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Discussion Starter · #1 · (Edited)
Recently I installed a 32" curved light bar on my 2007 XC90 V8. There is going to be a picture with different color outlines, then below the picture there will be a corresponding color name and a description. I'm sorry for the phone pictures, but I don't have a decent camera.

Links to what I used:
Light Bar on Amazon: http://www.amazon.com/gp/product/B00P8ZAR6E?psc=1&redirect=true&ref_=oh_aui_detailpage_o06_s00
Wiring Harness and Switch: http://www.amazon.com/gp/product/B00VMUAHCS?psc=1&redirect=true&ref_=oh_aui_detailpage_o07_s00

NOTE: This was a 10+ hour in depth project. I did have to cut and sand small sections of the bumper to make the 32"fit. Any smaller size will fit without issues.

https://flic.kr/p/CNFyhPhttps://www.flickr.com/photos/[email protected]/
Finished Product!



https://flic.kr/p/CLKd42https://www.flickr.com/photos/[email protected]/
First Remove the front bumper. On the underside of the bumper in front of the wheel, there are two clips that hold the plastic parts that go around the fog lights. Pry these out with a clip tool (shaped like a large 2 pronged fork). The piece then comes up and out diagonally away from the car. It is attached to the silver trim, but pulling upwards releases the clips.
RED: There are only two bolts that hold the bumper to the frame. 10mm if I remember correctly.
YELLOW: The rest of the bumper is held on with clips. Simply use a bone tool (or flat-blade screwdriver. Be careful!) to pry the clips off.

https://flic.kr/p/CU3x6Dhttps://www.flickr.com/photos/[email protected]/
Closer in on the clip area.
YELLOW: Clips run inside the boxes. The oval indicates approximately where the clips are for the plastic fog light surround. When pulling the bumper off, make sure to unclip the fog lights and headlamp washer line.

https://flic.kr/p/CJuGwChttps://www.flickr.com/photos/[email protected]/
Bumper removed.
RED: Where the bolts attach.
YELLOW: Where the clips attach.

I worked on cutting the bumper first.

https://flic.kr/p/CLKec4https://www.flickr.com/photos/[email protected]/
YELLOW: There needs to be plastic left for this clip to reattach.

https://flic.kr/p/CrVxhLhttps://www.flickr.com/photos/[email protected]/
https://flic.kr/p/CRJMCUhttps://www.flickr.com/photos/[email protected]/
YELLOW: The silver accent piece needs to be removed. Clips are along both the horizontal and vertical parts. Four of mine needed to be pushed down with a screwdriver.

https://flic.kr/p/CLoSc3https://www.flickr.com/photos/[email protected]/
Silver accent removed.

https://flic.kr/p/CJuE9Shttps://www.flickr.com/photos/[email protected]/
YELLOW: Mark along the bumper for where to cut out. I used a dremel tool with a cut-off bit to cut it away.
RED: I had to cut a little more off because the bar is so big :facepalm:

https://flic.kr/p/CLKer2https://www.flickr.com/photos/[email protected]/
Bumper piece removed.
YELLOW: Cut along the line you drew. This picture is before I cut along the red line from the previous picture.
RED: Notice there is still room to replace the clip.

The bumper is finished for now. Replace the silver accent piece.

Mounting the light bar

I didn't take many pictures for this, but it is straightforward.

https://flic.kr/p/CNGzxxhttps://www.flickr.com/photos/[email protected]/
I marked the center of the bumper, and the center of the light bar. Then I lined them up, marked the inside of the bracket holes, removed the bar, then drilled the holes. Sizes will be different depending on the bolts used.

https://flic.kr/p/CRJMS1https://www.flickr.com/photos/[email protected]/
YELLOW: Test fitting the bolt. This is a really tight spot for a ratchet. I was able to do one "click" per left to right movement. The bolt is slightly off kilter because of how I had the bar tilted. This corrected when I tightened it down all the way.

https://flic.kr/p/CmzA8qhttps://www.flickr.com/photos/[email protected]/


Test fitting the bumper.

https://flic.kr/p/BWwKwuhttps://www.flickr.com/photos/[email protected]/
RED: I had to sand the silver accent to fit the 32" bar. I used a Dremel Stylus with a sanding drum attachment.

https://flic.kr/p/CJuH8shttps://www.flickr.com/photos/[email protected]/
YELLOW: It fits! I took an hour to do this alone, and I test fit the bumper probably over 100 times to get a tight fit that was the most invisible.

https://flic.kr/p/BWDU2Fhttps://www.flickr.com/photos/[email protected]/
I took the bumper back off to secure completely.
RED: Turn the bolt enough to secure with Threadlocker Red (high strength). Then re-tighten to completely snug. It takes a while at 1 "click" per back and forth. I'm pretty sure the nut was only spinning a millimeter or so per twist.

