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850 Headlight wiring harness problems

Help, Advice and DIY Tutorials on Volvo's extremely popular car line -- Volvo's 1990s "bread and butter" cars -- powered by the ubiquitous and durable Volvo inline 5-cylinder engine.

1992 - 1997 850, 850 R, 850 T5-R, 850 T5, 850 GLT
1997 - 2000 S70, S70 AWD
1997 - 2000 V70, V70 AWD
1997 - 2000 V70-XC
1997 - 2004 C70

Cincyken
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Cincyken

850 Headlight wiring harness problems

Post by Cincyken » Thu Jan 26, 2017 6:20 pm

Volvo has had a lot of problems with the insulation deterioration on the wiring harness inside the 850 headlight. I have heard that volvo makes a retrofit kit for this problem but I cannot find out any info on this.
Does any one know of a Volvo retro kit or an after market kit by someone else?

BenSteiner
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BenSteiner

Re: 850 Headlight wiring harness problems

Post by BenSteiner » Fri Jan 27, 2017 6:23 pm

I had the same issue w/ my 97 850 GLT, but didn't know about it until I recently took it in for an oil change. I had a headlight out and the quick lube guys informed me that not only was it burnt out, but that the wiring harness insulation had pretty much disintegrated.

Long story short, the quick fix was basically wrapping it up w/ electrical tape.

¯\_(ツ)_/¯

scot850
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scot850

Re: 850 Headlight wiring harness problems

Post by scot850 » Fri Jan 27, 2017 11:45 pm

I have seen the wire insert over the years fitted to the headlights of some cars in PnP. Sorry but can't find a part #. Try calling a dealer as it was a modification I think that was either a recall or a technical bulletin.

Neil.
2000 V70 R - still being an endless PITA
2006 XC70
2003 Toyota 4Runner V8 Limited
2015 Kia Sportage EX-L
1993 850 GLT -Sold
1998 V70 XC - Sold
1997 Volvo 850 SE NA - Went to niece in California - Sold
2000 V70 SE NA - New project and test bed - Sold

Cincyken
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Cincyken

Re: 850 Headlight wiring harness problems

Post by Cincyken » Sat Jan 28, 2017 12:00 pm

I was going to try electrical tape but i was concerned about the temperature inside the headlight. In the summer it gets pretty hot in there, not sure how well the tape would hold up.
The local Volvo repair guy (not the dealer) told me to go to the junkyard and get a headlight out of an S70, then remove the wiring harness from it. He believes the S70 had an upgraded harness.
On Monday i will stop at the local Volvo dealer and see if they know anything about a recall.

Thanks for the info.

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dyn blin
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dyn blin

Re: 850 Headlight wiring harness problems

Post by dyn blin » Sat Jan 28, 2017 2:24 pm

It's not much of a project to clean and resheath the wiring . You can easily remove the headlight modules, and the wire terminals come out of the connector with a connector pick or eyeglass screwdriver. Then it's just a matter of sliding on some clear heat shrink tubing after cleaning up any corrosion, some heat and secure the terminals back into the connectors in the same positions.
'97 850 GLT Wagon- Driving to see 300k in the rearview

Ozark Lee
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Ozark Lee

Re: 850 Headlight wiring harness problems

Post by Ozark Lee » Sat Jan 28, 2017 10:37 pm

I think the 70 series harness and the 850 harness are different but I'm not for sure. The only ones I have had to mess with were on the 70 series and the internal harness to the lamp assemblies all terminate on a connector that snaps into the back of the headlight assembly itself. I don't recall seeing that connector on the 850s but then again I have never had to look for it.

...Lee
'94 850 N/A 5 speed
'96 Platinum Edition Turbo
Previous:
1999 V70XC - Nautic Blue - Totaled while parked.
1999 V70XC - RIP - Wrecked Parts Car.
1998 S70 T5
1996 850 N/A
1989 740 GLT
1986 740 GLT
1972 142 Grand Luxe

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volare
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volare

Re: 850 Headlight wiring harness problems

Post by volare » Sun Jan 29, 2017 10:27 am

Back in here pulling my hair out, same problem with the Falcon. Pass side headlight being a pain; bulb is fine, works on hi-beam, nothing otherwise tho low beam will sometimes come on and off again if I tap it or wiggle the wires. The wiring inside the headlight assembly looks like absolute hell. Am I just wasting perfectly good electrical tape trying to rewrap the wires that have the cracked insulation before I can get hold of a new one?
The connectors I found go from a 4-pin to a 3-pin into the headlight assembly as Lee described. The part number matches the TSB third wire issue (9162343)
Image
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