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S80 3.2 Headlight Wiring Fail!

Help, Advice, Owners' Discussion and DIY Tutorials on the third generation Volvo V70 wagon and XC70 crossover, and second generation S80. Are you an owner? Prospective owner? Get in here and join us! Start a new topic or comment on an existing thread.

2008-2016 V70
2008-2016 XC70
2007-2016 S80

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Year and Model: XC70 2006, S80 2007
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S80 3.2 Headlight Wiring Fail!

Post by Skymongrel » Sat Jun 13, 2020 5:58 am

I have a 2007 S80 3.2 with 123K and recently the low beam headlight blew. Easy enough, replace bulb and all is good. But then, I noticed a problem! The wiring to the headlight socket had lost its insulation. Passenger side was the worst but at least 3/4 inch of wiring was bare and lots of open cracks along the length of the wiring.

There was no sign of electrical shorting that I could see, no burnt marks. I wrapped wires with electrical tape which didn't really hold well and I'll have to revisit a solution but I thought I'd heard of someone going through headlight bulbs too frequently and thought I'd share this.

And there are pics!

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Re: S80 3.2 Headlight Wiring Fail!

Post by RickHaleParker » Sat Jun 13, 2020 7:58 am

Standard H11 wiring harness. Google "H11 wiring harness" You can get replacements all over the place. NASA splice the new ones on.
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Platform: P80 1998 C70, B5234T3, 16T, AW50-42, Bosch Motronic 4.4, Special Edition package.
Platform: X40 (Nedcar) 2003 S40, B4204T3, 14T twin scroll AW55-50/51SN, Siemens EMS 2000.
Platform P2 2005 XC90 T6 Executive, B6294T, 4T65 AWD, Bosch Motronic 7.0.
Platform P2 2004 S60R, B2524T4, AW50/51 AWD, B8444S TF80 AWD, Bosch Motronic 7.0, BorgWarner K24 turbocharger. V8 conversion in progress.

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