Volvo Auxiliary Light Mounting and Wiring Kit
Today, I completed the installation of the Volvo OEM Auxiliary Light Kit. The kit consists of a front bumper mounting bracket which can be used to install mostly any standard fog or driving lights. The bracket mounts under your number plate, and the number plate then mounts to the bracket. It also includes all of the necessary wiring, as well as a necessary fuse, and a switch which installs below the climate control in the switch bank. The rest of the wiring is pre-wired in the car. *NOTE* This is something not mentioned in any of the Volvo documentation. The lights will only work WHILE the high beams are activated. While the high beams are on, you can press the button to turn on the auxiliary lights, so you have a choice as to whether or not you'd like to use them. The car will remember the setting from the previous time you used your high beams. There is an LED on the switch which illuminates when the lights are on. Depending on your local regulations, it may be necessary to fit plastic covers on the lights when they're not in use. Technically in Pennsylvania, these can't be used on the road, however I'll be using them only on the days when we get extremely heavy snow on my commute.
Note: The XC90 kit does not appear to be available from Volvo. However, I used the V70/XC70/S60 kit, and it contained all the necessary parts, and everything fit and worked perfectly. There appears to be no discernible difference between the two kits.
XC90 Kit: NO LONGER AVAILABLE
V70/XC70/S60 Kit: 30772053 - $144.56 (From Tasca)
You'll also need to purchase a pair of lights. Volvo has their own lights which appear to be Hella 500 lights repackaged in Volvo boxes. I elected to go ahead and order a set directly from Hella for a cost of around $60. There are several different types for several different results. I wanted lights which would stay low to the ground, and would help me when driving in heavy snow, so I went with the fog lights. There is also a promo photo from Volvo shown below so that you can see the size and shape of the actual bracket. If you have a European Union style number plate, the bracket is completely covered by the plate.
Volvo Installation Instructions:
Click Here for a PDF of the detailed installation instructions as issued by Volvo.
Some Installation Notes:
First of all, the instructions are wrong with regard to the procedure for disconnecting the battery. Before disconnecting the battery, place the ignition to position 1. Then, once you complete the installation, place the ignition in position two, and then reconnect the battery. The battery must be disconnected for a minimum of 5 minutes, however it'll take you quite a bit longer than this to complete your installation. So, there's no reason there should be any issue here. Just pay attention to the key position. This is the procedure which allows the CEM to learn the positions of the switches in the switch bank.
The pre-routed wiring in the car terminates next to the airbox behind the drivers side headlamp. This photo shows that plug with the kit wiring harness plugged into it. This photo is looking straight down between the airbox and the drivers side front fender.
The Volvo installation instructions are fairly unclear as to where to ground the wire harness. I used the highly visible ground points next to the airbox.
Ultimately, you'll end up routing the ends of the wire harness through the center bumper grille like so. There are two sets of blue and black wires. The longer set obviously goes to the passenger side. The Hella lights also have blue and black wires, so hooking them up is quite obvious. I simply spliced the wires together, rather than following the Volvo instructions which assume you're using the OEM volvo lights.
I wrapped the wiring with electrical tape so there are no bare wires, however I will be going back and covering it with the accordion style wiring loom for added protection.
One last pic showing the installation of the switch in the main switch bank. You can install the switch into any empty slot. The car will learn where it is. Don't forget to insert the fuse in the under hood fuse box. It is labeled for the auxiliary lights on the sticker under the fuse box lid, and in my car it was the only slot in the fuse box which was missing a fuse.
Pics Showing Different Light Modes:
Low beam headlights (Active bending bixenon) and LED running lights.
Original daytime running lights, along with the retrofitted LED running lights.
Only the LED running lights.
High beams (BiXenon Active Bending) with Auxiliary lights.
low beam headlights with LED running lights, and covers on the Auxiliary lights.
My car was filthy in those first pics, and I'm borderline obsessive about my cars being clean, so I felt as if I had to post some pics of the car with the lights fitted and in clean condition, so here they are!
If you have any questions, please let me know by posting in this thread. I want to try to keep all information public. I am also in the first stages of creating a sticky for the XC90 forum which lists all of the how-to/diy/info threads in a single place. I made one for the S80 forum about a year ago and it has become a very valuable resource.
While installing the lights, I also found an excellent writeup done on another forum which details the installation on an XC70. Click here for that.