Re-secure the bumper, but leave the plastic fog surrounds off to leave access to the height adjustments on the bar.

Switch wiring--Disconnect the battery before doing this part!

https://flic.kr/p/CrVzWJhttps://www.flickr.com/photos/[email protected]/
https://flic.kr/p/CLeQkbhttps://www.flickr.com/photos/[email protected]/
I used a self tapping screw to secure the relay (far bottom left), and zip tied the wire that would normally go to a second light near the relay for future use.
YELLOW: Connect the red wire to the positive terminal in the engine compartment. there is a 12mm (I think) bolt that unscrews. Place the ring connector on the column, then re-tighten.
BLUE: Zip tie the switch wire to this hole in the plastic to keep it out of the way of moving parts.
WHITE:Run the switch wire here. It will enter the passenger compartment through the steering column boot.

https://flic.kr/p/CmzUBEhttps://www.flickr.com/photos/[email protected]/
I connected the black ground wire to one of the main ground screws. The included ring connector was too large, but still makes a good ground. I might go back and switch in a smaller ring.

https://flic.kr/p/CTtXJUhttps://www.flickr.com/photos/[email protected]/
Secure the extra wiring to the frame after connecting the harness to the light bar. Mine came with male/female spade connectors, but simple cartridge splices or soldering will work as well.

https://flic.kr/p/CD8dGGhttps://www.flickr.com/photos/[email protected]/
Steering column boot from the cabin. Behind the accelerator pedal. Notice I also have the right lower panel removed to run the switch into the center console area.

https://flic.kr/p/CRJLAJhttps://www.flickr.com/photos/[email protected]/
RED: Peel the outer boot back in direction indicated.
YELLOW: Run the wires between the inner and outer boot, then fold the outer boot back down.

https://flic.kr/p/CLKgbVhttps://www.flickr.com/photos/[email protected]/
YELLOW: For my switch, I cut a section of the console out next to the shifter. To remove this, engage the parking brake, turn the key to position 2, put the car in drive, and pull the shifter knob off. The trim piece then comes out if you pry between it and the cup holder cover. The shifter fascia is only attached with clips, and were easy to unclip. I then drew an outline of the switch on the console piece that I pulled out, and cut it out with a Dremel tool with a cut-off bit.

https://flic.kr/p/CtHvTWhttps://www.flickr.com/photos/[email protected]/
YELLOW: I had to sand out part of the plastic here to make the switch fit. I used a vacuum to collect the dust emitted.

https://flic.kr/p/BWwGsyhttps://www.flickr.com/photos/[email protected]/
YELLOW: All my wires connected per the included diagram. See why I had to sand that part out?

https://flic.kr/p/Cfct8Hhttps://www.flickr.com/photos/[email protected]/
Switch installed! Yes, it does say Zombie Lights :D , and the symbol lights up when it's on. The company, MicTuning, makes all sorts of other designs. Search rocker switch on Amazon and they will pop up.

Final Touches

Once you are done, raise the light bar to your desired position and tighten the locking hex bolts. Test it at night before you reinstall the plastic fog surrounds, I had to move mine up more.

Then reinstall the plastic fog surrounds, and make sure to replace the clips that go in front of the wheel. They are 2 parts. The outer part goes into the hole first, then the inner "pin" slides in to lock it in place.

Stand Back And Admire Your Handy Work!-- Note my light bar is brighter than my headlights, in broad daylight! I still couldn't look at it without hurting my eyes.
 

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Discussion Starter · #2 · (Edited)

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HOLY CRAP! That's a lot of installation work for a light! Good job!
 

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Yeah seriously I did mine without any of that effort :) good job though.

Heres mine. I tinted it yellow with headlight tint.



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Discussion Starter · #5 ·
Yes, it was an insane amount of work, and there were two of us working on it! But I'm OCD and any tiny detail or error would drive me nuts! I wanted it as integrated as possible, including the switch. Any smaller bar will work fine without all the cutting and sanding, but again, the OCD kicked in and I had to fill that gap completely. Otherwise it wouldn't look quite right to me. Ou2mame, do you have a link for that tint, or was it a local auto parts store? Eventually I will do that with the current bar after I hook up a 24" dedicated to brights that is higher on the car.
 

