PDF WITH PICS ATTACHED
Problem

I replaced both Headlight assemblies because my reflectors had become frosty instead of mirror like.
18 year old tabs on parking lights did not survive the operation. As I had just put a lot of money in the car, I wired it up to keep going down the road.


Drill hole ...

Just found out I could post the PDF

Once you read the TSB it is obvious you can fabricate a new cable for a few bucks and run it the same way the OEM cable was run. I had an OEM cable on hand so I used it. I plan to keep an eye on mine...at the first sign of over heating,I will run a "helper" cable. So far, even with lights and AC ...

Replaced cable yesterday Per TSB instructions. Easy to follow. But note: Old cable i removed by cutting off end at battery and puling cable out from the TOP of the fuse box. The new cable is installed by passing the battery end DOWN through the top of the fuse box and through the bottom grommet. To ...

I replaced the B+ cable as the next step in diagnosis. Yup! That was it!!

Cable end in fuse box had green wires and insulation melted.
Evidently, the voltage drop from battery to fuse box was so great clutch could not be energized.

BTW, nut on B+ cable was only finger tight. My theory is heat ...

I sent it to Matthew today as only he can post it.

PM me. I have the TSB

I have the TSB. PM me and I will send the pdf to you. Just picked it up today.

We replaced the AC compressor, drier, new expansion valve, all o rings. System was evacuated and filled with R 134a.
Clutch will not energize. We ran a wire directly to it from the batteryand it does energize.

Checked all fuses in the circuit and put in a new relay. No change.

AC was working ...

The fuel line numbers are: high pressure fuel filter to pump 9186286 at Eeuroparts $58.99.This is what breaks the most often.
Low pressure return line 9189294 $97.99.
I had a heck of a time getting these part numbers. It took a great parts guy and a tech to figure out the Volvo fuel line diagrams!
I ...