Before you start, figure on this being a 2-3 hour job. I found it to be easier to bundle the wires in wire looms before I started. 3/8 or 1/2 inch wire looms are the best size for this job. Simply open the loom, and insert all the wires. Once you have the wires positioned, close the wire loom and secure it with zip ties as shown below.
The challenging part of installing this kit involves cutting the headlight housing. This proves most difficult on the left side due to the lack of space. The first step is to remove the old bulb. Once this is accomplished, start making room for the next step. Remove the ECU tubing and swivel it out of the way. Now, remove the diagnostic box and put it to the side. There should be enough wire to simply lift it out of its receiver and put it to the side. Now that you have more working room you need to make a .25"x.5" cut in the light housing. Look at your headlights and HID kit to establish exactly where. Before you cut, shove a clean rag into the ECU tubing to prevent filings from entering. The same should be done to the light housing. Packing the headlight housing with a rag and then vacuuming the rag as you remove it should prevent unwanted filings from entering your headlights. I used a dremel and cutting bit to make the cut. However, any rotary tool should work, provided you have the right bit. If you don't have a rotary tool you could use a hand saw. Circled below is the cut I made to the housing.
With the cut made, you can now install the bulbs. They install the same way as a standard 9006 bulb. Before you continue make sure to pull out as much of the stock harness as you can. Now plug in the HID extension cable to the stock harness. Once that is done connect the other end to the ballast. Now connect the new HID harness to the bulb. It will press on and turn clockwise. It is best now to check to make sure they work. If the bulbs do not light then it is likely that you have the polarity backwards. Switch the wires and try again. The bulbs should light now. On 850s the red wire goes to the yellow, and the black goes to the brown.
Now that the bulbs are working, you need to mount the ballast. On the right side I mounted the ballast to a piece of plastic above and to the right of the cooling fan as shown above. The ballast fit perfectly and mounted with the provided Velcro. As an added precaution I drilled a hole through the plastic piece and zip tied the ballast in place. This takes at least a 12 inch zip tie. On the left side of the car I mounted the ballast to the top of the battery. Depending on your car there may be better places to mount the ballasts. In the above picture you can see a red arrow pointing to a small plastic tab. Drill a small hole in the back of the tab and zip tie the stock harness and wires to it. This will help keep everything neat. Now either wrap the wires with electrical tape or use liquid electrical tape to insulate the wires.
Now check to see if your headlights are properly aligned. If needed use the built in levels to level your headlights. You are now done. Sit back and admire your work until it becomes dark and you can reap the benefits of your HID installation.
http://volvospeed.com/Mods/hids.htm
Volvo S70 HID conversion kits installation
Linear Mode
