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Old 04-30-2007, 04:34 PM
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Default Single to Dual Bulb Headlight Conversion

This is not my writeup. This is NA850's from Volvospeeds writeup

Single Bulb To Dual Bulb Headlight Conversion
, How To Write Up:

First gather your materials:
- 2 DUAL Bulb headlights
- 2 Corner Lights
- 2 Trim Pieces(goes below headlights)
- Wiring Harness from 95+ Volvo 850 (Grey plug)
- Tools
- Drill & drilling bit
- Dremel
Here's the wiring harness. No you do not have to get the ENTIRE thing but I like to be careful.(The only plugs you will use are the grey ones)

And the tools.

I began on my drivers side.
First begin by removing 2 bolts that hold in the hood latch. You need to do this so u can reach 2 bolts that hold in the headlight.

Once you have the hood latch unbolted carefully move it out of the way.(I put it on top of the battery)
Then start removing the bolts that hold in the headlight housings.

Once you have everything unbolted. Remove the Corner lights. Then take out the headlight housing.

Now take the headlight wiring.

And cut the wires.

Now take your new plug(The grey one). And match up the wires and solder them together. Once done with that put a generous amount of electrical tape over each individual wire. Then put more over all three wires as a whole.

Now you can remove the trim piece. When installing the new trim piece(if u have the wipers installed) the shaft for the wiper is to low to pass through the hole on the trim.

So what I did is take a drill bit and cut a little hole below the hole.

After I cut the hole for the wiper shaft I ran into another problem the end of the trim piece is to long and when installing it will hit the header panel.

Easy fix, just dremel off the excess.

After modding the trim pieces you can now put in the new headlight. Rebolt the 3 bolts that hold the headlight housing in. Then Plug in your new socket to the headlights. Install your corner light. And put on your trim and assemble your wiper.

Make sure that when you bolt back up your hood latch that it is set at the right height.
Being to low and the latch wont catch your hood and it will not lock down.

After stepping back and really noticing there will be a little gap between the hood and the headlight.(This is a good excuse to buy some eyelids.)

[IMG] 6d2f616c62756d732f6b3137362f6c6f6f6b6261636b313238 2f566f6c766f2532303835302f4e6577253230486561646c69 676874732f7965732d312e6a7067">

That was easy right..Well the passenger side is not harder it will just require you to take out a few more pieces.

Start by taking out some tubing(circled in yellow). And a black box(fault computer) with some wires going into it.(circled in white) You can see where I took it off of(look at the ballast then a little to the right)

<img src="[/IMG]

Pull it out and you can swing it over to the right(look above the spark cover). To take the black box off just pull up and place it below everything.

Next pull out another tube that is below where the black box was.(circled in green)

It easily pulls str8 out.

Last remove the Windshield Fluid tube.(circled in red)

After you get all of that removed begin the same process that you did for the other side. Then reinstall and check your lights then enjoy the excellent upgrade.

Old 03-16-2009, 07:03 AM
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It is such a useful article and I found a lot of information with the help of this article. Thank you so much for sharing.

Old 03-17-2009, 07:43 PM
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Location: Orlando, Florida
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Can you fix the pics?
Old 03-18-2009, 06:33 AM
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Originally Posted by tech View Post
Can you fix the pics?
Nope, don't have them anymore and don't know where I got them.

Sorry folks.
Old 03-18-2009, 06:47 PM
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Location: Orlando, Florida
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OK thanks.
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