Since I'm doing a swap from Valeo USA Spec headlamps to Cibiw European Spec Headlamps this weekend I wrote up a simple instruction sheet and decided to post it here so others may use it...

please RED STAR thsi so it ends up in the archives...

Ecode Headlamp Conversion for Volvo 1986-1993 240 DL/GL

By James Stoney-jbstoney@earthlink.net July 1999

This is an instruction sheet for the retrofitting of Cibie European Headlamps using the H-4 bulb in place of the stock Valeo USA Headlamps using the 9004 bulb.

* This is not for pre-1986 Volvo 240 models as the fender design will not allow installation of the 1986 and later turn signals.*

Parts needed:

Cibie headlamps Volvo part numbers 1372394 & 1372395

Cibie Turn signals Volvo part numbers 1312755 & 1312756

Volvo Headlamp trim part number 1312634 & 1312636

Hella H-4 lamp socket 2 needed

All other trim attached to the Valeo USA headlamps and turn signals can be transferred to the Cibie European headlamps and turn signals.

Tools needed:

10 MM Deep Socket 3/8ths drive

3/8ths Ratchet Drive Handle

6 inch 3/8ths Drive Extension

Phillips head screwdriver

Needle Nose Vice Grips

Penetrating Solvent (IE: PB BLASTER or CRC - NOT WD-40!)

Begin on the drivers side by disconnecting and removing the battery. This allows access to the 10 mm nuts that secure the lamp housing to the body. Spray the 4 securing nuts with the Penetrating Solvent and then go to the Passenger side and do the same to the 4 securing nuts on that side. Wait 5 to 10 minutes while the solvent penetrates and loosens the bond.

Remove the 9004 bulbs and disconnect the wiring going to the bulbs and disconnect the connector going to the turn signal and disconnect the ground wire at the inner fender.

Starting on the Drivers side using the 10 mm Deep socket 3/8ths drive and the 6 inch Extension, (if needed), remove the 4 securing nuts. They will probably be rusty and they may be bonded to the bolts. If the bolt shaft starts to spin, stop and spray more solvent and go work on another of the nuts. Leave the frozen one for last. If you can get the other 3 nuts off then you can ease the lamp housing out a bit so you can see the shaft of the frozen bolt. Use a needle nose Vice Grip and grasp the threaded portion of the bolt shaft and hold it secure while you loosen the nut with the 10 mm Deep Socket.

After the 4 nuts are removed, slide the lamp housing forward, being careful to not snag the turn signal wiring.

Remove the Black gasket trim on the grille side of the Valeo USA Headlamp housing and the Chrome trim on the Turn Signal housing. Attach these in the same positions on the Cibie Headlamp housing, and then install the new upper trim above the headlamp (Part #13122634/1312636) all using the existing Phillips head screws.

· (You cannot use the existing upper Headlamp Housing trim as the depth of the Cibie European Headlamp Housing Lens is different and the Valeo style trim is too short in length and too shallow in depth and the mounting holes are incorrectly spaced, so it will not fit!).*

Then install the Turn Signal to the Headlamp Housing using the "snap fit" system that is molded into the Headlamp Housing. Line up the upper and lower guides and slide the 2 parts together until the central prong "snaps" into the notch in the Headlamp Housing.

Install the new lamp housing in reverse of the removal method, first feeding the turn signal wiring through the opening in the backing plate. Use the same 10 MM nuts to secure the lamp housing in place, connect the new turn signal wiring to the connector in the chassis harness and connect the ground wire in the same place as the previous ground wire.

Take the rubber sealing boot off the rear of the Headlamp housing and remove the white plastic plug. Cut the 9004 connector off the existing wiring leaving at least 4 inches on the 9004 connector.(This is in case you ever want to switch back and need to reconnect/solder the 9004 connector back in place.) Pass the wining through the hole in the rubber boot and install the H-4 bulb connector wiring as follows. Looking at the bulb from the back side.

Red-High Beam to Terminal 56a right side of connector

Blue-Low Beam to Terminal 56b top side of connector

Black-Ground to Terminal 31 left side of connector

This wiring is OK for 60/55 watt bulbs only. Do not install over normal wattage bulbs using this wiring as the amperage draw of the higher wattage bulbs will burn the wiring out due to the gauge of OEM wiring used.

If you intend to use over normal wattage bulbs then install 12 or 10 gauge wiring and a relay system to control the headlamps.

I recommend the IPD Headlamp Plexiglass shields as a protective and anti theft method. The turn signal side skirts cover the screws that hold the turn signal covers on and the plexi keeps rocks/stones, etc from shattering your new *expensive* headlamps but you CAN get replacenment lenses without having to buy the whole headlamp! :)

Thanks to Tony Verrigni of Verrigni Marine, Boca Raton, FL 800-888-6586 for the parts and for having a sense of humor about the whole thing...