Volvo S60 headlight wiring

HAROLD9735

MEMBER
2005 VOLVO S60
4 CYL
2WD
AUTOMATIC
65 MILES

I have a 2005 S60 which needed to have the headlight wiring (both lights) replaced becasue of defective wiring. Volvo makes a quick kit for this repair so they are aware of the defect. After one year the quick kit repair wiring has now gone bad. The lights go off and on intermitting with out any driver assistance. The dealer said that they would eventually go out and not come back on so it is a safty issue. I complained to Volvo about this but they say because the car is out of warranty it is again my responsibility/problem. Do you know if this has happended to other Volvo owners? Do you have step by step repair instructions for this repair? It cost me $580 at the dealer, the kit is about $75.

1 Reply

JIS001

MECHANIC
3,408 POSTS

The issue is not really the wiring, it was the connector starting to melt because the lights are hot from being on all the time. What Volvo did was come out with a connector replacement to save you from having to buy the whole headlight assembly. The repair was to remove the light assembly which requires removing the bumper skin to access the bolts and cut and solder the connectors. What you should do is have the daytime running lights disabled or have them programmed to come on using the sun sensor on top of the dash. When it does not sense the heat from the sun, the lights automaticly come on. I disabled my daytime lights and just turn them on manually at night. I save on having to replace the headlight and position bulbs. Good luck and keep me posted.