2009 Xc70 DIY Rewiring Headlight with NEW wiring harness Topic is solved

[MauiVolvoGuy]

Greetings from Maui Hawaii;
Been doing lots of projects on my very loved 2009 Xc70 Wagon 3.2 turbo

Perhaps its where I live with lots of moisture & high humidity but all the wiring in both headlights has completely lost its casings. Recently I lost my passenger side turn signal & put new bulbs front & back, checked the fuse but still have turn signal on right side blinking super fast. from what I can tell it must be the fact that I can actually see bare wires & I'm certain they are crossed up making turn signals not work.

So I found the proper wiring harness for my car part# 30763979 & took a good look at they inside of headlight & looks pretty manageable EXCEPT the main connector I can move a couple of mm but that is all.

I have searched utube & google & really can not find ANY info on taking this apart so I am reaching out here.

Anyone ever done this? I watched videos where they put the head light assembly in the oven at 200 degrees for 20 minutes & pull the cover off. Is this what I need to do to get access to inside of headlight ?

Please any help would be appreciated.
Mahalo from very wet north shore of Maui Hawaii
Tad

[dwcatcvg]

For anyone who finds this 10 month old post, I will say that it can be done without separating the cover from the lens. In fact, I'm not sure removing the lens would give you any better access to the wiring. The hardest part was removing the connector from within the sleeve in the housing. I cut one of the housings in my car to make it happen faster.

With the wiring and bulbs out of my lights, I resorted to "rinsing" the deteriorated bits of jacket out of the headlight. I still have a few bits of plastic floating around in there 3 years later. Volvo should have replaced these headlights in a campaign. Wires shouldn't lose their insulating jackets like this. It was shocking my lights worked at all, though. Some of the wires were not only bare, but almost braided around one another.

[xyznyc76]

For anyone that should find this post and needs further help, the secret to removing the main connector is to use the headlamp beam leveling knobs to push the lense housing as far forward as possible to be able to freely remove connector inwards. This way you gain just enough space to be able to wiggle it out (inwards). Watch out that you don't break the black tabs (guides) on the inside of the housing that can be visible on the connector when looking inside. They easily break and it will be next to impossible to hold the new main connector (once in) securely in place. Crazy design but it can be done with just enough patience. Good luck!