A BRIEF HOW TO WIRE RELAYS
This is a general how to based on the mid 80s Volvos, using stock lights or at maximum 55/65w H-4 outer lights with 100w inner high beams. If you are planning to run 80/100 or 80/120 H-4 outer lights you will need an additional LH fuse so you can run dedicated power to one of the high circuits.
Parts needed
The bar off drivers side inner fender with power distribution buss (the black cover with all the heavy wires)
3 relays Volvo number 0332015012 12v - 2X15A with the clips that hold them to the bar.
One of the LH fuses off the later 240s with the eye that attaches to the battery and as much wire as you can get with it.
1 roll 16 gauge wire for signals.
3 rolls 12 gauge wire, blue, red and black.
1 roll red 10 gauge wire if location of bar is too far from alternator for the wires on the LH fuse to reach.
A bunch of male and female crimp on spade terminals for running the wires. (get the right sizes for the wires)
4 loop terminals for #12 wire for running the grounds for the lights.
30 amp fuse.
Locate the bar in a position that is easy to get to and as close as possible to alternator.
Disconnect negative terminal of battery.
Solder one end of the wire on the LH fuse to the heavy wire of the power buss.
Run the other to the B+ terminal of the alt' you can run it to the battery if location demands it. Run the wire with care so it will not rub on anything and short. Pull the fuse and re-connect the battery.
Mark the relays L, H1 and H2. Do not clip them to the bar yet.
Remove black cap off the buss, run separate 12 gauge wire from buss to terminal #30 of each relay.
Replace black cap.
Run signal wires:
Pull the plugs off the back of the lights, check with meter which is low, high and ground. Blue should be low, Red should be high and Black should be ground, Check by turning on lights and testing with meter!!.
Run wires from the low side of the plugs on both sides, splice them together and run to terminal #86 of relay L.
Using a signal from both sides will keep the light out warning from being on all the time.
Run wire from high side of any plug and split the signal to the #86 terminals on relays H1 and H2.
(The high beams are not run through the light out warning so you can use only one signal for both relays)
Run your ground wires:
Run a # 12 black ground wire from the ground terminal on all 4 of the lights to the nearest well grounded screw.
Run a wire from terminal #85 of each relay to a good ground.
Run the power wires.
From terminals 87 and 87b on relay L run #12 blue wires to the low beam terminals of the outer lights.
From terminals 87 and 87b on relay H1 run #12 red wires to the high beam terminals of the outer lights.
From terminals 87 and 87b on relay H2 run #12 red wires to the terminals of the inner lights.
Clip the relays to the bar, inspect for any rub areas that may cause shorts and put the 30 amp fuse in. Test to be sure everything is working properly. With the short length of the wires the 30 amp fuse is fine, no excess heat and 30 amps will allow up to 350 watts of lights at any one time with a 5 amp safety margin. 30a X14v = 420w if you are running 100w high beams on all 4 lights you will want to independently fuse one of the high beam relays.
