This 2008 Volvo XC90 came in with the complaint that the driver’s side low beam headlight does not work most of the time. Every now and then it will work after hitting a bump in the road.
Since it is likely to be a faulty bulb or connection at the bulb, the first thing to do is a visual inspection. After opening the hood the headlight retaining bars have to be removed.
They lift up without too much effort.
There are two retaining bars.
Rather than disconnecting all of the wiring and fully removing the headlight assembly, I simply installed a fender cover over the bumper and turned the light assembly over on it.
There is a large disc cover that has to be removed to get to the bulb. There is a spot for a retaining screw but this assembly does not have one. Most do not.
It turns counter clockwise to remove it. That is to the left for you of the digital age.
Once it is turned fully counter clockwise the cap will lift off.
There is some discoloration on the green part of the bulb base.
The insulation on the black wire is melted.
The bulb and matching harness terminals are burnt.
Neither the new or the old connector had seals where the wires enter the connector housing. The reason is heat retention. The bulb and connector are within a sealed environment inside the headlight assembly. If the connection was outside of a sealed in area, the wire entry point would have to be sealed as well.
I spliced in the new harness connector and staggered the splice connection points. To purchase the harness connector, please click here.
Placed the heat shrink tubing in place and heated with a small torch.
I then installed the connector into the new bulb.
I made sure that the blue silicone seal was fully seated.
Then installed the assembly into the headlight.
The only thing to do now is to replace the cover and install the headlight assembly.
The headlight is now working again. Keep in mind that if there is heat damage to a component, the component and the harness connector have to be replaced at the same time or the condition will return quickly.
