Wiring Harness Installation - 2004 Volvo XC90

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This Product Fits The Following Vehicles

2003 - 2004 Volvo XC90

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Circuit Protected Modulite 4 Pole Harness with Hardwire Kit (Includes Testers)

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Installation of a Wiring Harness on a 2004 Volvo XC90

What we are going to is a module light install on a Volvo XC90 2004 model. What we have done so far is taken out the interior pieces, got down to the battery with the jack storage compartment, and then we actually took out this panel here to get access to the wiring for the lights. Well have to do our splicing within this wiring bundle here. We used the light tester to figure which colors are what in fact in this case all the turn signals, the brake and running lights all happen to be green. Take care when testing, do one at a time complete your circuit and move on to the next one.

Now what were going to do is route our wires where they are going to go first and then make the wire connections. I think what well do is go ahead and put this in the cavity here, were going to leave this out because this wire is going to be ran underneath the Styrofoam here to the other side. These wires here will be ran up behind the plastic, make our connections and were going to try to ground it right here, so lets get started with that section. Well check our connections. Apply the foot brake and test our connection. Now lets install our ground.

Next well take our green wire and our power wire and route it back through here. Sometimes its a pain to go ahead and run that wire. So well cheat and use this safety wire and use that instead to pull it through. Lets see if we can go all the way across to the other side when we get ready to do that side. Well tuck it all behind this. Well go ahead and run our right turn signal circuit over, do something simple as following this wire here. What we can do is just come up behind this steel bracket, feed it back here. You can push it behind this box here and well zip tie it eventually to this wire harness. Next well make our connection back up in this harness here and well test for that. Lets go ahead and test for our right turn signal. Okay lets work on our battery connection now.

Next lets make our battery connection first we need to get to the battery. Take the cover off and were to our battery connection. What we need to do is install our fuse holder. What well do is install it on this nut here and run it to our power line here. We hold it up to it and split our wire harness, it looks like its just going to be long enough. You have to take into consideration of the box taking up space. Were going to cut off about a foot off our wire from the install kit, its kind of a waste of this wire part here, but you get the fuse holder the connectors and the fuse. So lets get started with that part. Cut the wire, start our splice and the power supply here.

Next thing is connect to the battery, its always good practice to disconnect your battery totally before you make any connections, and connect your battery last. Well do it that way. Now we have the battery disconnected, lets go ahead and make our connection to here and reverse the process. If you notice here, its kind of a sloppy fit there, it may be a good idea to go to a ground it with a smaller ring terminal or find a nice washer to sit on top of it and hold it into place. Well try to find a washer to put on top of that . Now we have our washer here well put it on our connection there and reverse the process. Well connect positive first. Lets go ahead and put our battery cover back on and see how much we have left over. There is a nice spot there for it to stay out. Well go ahead and put our fuse in and zip tie our wires up. Well go ahead and put our excess back in the cavity since nothings happening back here anyway. Well route our wires about like this and zip tie them. Now well but our battery covers back on, we have our plastic case on now well get to the metal bracket. Now we have made our connections finalized, lets go ahead and test our four pole and make sure our circuits are working. Notice I am using our ground tester on this ground here just to verify our ground is working through our wire. Well try our running lights first, then our right turn signal the green wire, the brake light and then left turn signal. What we are going to do now is go ahead and run our wire to the outside of the vehicle, cut this and run our wire through inside out up in this cavity here and then make a reconnection that way. We pull the plug, there are about two or three of these rubber plugs down there, pull this out from the bottom next to the battery. So what well do is make a little splice in here poke our wire through use that for our grommet. Now that we have made our slice here, well run our wires through the slice, and this will be our grommet. Well pull it through and go from underneath the vehicle and pull it through the hole next to the battery. Now that we have our wires pulled back through, we just need to reconnect these. Well use our buck connectors, put them back together, take our excess we do not need and just zip tie it back up inside here. Now well wrap these up in some electric tape. Next thing we want to do is install our bracket. This hitch already has a metal bracket installed, well mount it right there, and our four pole will be a friction fit right there.