Automotive Manual PDF

On most models, access to the 3-pin plug of the headlamp is possible simply by reaching it from underneath the front fairing or from behind the dash. There is usually a rubber splash cover over the 3-pin plug, which has to be peeled back. Installation is simple: unplug the headlamp, insert pathBlazer, and then re-connect the 3-pin plug.
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This manual has eight modules, covering key topics relating to Towbar electrics. Each module except 3 and 4 has a guidance section and a review section.
• Each Guidance section contains information and best practice.
• Each Review section is a form of self-evaluation chart and is to be used by the trainee during their everyday work, to judge their own performance against the standards indicated. The principle of the reviews is to harness the natural enthusiasm most people have to measure their own work against the highest standard
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This is an install document for a High Intensity Discharge Kit for the Volvo S40. This is a fairly simple procedure and should take approximately 45 minutes to install.
Kit Details
DDM HID Kit including:
2 – Ballasts and Igniter assemblies
2 – HID Bulbs w/wire assemblies
2 – Ballast to Bulb connecting wires
2 – 3M Double sided adhesive tape
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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.
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primary harness (H1) wire connection guide
primary harness (H1) wiring diagram
The primary harness supplied with this unit is the standard 12-pin harness used. Two wires in the plug are not used. The upgrade from this unit to a security system would simply require unplugging and exchanging control units and connecting the necessary wires to the vehicle. The functions of all the wires that are used in the primary harness are outlined in the following wiring diagram and the wire connections are described in the wire connection guides
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The tools you needs:
A drill with a smaller bit such as a 1/4″
A dremel or similar to cut a hole in plastic
T27 Torx bit and driver with 4” extension
Extendable magnet
Pliers

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. There are 3 T27 torx screws holding the headlight on. The 2 on top are visible in this picture.
3. with the 2 screws removed…
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Turn signal
Illuminates when the left or right turn signal or the hazard lights are turned on. If one or both of the indicators stay on continuously or flash faster, check for a burned-out turn signal bulb. Refer to Exterior bulbs in the Maintenance and care chapter.
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The warning lights described on this page should never be on when driving. When the ignition is turned on, and before the engine starts, all of the warning lights should be on to test the function of the bulbs. Should a light not go off after the engine has started, the system indicated should be inspected. (However, the parking brake reminder light will not go off until the parking brake is fully released.)
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If you encounter instances in Model 203 vehicles of the front turn signal not working, this may be due to a contact problem between the turn signal bulb socket and the headlamp housing. In this case, perform the following repair only on the affected side of the vehicle.
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