As promised, here is a full write-up on how to retrofit projectors on the R. It will cover everything you would need to know starting with removing the headlights from the car and ending with the final product. When reading this, it seems like a million steps but I literally took a picture of every single step and made the assumption the reader has no level of expertise. Feel free to ask any questions I may not have addressed. I hope for this to be my greatest contribution to the forum. I was pretty well know on Volvoforums for doing an LED dash conversion write-up for the 850. I tend to be extremely detailed.
Tools Required
-10mm socket wrench (bumper screws)
-8mm socket wrench (headlight screws)
-6mm socket wrench with extension (leveling motor adjustment)
-Needle nose pliers
-Philips head screw drivers (different sizes)
-T10 torx head screw driver
-T25 torx head screw driver
-Heat gun (optional but recommended)
-Spring loaded clamps (optional but recommended)
-Other misc. tools that you should have somewhere
Supplies
Projector Lenses:
http://www.theretrofitsource.com/product_info.php?products_id=236
Projector Shrouds:
http://www.theretrofitsource.com/product_info.php?products_id=72
*No need to but the premium. I did and they were poorly manufactured anyway. Wasted $20 but got refunded for the poor craftsmanship.
CCFL Angel Eyes:
http://www.theretrofitsource.com/product_info.php?products_id=103
*80mm for my install. 100mm if you want to put them in the shroud.
Step 1: Headlight removal
First, we need to get that front bumper removed. Start with the 6 pins at the top just under the hood. To remove them, push in the center with anything small and rigid then pull out using a flat head screw driver.
Next, loosen the T25 torx head screw in the front wheel well. The picture is taken looking forward on the car. Loosen this screw 5-10 turns then use the screw driver to push the screw in. Pushing this screw in releases a lock which pulls the bumper onto the car when re-installing.
Starting with the circled area, use a small flat head to pry off the trim piece. Be careful not to damage your paint. Once you get it started, put down the flat head and continue to pull off.
The two arrows below show where two 10mm bolts will be hidden. Remove with socket wrench and pull out CAREFULLY. Make sure the bolt stays in the socket when pulling out because if it falls in the bumper it is a PITA to get out from the internal cavities of the bumper.
Now, pull outwards on the circled area below while also pulling the bumper forward, off from the vehicle. If you pushed in the locking segment far enough when tackling the T25 screw this should be easy. If it doesn't want to release, loosen the T25 screw a few more turns and push it in a second time. Once both sides are released, pull the bumper off from the front of the vehicle.
The next two pictures show where the 8mm screws are located to release the headlight assembly. I show three screws but there may be a fourth underneath the headlight. I may have removed mine and chosen not to replace because it may be hard to access. Hopefully someone can chime in and clarify this step.
Lastly, pull out the headlight slightly and remove the following three connectors to release the assembly. The assembly is now removed from the car.
Tools Required
-10mm socket wrench (bumper screws)
-8mm socket wrench (headlight screws)
-6mm socket wrench with extension (leveling motor adjustment)
-Needle nose pliers
-Philips head screw drivers (different sizes)
-T10 torx head screw driver
-T25 torx head screw driver
-Heat gun (optional but recommended)
-Spring loaded clamps (optional but recommended)
-Other misc. tools that you should have somewhere
Supplies
Projector Lenses:
http://www.theretrofitsource.com/product_info.php?products_id=236
Projector Shrouds:
http://www.theretrofitsource.com/product_info.php?products_id=72
*No need to but the premium. I did and they were poorly manufactured anyway. Wasted $20 but got refunded for the poor craftsmanship.
CCFL Angel Eyes:
http://www.theretrofitsource.com/product_info.php?products_id=103
*80mm for my install. 100mm if you want to put them in the shroud.
Step 1: Headlight removal
First, we need to get that front bumper removed. Start with the 6 pins at the top just under the hood. To remove them, push in the center with anything small and rigid then pull out using a flat head screw driver.
Next, loosen the T25 torx head screw in the front wheel well. The picture is taken looking forward on the car. Loosen this screw 5-10 turns then use the screw driver to push the screw in. Pushing this screw in releases a lock which pulls the bumper onto the car when re-installing.
Starting with the circled area, use a small flat head to pry off the trim piece. Be careful not to damage your paint. Once you get it started, put down the flat head and continue to pull off.
The two arrows below show where two 10mm bolts will be hidden. Remove with socket wrench and pull out CAREFULLY. Make sure the bolt stays in the socket when pulling out because if it falls in the bumper it is a PITA to get out from the internal cavities of the bumper.
Now, pull outwards on the circled area below while also pulling the bumper forward, off from the vehicle. If you pushed in the locking segment far enough when tackling the T25 screw this should be easy. If it doesn't want to release, loosen the T25 screw a few more turns and push it in a second time. Once both sides are released, pull the bumper off from the front of the vehicle.
The next two pictures show where the 8mm screws are located to release the headlight assembly. I show three screws but there may be a fourth underneath the headlight. I may have removed mine and chosen not to replace because it may be hard to access. Hopefully someone can chime in and clarify this step.
Lastly, pull out the headlight slightly and remove the following three connectors to release the assembly. The assembly is now removed from the car.