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Headlight Wiring Assembly?

Help, Advice, Owners' Discussion and DIY Tutorials devoted to the second generation C70, S40 and V50 Volvos -- awkwardly model year 2004 ½ onwards -- plus where to go for advice and discussion on Volvo's sporty C30 Coupe powered by Volvo's ubiquitous inline 5-cylinder power plant.
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hershmagersh
Posts: 3
Joined: 7 September 2018
Year and Model: 2005 s40 2.4i
Location: Mississippi

Headlight Wiring Assembly?

Post by hershmagersh »

Hey guys! Never posted before, but I've used this site many times in my several years of volvo ownership, and it has been a great source of info for me over the years.

I'm in a bit of a pickle. My left headlight low beam has gone out, but the bulb is not the issue. The wires exiting the bulb socket have pretty much disintegrated. No big deal, should be easy enough to order a new one and swap them out. Except I cannot, for the life of me, find the correct part online.

Here is the bulb socket piece, where the wiring is destroyed
IMG_6199.jpeg
Obviously, there are 3 wires leaving this part and snaking around down to their respective positions in the main harness connector, pictured below
IMG_6198.jpeg
When I search for parts, I can't find anything that has either the correct number of wires or terminates into this main harness connector -- they all seem to have plastic fittings on both sides (whereas the 3 OEM wires appear, from what I can see, to individually connect into their slots in the main harness connector). You may be able to tell from the second image, but the release mechanism on the main harness connector is also broken, so I can't even remove it from the headlight assembly without destroying it. For this reason, I would actually prefer to just replace all of the headlight wiring from the main connector out to the headlight assembly all at once. I have a soldering iron and am fairly proficient with it, so I should have no problem doing this myself.

To your knowledge, can that part be bought on its own? I suppose I would settle for the correct bulb socket-to-harness connector if someone could find it, but ideally I would like to replace all of it. Am I out of luck? I can buy an entire new headlight assembly if all else fails, but I'm trying to avoid spending that kind of money if I can help it.

Thanks for any guidance on this! Let me know if I've been as clear as mud about some of this, my terminology is perhaps not up-to-snuff in some instances.

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RickHaleParker
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Post by RickHaleParker »

The first one is easy just google "H11 headlight connector". NASA splice a new one on.

What is wrong with the second one?
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1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
2004 S60R, B8444S TF80 AWD. Yamaha V8 conversion
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hershmagersh
Posts: 3
Joined: 7 September 2018
Year and Model: 2005 s40 2.4i
Location: Mississippi

Post by hershmagersh »

Thanks! Guess I'll go ahead and order an H11 connector then. The problem with the second one is that the release mechanism has been broken by whoever worked on it last, and I haven't been able to get it to come off. That's why I was thinking of just replacing all of the wiring from that point on, but I don't know if that's practical or even doable.

hershmagersh
Posts: 3
Joined: 7 September 2018
Year and Model: 2005 s40 2.4i
Location: Mississippi

Post by hershmagersh »

Sorry to bump this thread again. I've got the h11 connector, now my only question is what to do with the ground wire. My intuition tells me I can just wrap the end of the ground wire up with the other brown wire (positive?) and shove both ends into the one h11 tail, but I don't want to screw it up and give myself more headaches over an assumption. Is this the move or am I missing something?

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