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Hmmm, you and I both thought you'd be done once the falling-apart old harnesses stopped shorting wires one to another.
Now you're going to have to actually troubleshoot. The lights you are referring to are the low beams, right? Check and be sure. Then locate the headlight relay which will be under the driver's left toe, more or less, identified by the wiring colors in the socket. Big yellow, big green/red, small white, blue/white, and black. Check the number on the relay, if there's any chance someone put the wrong type in: 1324749*.
That relay is what turns on the lights. It is wired to turn them on only with the key switch on. So, if the lights are on, the blue/white wire ought to have battery voltage on it. But it should not if the light switch is turned off, so you need to find out why it does if it does, or how the lights could come on without the relay being energized. You might find the relay is full of water and rust. I can envision a similar symptom arising if the bulb failure warning switch (orange can) got full of water.
*On mine, the Volvo p/n is nowhere to be found. Bosch 12V 2x15A 0332015012
--
Art Benstein near Baltimore
The secret of a good sermon is to have a good beginning and a good
ending; and to have the two as close together as possible. - George
Burns
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