2007 S80 Headlight Insulation failure
 

Warning light on dashboard indicated right front headlamp out. Repair shop removed and replaced original component with new component. Internal inspection of light assembly revealed missing insulation(photos attached) on wiring harness causing a short circuit which also ruined the headlight igniter and control module. Shop stated that this issue is NOT uncommon with Volvo lighting systems. The current concern is the same condition is present in the left(driver) headlight and could cause a short and fire within the headlight assembly. Correspondence with Volvo resulted in no resolution of the issue and lack of concern for the reliability of installed components or possible safety concern for their product. Anyone else have this issue and was it resolved by Volvo? Customer care has basically told me "Too Bad. Sorry we can't resolve this for you." So, currently filing an NHTSA report of a safety concern.

https://cimg1.ibsrv.net/gimg/volvofo...76249ce72c.jpg
2007 S80 Passenger Headlight
https://cimg2.ibsrv.net/gimg/volvofo...709b79795d.jpg
Failed insulation 1
https://cimg3.ibsrv.net/gimg/volvofo...f20cebcda3.jpg
Failed insulation 2
https://cimg4.ibsrv.net/gimg/volvofo...d2dff2fd22.jpg
Failed insulation 3
https://cimg5.ibsrv.net/gimg/volvofo...16e1d11021.jpg
Failed insulation 4
https://cimg6.ibsrv.net/gimg/volvofo...4d7ddd438d.jpg
failed inulation 5
https://cimg7.ibsrv.net/gimg/volvofo...00dcde5ca5.jpg
Failed insulation 6
https://cimg9.ibsrv.net/gimg/volvofo...0de17a4d60.jpg
Shorted igniter and control module

Certainly - have seen many Volvo headlamps for all years with damaged wiring. If you want just replace the harness inside the lamp. Attached is a sample harness picture and the parts page for an active headlamp. Harness is about $50
https://cimg1.ibsrv.net/gimg/volvofo...c70f154aa6.jpg
https://cimg2.ibsrv.net/gimg/volvofo...bd3f5356fc.jpg

Thanks for the feedback and link. I may end up going that route. Shame that Volvo was/is so nonchalant about the issue. Now we wait and see if NHTSA will do anything. No betting on it.

Also found similar at this link:

https://www.suburbanautoparts.com/oe...Y4LWdhcw%3D%3D

Rktman