Retailer Technical Journal Headlamp low beam connector replacement

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Retailer Technical Journal 19254 Headlamp low beam connector replacement Date 7-6-2009 Volvo Cars of North America, LLC Technical Support Reference: VIDA, Retailer Technical Journal 19636 Note!

1 Retailer Technical Journal Headlamp low beam connector replacement Date Volvo Cars of North America, LLC Technical Support Reference: VIDA, Retailer Technical Journal Note! If using a printed copy of this Retailer Technical Journal, first check for the latest online version. NOTE! THIS DOCUMENT SUPERSEDES THE PREVIOUS RETAILER TECHNICAL JOURNAL HEADLAMP LOW BEAM CONNECTOR REPLACEMENT, DATED THIS RTJ NOW INCLUDES REPLACEMENT OF BOTH HEADLAMP BULBS WHEN THIS METHOD IS COMPLETED. AFFECTED VEHICLES: Models Type Model year Chassis range XC V XC S DESCRIPTION: In an effort to reduce warranty and customer expense for Halogen type low-beam headlamps, a new method of repair has been developed to address complaints for the vehicles listed above. MATERIAL: Description Quantity Part Number Cable harness* Splice *This part number has been used for two replacement connector types, see the following page. SERVICE: If the cause of the customer complaint is a bad Halogen low-beam bulb, replace both bulbs per Retailer Technical Journal 19636; dated 9/2/2008. If the cause of the complaint is that the harness within the headlamp assembly is damaged, DO NOT replace the headlamp assembly. Replace the low-beam harness connector AND the headlamp bulbs on BOTH headlamps as described in the following. Read this complete document prior to beginning repair. Copyright 2008 Volvo Cars of North America, LLC. All rights reserved. Page 1 of 5

See the instructions on the following pages for two wire or three wire repair as needed. Both the original and replacement connectors have an "alignment slot".

2 For reference here is a photo of the original and replacement connectors. Original Original Alignment slots Replacements types Black type The original connector shown at the far left has three wires to it. The number of wires to the connector will vary based on the model. See the instructions on the following pages for two wire or three wire repair as needed. Both the original and replacement connectors have an "alignment slot". This should be used to determine the position of the spliced wires On the original and the "grey" replacement type; each terminal has an identification of "A" and "B"; they are not consistent from the original to the replacement. Disregard the labelling of the terminal and pay attention to the physical locations. NOTE: The "black" type replacement does not have any terminal identification marks. The black type also has a different locking tab. The original and the grey replacement types lock onto the bulb at the sides, the black type locks onto the bulb at the back as shown here. ADDITIONAL NOTE: the orange seal (shown in these pictures) installed with the original connector should not be used when installing the replacement type connectors! Remove Headlight Assembly Remove headlamp according to VIDA: - 35 Lighting - Lighting, front - Headlight / bulb, replacing Caution! The plastic lens on the headlight scratches easily. Do not place the headlight on a hard surface with the lens downwards. Copyright 2008 Volvo Cars of North America, LLC. All rights reserved. Page 2 of 5

For vehicles with two wire harness: TIP: To simplify the process, cut and splice one wire at a time. Be aware of the physical location of the wire in the connector.

Cut off the original low beam headlight connector and up to 1 inch (30mm) of the replacement harness as shown here. Discard the old connector.

3 For vehicles with two wire harness: TIP: To simplify the process, cut and splice one wire at a time. Be aware of the physical location of the wire in the connector. Placing both original and replacement connectors next to each other, slot up and cutting and splicing the wires one at a time will ensure correct locations. Cut off the original low beam headlight connector and up to 1 inch (30mm) of the replacement harness as shown here. Discard the old connector. Install the new connector; join the cables according to VIDA: - 37 Cables and fuses - Wiring - Joining the cables NOTE: These butt connectors are the heat-shrink type, be sure you heat shrink to install completely. REMINDER: Replace the connector on both headlamps. Copyright 2008 Volvo Cars of North America, LLC. All rights reserved. Page 3 of 5

For vehicles with three wire harness: IMPORTANT: For vehicles with three wires to the connector, as shown here, it is important that the wires are installed in their correct locations.

Be aware of the physical location of the wire in the connector.

4 For vehicles with three wire harness: IMPORTANT: For vehicles with three wires to the connector, as shown here, it is important that the wires are installed in their correct locations. Be sure when cutting and splicing that you follow the instructions below TIP: To simplify the process, cut and splice one wire at a time. Be aware of the physical location of the wire in the connector. Placing both original and replacement connectors next to each other, slot up and cutting and splicing the wires one at a time will ensure correct locations. Cut off the original low beam headlight connector and up to 1 inch (30mm) of the replacement harness. Discard the old connector. Install the new connector; join the cables according to VIDA: - 37 Cables and fuses - Wiring - Joining the cables NOTE: This picture shows the splicing of the two wires into one connector as shown in VIDA. Once this has been completed the replacement connector can be added as well. These butt connectors are the heat-shrink type, be sure you heat shrink to install completely. REMINDER: Replace the connector and bulb in both headlamps. Copyright 2008 Volvo Cars of North America, LLC. All rights reserved. Page 4 of 5

5 Reinstall Headlamp Install the headlamp according to VIDA: - 35 Lighting - Lighting, front - Headlight / bulb, replacing Test the function. WARRANTY CLAIM INFORMATION LABOR OP LABOR DESCRIPTION LABOR TIME Headlamp (x2) remove / install XC hrs XC70 ( ) 1.4 hrs S60, V70 ( ) 1.5 hrs S60, V70 w/ B5254T4 engine 1.9 hrs Connector low beam, replacement (both sides) 0.1 hrs Claims may be submitted under the new car warranty when there is a documented customer complaint using claim type: 01 VOLVO for life, Volvo Cars of North America, LLC Technical Service Copyright 2008 Volvo Cars of North America, LLC. All rights reserved. Page 5 of 5

VOLUNTARY SERVICE CAMPAIGN ALTIMA; HALOGEN HEADLAMP GROUND PLATE KIT

VOLUNTARY SERVICE CAMPAIGN ALTIMA; HALOGEN HEADLAMP GROUND PLATE KIT Reference: NTB05-057b March 14, 2008 Date: VOLUNTARY SERVICE CAMPAIGN 2002 2003 ALTIMA; HALOGEN HEADLAMP GROUND PLATE KIT This bulletin amends NTB05-057a. The IMPORTANT statements on page 3 and page 20