I think we need more clarity to the use of the auxiliary relays in conjunction with the stepper or dipper relay used on the car from Volvo.

The dipper relay can control other relays. Those relays then can handle power directly from the battery as a complete and separate entity. Is that what was done or you are in limbo with as far as systems?

A headlight relay that you ask about, on the early nineties cars, is located clipped to a rail of the dash beneath the small instrument panels and vents. It is know to be problematic as far as overheating the connector.

The bulb failure relay works on current imbalance scenario from one side or front to rear of the car, to the other. So, if both lights do not work at one time, there is no imbalance.

If you could find the wiring diagram for your car and chicken scratch in the changes made we might be able to jump on it like a rooster for ya! (:-)

Phil