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On my year that's the largest I could go without cutting the bumper up because the space in smaller than yours. I believe I have a 24" bar. But I'm glad because it's already really bright lol

I used some tint off ebay that's guaranteed for 5 or 10 years or something. Go with gold yellow not neon yellow because the neon shows up as green with the led bulbs.

I like your switch, I was going to order one and mount it there but I got lazy and just stuck the switch that came with my harness in that spot. I might revisit the idea, but who knows.

Heres where I has to cut


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Discussion Starter · #7 ·
I was hoping for straight gold tint, I'll have to check it out! On the light bar, I wish the mounts would turn in instead of having to face out. It would be more compact and I wouldn't have had to cut so much. Your's looks nice and full in its place too! I just couldn't put a 10" in that spot and be happy. The switch was the easiest part for me. Frayed nerves while I was cutting, but it was simple. The sanding made me nervous because it was near electronics, but our high suction Kirby vacuum got all the dust. We definitely got our bars from the same company! If you don't mind me asking, how much was yours? Mine was about $65 or $70 for the bar.
 

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I paid 38 bucks I believe. I got it on Amazon or ebay I forget which. Probably amazon because we have amazon prime. I bought a pre-built harness for 8 bucks because it wasn't much more than making one. I tried to track down the seller of my tint but ebay won't let me go back that far. They actually sent me the gold tint for free after the neon yellow ended up very green so that was cool of them. Id like to recommend them if I could lol

After I opened it to put the tint on the inside, I didn't trust the water proofing so I sealed it with silicon. I'm sure it's fine but I had it laying around and figured it can't hurt. Then I tinted the outside to make it more yellow and cut down the light output a bit more. It's still very bright but not as eye piecing if another drive sees it. I did have a cop pull me over, but he just wanted to ask where I got it.

Mine is the bar with the spots in the center and wide angles on the sides. It throws a lot of light to the sides which is great. I got it mainly because of the deer population that we are seeing now here. It definitely comes in handy. You can see their eyes from very far away. I'd love to see it in the snow if it would actually snow here in new york.

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Would this amount of light be legal in bigger city areas???

I guess if you need the light... more power to you, but I wouldn't want to be on the receiving end of this. Must be like 'looking at the sun'! Yikes.
 

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Discussion Starter · #11 ·
Would this amount of light be legal in bigger city areas???

I guess if you need the light... more power to you, but I wouldn't want to be on the receiving end of this. Must be like 'looking at the sun'! Yikes.
Check your laws, but mine is ok because it replaces my brights. Ou2mame's is ok because he tinted it to cut down on the light output. A good rule of thumb is if you can't look at it, no one else can either. Being brights, no one will be looking at mine, so I didn tint it to get maximum light output for animals. Google a Bison. Or a bison wreck. Their eyes don't reflect, so you have to see their outline to spot them.
 

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Discussion Starter · #13 ·
Parts!

Opened the box.
https://flic.kr/p/CFojnMhttps://www.flickr.com/photos/[email protected]/

Curved for better flood beams at a wider angle.
https://flic.kr/p/CFoEiPhttps://www.flickr.com/photos/[email protected]/
https://flic.kr/p/BRbP3Yhttps://www.flickr.com/photos/[email protected]/

Included mounting hardware. It came with both nuts, I just forgot to put one in the picture. I didn't use the included bolts and nuts because they were too short.
https://flic.kr/p/BZWKEthttps://www.flickr.com/photos/[email protected]/
 

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Guys are you insane? Why did you ruin such a beautiful car?Now it looks cheap and awful. Sorry being honest...


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If I'm going to be real with you.. I did it specifically to ruin it. I'm not even a Volvo fan. I just buy them and make them look stupid to diminish their value as a company ;)

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Great write-up, even for just the bumper removal guide alone. There are a few mentions on removing the XC90 bumper on various threads here and on other forums, but this really shows you exactly what you're doing step-by-step (helpful for my OEM fog-light to LED driving light install as well as any light bar modifications). Thanks!

Now it's just time for a Euro-style tag to match the lines of the light bar and the bumper guard. ;)
 

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Discussion Starter · #17 ·
If I'm going to be real with you.. I did it specifically to ruin it. I'm not even a Volvo fan. I just buy them and make them look stupid to diminish their value as a company ;)

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Exactly my thoughts! Spend $200 to ruin the looks of my car! LOL! Personally I did mine for safety. See animals sooner, stop sooner. The looks are a bonus :D I think it makes it look meaner. But each to their own. That's why they make different trim levels.
 

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Discussion Starter · #19 ·
And how's the light? Good color and output still? :D
 
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