Volvo 850 series, 1998-2000 S/V/70 and 1998-2004 HID conversion installation instructions
1. Take the kit out of the box and lay everything out. You can install either the ballasts or bulbs first but typically it is easier to install the bulbs first.
2. Remove the access cap from the rear of your headlight housing as shown.
3. Drill a hole in the center of the cap as shown. If you use a hole saw that will be all you need. If you use the small drill bit you will need to use your dremel to cut a 1″ hole. You may want to use some sand paper just to smooth the edges you have cut.
4. Some of the bulbs come with adaptors that some other cars require (shown by the blue arrow). This Volvo installation does not require them. Take your plyers and cut them off. This will allow you to remove the base of the bulb case later on (shown by the red arrow).
5. Feed the AMP connector ends of the bulbs through the hole from the inside out and seat as shown. Seal the provided 1″ gasket in the hole you have made. You should have two connectors coming out of the same side as the bulb that will eventually connect to the OEM harness- these will be connected later. Leave the bulb in the case for now.
6. Now you can get a feel for how much length you’ll need to connect the ballasts to the wiring harness that is currently going through the headlight cap. Find a place to mount the ballast that best suits your needs. Here are some examples of where people have mounted theirs. A common place is on the battery or just by it behind the headlight on the drivers side. On the passenger side some people mount it to the ECU box or again just behind the headlight housing. One person mounted it just to the passenger side of the fan shrowd as shown. You can use the provided zip ties (more may be needed depending on your mounting location), the double sided tape (provided), or screws or nuts and bolts (not provided) to mount the ballast to a flat surface.
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