Installation kit for auxiliary lamps (1997, 1998)

• Make a note of the radio code
• Disconnect the battery leads
• Remove the battery.

• Remove the soundproofing panel (1)
• Locate the accessory duct. Remove the rubber grommet (2)
• Cut off one of the cut-outs. Adjust the size of the hole for the green/orange (GR/OR) cable from the kit.

• Remove the cover (1)
• Insert the 6-pin yellow (Y) connector for the auxiliary lamp cable harness through the hole in the control panel. Connect the connector to the switch for the auxiliary lamp
• Install the switch in the control panel.

• Connect the relay to the cable harness for the auxiliary lamp
• Clamp the relay to the bracket for the switch units. Use a tie strap
• Secure the cable harness using a tie strap.

Illustration A applies to left-hand drive cars

• Detach the accessory duct from the holder. Remove the rubber grommet (1)
• Cut off one of the cut-outs (2) in the grommets. Adjust the size of the hole for the green/orange (GN/OR) cable
• Remove the connector (3), ignition cable (4), hose clamps (5), intake hose (6) and the preheating hose (7)
• Detach the air cleaner (ACL) housing and fold to one side over the engine.

Illustration B applies to right-hand drive cars

• Detach the accessory duct from the holder. Remove the rubber grommet (1)
• Cut off one of the cut-outs (2) in the grommet. Adjust the size of the hole for the green/orange (GN/OR) cable.

• Insert the green/orange (GN/OR) cable through the rubber grommet and the accessory duct into the passenger compartment. Ensure that the black casing enters the rubber grommet in the engine compartment to form a seal. Welding rod (wire) can be used to help insert the cable through, if necessary
• Reinstall the rubber grommets on the accessory duct in the passenger compartment and engine compartment.

• Remove the pre-routed yellow (Y) 8-pin connector (1). Remove the cover plug (2)
• Open the catch for the wiring on the yellow connector. Connect the green/orange (GN/OR) cable (3) to terminal 7
• Reinstall the connector
• Reinstall the soundproofing panel.

Illustration A applies to left-hand drive cars

• Route the green/orange (GN/OR) cable (1) under the cable duct
• Connect the connector (2) to the connector (3) from the cable harness for the auxiliary lamp
• Connect the black (SB) cable (4) to the pole piece on the battery negative lead using nut (5)
• Route the cable harness for the auxiliary lamp through the openings (6) on the radiator member.

Illustration B applies to right-hand drive cars

• Route the green/orange (GN/OR) cable (1) between the spring strut turret and the radiator expansion tank. Continue along the side to the bonnet catch
• Connect the connector (2) to the connector (3) from the cable harness for the auxiliary lamp
• Connect the black (SB) cable (4) to the screw in the bonnet catch. Remove the screw and position the cable in between. Tighten the screw again
• Route the cable harness for the auxiliary lamp through the opening (5) on the radiator member. Secure the cable using tie straps (6) at suitable positions.

• Check the clearance between the bonnet catch and bumper. If the clearance is below 4 mm, the bumper must be adjusted downwards.

• Remove the horn (1).

Illustration A

• Position the auxiliary lamp bracket (1) centrally
• Make a mark using a sharp object to cut out the bumper cover where it is in contact with the mounting (2)
• Measure approximately 5 mm (13/64") to the left of the auxiliary lamp bracket. Mark out the rest shown in the shaded area (3)
• Cut or saw out according to the new markings.

Illustration B applies to turbocharged cars

• Remove the clips (4)
• Cut a 40 mm deep, 25 mm wide groove (5) in the air baffle.

• Wipe dry the underside of the bonnet
• Secure the two transparent pieces of tape to the underside of the bonnet as protection against the auxiliary lamp bracket.

• Reinstall the auxiliary lamp bracket
• Mark and drill two 4 mm (5/32") holes (1).

Use auxiliary lamps recommended by your Volvo dealer.

• Separate the auxiliary lamp by removing the screw (1) and the cover
• Press lightly on the lens (2)
• Position a screwdriver (3) between the insert and lamp housing and pry gently.

• Install the lamp housing using the screw and nut in the front position on the auxiliary lamp bracket. Finger tighten.

Applies to larger/heavier auxiliary lamps

• Install the mounting bracket. See point en-GB0900c8af81e3dea6#KC08716567.

Illustration A

• Tighten the screws (1) on the auxiliary lamp bracket (2) a few turns
• Position spacers (3) between the radiator member and screws (1). Tighten the screws.

Примечание: Do not damage the radiator. Use a ring wrench. Check that no wiring is trapped.

• Tighten the auxiliary lamp bracket in the bumper rail using two pre-sunk screws (4). Tighten to 4 Nm (3 lbf. ft.)
• Route the wiring (5) to the auxiliary lamps
• Reinstall the horn.

Illustration B

Applies to cars with turbochargers (TC)

• Reinstall the air baffle (6). Install the clips
• Reinstall the horn.

• Route the wiring through the rubber grommet (1)
• Install cable terminals.

• Remove the backing from the tape on the cable protection
• Position the wiring on the left-hand side of the auxiliary lamp bracket. Install the cable protection.

• Close the bonnet carefully. Check that the underside of the bonnet does not catch the auxiliary lamps
• Slacken off the screws/nuts (1) slightly. Adjust the auxiliary lamps so that they are as close to the bonnet edge as possible
• Tighten the screws /nuts (1).

Applies to heavier/larger auxiliary lamps

• Примечание: > Use an extra mounting bracket to relieve the load on the auxiliary lamp bracket when installing heavier auxiliary lamps.

• Wipe dry the surface on the bumper where the mounting bracket (1) will rest

• Mark and install the pieces of tape (2).

• Connect the grey (GR) cable to the lamp cable via a socket housing
• Connect the black (SB) cable to ground on the lamp insert.

H3 bulbs must be purchased separately.

• Assemble the auxiliary lamp.

• Secure the wiring using a tie strap (1) on the auxiliary lamp bracket.

Illustration A applies to left-hand drive cars

Illustration B applies to right-hand drive cars

• Check that there is a 30 A fuse in terminal 16 in the fusebox.

• Reinstall the air cleaner (ACL) housing and connections
• Reinstall the battery
• Connect the battery positive lead
• Turn the ignition key to position II
• Connect the battery negative lead
• Enter the anti-theft radio code

• Check the function according to the relevant statutory requirements. Applies to Sweden: Auxiliary lamps may only be used together with high beam.

• Adjust the distribution of light by slackening off the screws/nuts slightly as the auxiliary lamps are secured to the mounting. See illustration point en-GB0900c8af81e3dea6#KC08716566.

Wiring diagram

• A - Auxiliary lamp switch
• B - Relay
• C - Connector
• D - Cable harness
• E - Ground lead
• F - Auxiliary lamps
• G - Fuse 30 A
• H - Connector, existing yellow
• I - Connector, from the kit.