do all 240's have headlight relays? If not, than which years? If relays are added do they disable or interfere with the bulb failure light? Thanks.

You will have to add relays to get the benefits you're interested in. I added 4 relays -- 2 each side - 1 for each low beam and 1 for the high beams. I used 10 ga. wire for hot and grounds and used the factory wiring to "trigger" the relays. I measured 0.00V drop between the hot source (alternator output) and the bulb -- which means I'm getting 14.6V at the bulbs with the engine running. With the stock set up I was seeing about 11.5V there -- BIG difference in lumens.

Good write up here about the benefits -- http://www.danielsternlighting.com/tech/relays/relays.html

your diagram is just what I'm talking about and I have both built and purchased them. The talk about other relays far away does not make sense as locating a relay at the far end of a thin wire can't be correct and has no value. Sometimes a car company builds a relay in but more often, like Chrysler, Ford, Jeep, and others ( z cars) it is cheaper to skip. It is a valuable upgrade when you have very poor headlights, as US model 240's do. Thanks!

And my relays are about a foot away from my battery.
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Post Back. That's whats makes this forum work.

I'm thinking that a relay near the switch or under the dash is unlikely to be a headlight relay. The relay would have to permit a very short trip from battery to light without ending under dash or my switch.

Here's the deal. I have done this before, but...I have an old 94" Dakota which had 3 problems, a) terrible plastic aero lights (like old Volvo's), terrible 9004 bulbs (like old Volvo's) and difficulty upgrading performance. On the Dakota we basically replaced the entire nose (radiator core support, grill, wiring harness, and finally upgraded the small rectangular Hella H-4'S with some Indian made H-4 70/75w bulbs. Still not terribly impressive. Next week putting in a twin relay kit to brighten the bulbs and ease the burden on the headlight switch. This has been done before on other cars. it works.
Putting in proper Cibie headlights with H-4 (or the rare Chinese version) is neither great nor cheap, and the 9004 bulbs are still terrible in design. The headlight relay kit can be an upgrade. There is a slight possibility of getting an upgraded bulb. The original build (and sealed beam versions) were 45w/60w, less than most bulbs. Most official sealed beams have been legally upgraded to 55 watt low. Having done my research I have found that nobody wants to upgrade the 9004 bulb, except for a few 45w / 100 or 120w versions that may be too bright IMHO, or the LED or HID units which raise concerns about glare. It's a money issue. A relay with some 70w/75w bulbs might be an excellent compromise. I know Volvo folks are extremely reluctant to make the slightest change to the NHSTA Joan Claybrook version. Anyway this is my thinking, improve via the relay, then possibly the 70w/75, similar in specification to Osram night breakers for H-4, albeit poorer in build. Older Volvo's are really slipping behind in lighting safety, and it is difficult to upgrade. That and the fuse box are the 2 really poor design flaws that can be upgraded easily. Unless we view Volvo's as cars to be driven rarely only on sunny sundays (like 2002's, 356, 911, 912, and even 914's)we need an economical upgrade. That is where I am coming from. Hella XL'S were an option, but not available for years. KC Highlighters apparently have a fake Hella XL, but don't know how they work.Thanks for your comments, and THAT is the relay I need.

As my friend Phil suggests, there is the step relay for hi/low beam, found in all 240's, and the headlight relay under the dash. His history is a bit off. The sealed beam headlamps were used through '85. The under dash relay was added in '86 actually and, if memory serves, it's purpose is to relieve the load at the switch.

But no 240 was ever made with the relay setup that you are wanting. At least not for the American market. I am not sure about other markets.

I believe some here have done this modification, especially when converting to E code lighting. We are not that reluctant to deviate from the original design.

You might take a look at the diagrams at Daniel Stern Lighting.


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'80 DL 2 door, '89 DL Wagon

Hello,
Since my name is Phil I will probably get "filled in" on the subject as well as you will. I do not claim to be all knowledgeable about 240's.

With that said I will give you what I know,
The Head light relays started being used on the 1985 models and forward.
The four bulb front lights ended in 1984 on North American models and the plastic lens types were introduced.
This relay only is for are the cars that have their headlights turn off when you turn the ignition key off.
It will only light up the headlights with the key on and the headlight switch on.
This relay is located to the right of the instrument cluster in the dash.

A low/high beam dipper switch is another relay located on the driver side fender well out under the hood. It is operated by the directional turn signal stalk on the steering column.
It is what is sometimes called a "I'm wanting or going to be passing your car" warning light or a "please dim your headlights" to on coming traffic in most states.

Basically, it's also an attention getter when on held on. It will operate with the headlights switch off and the ignition switch off. It's nice to blink in a parking lot to say "Honey, I'm over here."
Sometimes, if and-when, the headlight switch or relay total fails, the dipper relay will hold your high beam headlights on so you can drive.
Think of it as a redundant "NASA type" back up system only with human intervention, otherwise, you don't get home! Any car can help you into an APOLLO moon mission.


As far as the bulb out or Bulb Failure Sensor, it is independent of any relay circuit operation, as wired from the factory.
If one bulb draws more or less than it's "brother- like" bulb it will trigger the dash light.
IT does the walking around the car for you but it's still a RELAY that turns on a warning light.
I have read, it can do more a it can turn off lights that are fine.

What are you up too?
On what type of 240 are you working on or modifying?

Phil

Yes.
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Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502

Short answer, Yes.

Early version I believe 80-85: Part of the switch itself

86-90: moved from part of switch to behind the brake pedal on firewall,

91-93: moved yet again to behind the center console duel duct vent.

The years might not be exact, but a close estimate.

Why do you ask?

Matt

if I didn't make my self clear I am looking for a relay that minimizes current drop by working between battery and bulb, NOT providing flasher, bulb failure alert, or anything else scattered around car as auxiliary function. Just maximize current from electrician to the bulb for maximum brightness. Thanks. If it doesn't exist I will install one for that purpose.

All 240's made from 1975-1993 have a headlight relay under the hood.

The later 240's do have a relay on the fuse/relay panel behind the center console, but that is a light system relay and I am not referring to the bulb integrity relay. Those cars still have a headlight relay under the dash

Whether the stock headlight relay can handle your intended electrical load, I can't tell you.

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Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
hiperformanceautoservice.com or oldvolvosonly.com