs not HID and have not resolved the issue
• I've checked both fuses in the box under my hood (for driver's side and passenger's side) and they were functioning normal
• I've checked both fuses (left and right) in my passenger cabin which were both functioning normal
• I looked for any fowl wiring that had visible damage inside the headlight fixture after removing it
• I checked for circuit continuity at the the low beam bulb socket, high beam socket, fuse box under hood and fuse box inside cabin--everything checks out. I was able to pass 12 volts from an external battery through to the headlight socket

I'm assuming that the wiring harness is in good condition and that this is a bad relay. Digging around forms I see that relays can fail from hot conditions and always being on when the car running day/night. It seems to me like that's the most reasonable explanation. The actual component isn't that expensive to replace, and I feel semi-comfortable spilling the board and replacing the suspected bad relay. It would be nice if there were a youtube video or post with photographs specific to an S60 but I haven't found any yet. Anything out there you guys could share?

Does anyone have some guidance on this issue? Hopefully I'm headed in the right direction. I could use part numbers and any diagrams available. Also, if this is a high risk component to fix yourself I'd take the advice to bring my car in, be it a defeated man but one who still has a drivable vehicle without a fried computer. I feel up to replacing the relay if there aren't any major additional items like reprogramming software that come along with it.

Any help appreciated.


Dan

 

I have the same issue, i have taken out both head light units, tested and compared them and thay both work fine.

the wire in the plug to the passanger light gives out 14v and the wire to the driver light is almost zero, it is actualy 0.5v with ignition on regardless of the light on or off.

did you find your answer to the problem?

im going to just run a completely new single core wire from the fuse box and tye wrap it to the wiring loom if i carnt come up with a better plan soon.

 

the low beam relays are likely to be housed within the CEM. (common Volvo design starting around 2000). You need to look a wiring diagram to confirm then probe test to see if you have voltage at the headlight connector, then out of the CEM and finally into the CEM.

The CEM (central electronics module) can be rebuilt or replaced but note on the newer models, the CEM is paired to the car, so any replacement would require dealer programming.

Check out Youtube for vids (ie Volvo CEM) or go to a service that rebuilds CEMs like Xemodex or Midwest ABS for more info to see if your symptoms match up.