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Headlight issue on a '68 120-130

posted by  votx on  Wed Jul 26 15:51 CST 2017
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last visit: Thu Oct 23 18:48 CST 2014
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Greetings all,
I'm in the dark, literally, on this one. My '68 122 (2dr.) has a relay, P/N 85621 mounted on the firewall hump next to the serial number plate. I've been told '68 was the first year to use a headlight relay. My Haynes manual has not been much help. The relay is rectangular, approx 2 inches long by 1&1/2 inches tall. Unfortunately all the wires to the relay are missing. It has a total of 4 terminals, (2 on the inboard end, one on the front, and one on the other end). I presume these need to be connected to the fuse box, but don't know to which terminals. I don't want to fool around and fry something. All the other electrical stuff works, (horn, wipers, fan/blower, etc.) If anyone has a '68 with the same relay set-up can you please tell me how to wire it up? Or email a photo to me directly at blangdon@gvtc.com. I still haven't figured out how to post or view photos on Brickboard. Thanks guys,








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    Headlight issue on a '68 120-130

    posted by  someone claiming to be P of M on  Fri Jul 28 03:59 CST 2017 [RELATED]

    If u proceed with reasonable caution you can't "let the smoke out" on an Amazon . For starters the headlight circuit is dead simple in the stock configuration. If you have a NA Spec car wires go from HL switch to foot /dipper switch to HLs. (Dipper switch is a common failure point causing either no hi or no lo beam, or both). Test probe light will tell u where u do and don't have 12V+. Often people spend a lot of time chasing wiring when the HL themselves are burnt out.....test by removing socket plugand applying 12+ and - to the various points on bulbs, you can also easily check for voltage at the socket. The dashboard switch also can be a failure point, check to make sure wiring is tightly connected.
    hi/lo relay in the engine bay is a great option if u know how it works....I set mine up like that, works great and if done properly reduces load on the dash switch (which will then last longer) and improves brightness of the HL. Google simple HL circuits automotive to help understand the basics.







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      Headlight issue on a '68 120-130

      posted by  votx on  Sat Jul 29 13:35 CST 2017
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      last visit: Thu Oct 23 18:48 CST 2014
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      Sorry for the slow reply. I've been busy working on another batch of the blue after-market air filters (with replaceable elements) I make & sell on Ebay.
      Regarding my electrical situation,
      My original floor dimmer switch is O.K. so I see no reason to change over to the turn-lever set-up. I've also checked all the wiring & the bulbs. Once I find out how the relay is hooked up, I'm pretty sure I'll have headlights. Hopefully someone out there has a '68 with an identical relay. Thanks








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        Headlight issue on a '68 120-130

        posted by  someone claiming to be P of M on  Sat Jul 29 15:35 CST 2017 [RELATED]

        Afaik the 68 does not have that relay, someone probably put it there to mod the power distribution to the HLs like I have. My 68 certaintly didn't, I got my HL relay from a 140 or a 1800(can't remember). It is really just 2 standard relays in one box (if memory serves) or it may be 2 solénoïdes with a see-saw kind of switch. Your stock system did not have or need it, you can go straight from the foot switch to the HLs.....or you can go straight from the foot switch to the HL relay and use it to control a shorter larger gage wire from the battery + to the HLs.








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          Headlight issue on a '68 120-130

          posted by  someone claiming to be P of M on  Sat Jul 29 15:59 CST 2017 [RELATED]

          It's a see saw....see this.

          http://www.sw-em.com/headlight_control_upgrade.htm

          Like I said u don't need to control it with the stalk toggle. Actually no need for the old Volvo relay at all, I still have mine but I'm pretty sure I could control the HLs with something simpler vis à vis Relays et all..








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            Headlight issue on a '68 120-130

            posted by  planetman on  Sat Jul 29 16:18 CST 2017
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            last visit: Fri Oct 24 09:29 CST 2014
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            I too will tell you that Volvo did not have a relay for the headlight system on a 122.

            There was a relay for flashing just the high beams, but that was not allowed for USA cars, hence you will find the wires for the flashing relay wrapped up on the main harness along the left inner fender.

            --
            Eric
            Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
            Torrance, CA 90502








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              Headlight issue on a '68 120-130

              posted by  votx on  Sat Jul 29 18:42 CST 2017
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              last visit: Thu Oct 23 18:48 CST 2014
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              Once upon a time this car had air-conditioning, so perhaps this relay was used for that.








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                Headlight issue on a '68 120-130

                posted by  planetman on  Sat Jul 29 20:58 CST 2017
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                last visit: Fri Oct 24 09:29 CST 2014
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                That does sound like an A/C relay. The original high beam flasher relay Volvo used was squarish in shape and had only 3 terminals.

                Since you say the problem is only with the low beams and you have eliminated the foot dipper switch, the connection at the foot dipper switch and the headlight bulbs, then you are left with wiring and a few connections.

                The usual suspect is the connection at the left front core support.

                Try to clean the connectors for the gray wires at that connection.
                --
                Eric
                Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
                Torrance, CA 90502
                hiperformanceautoservice.com or oldvolvosonly.com








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                  Headlight issue on a '68 120-130

                  posted by  votx on  Mon Jul 31 20:03 CST 2017
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                  last visit: Thu Oct 23 18:48 CST 2014
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                  Well, I'm happy to report that my headlights are now working properly. I threw the relay in the trash since everyone said it was not used on a '68 USA model.
                  The problem turned out to be 2 of the wires on the headlight switch were switched around. Black & red. The red wire had some black heat-shrink-tube on it so I just got the colors mixed up when I re-attached them to the switch. I felt pretty stupid when I discovered my goof. Anyway, everything is working great now, and I want to say "thanks" to all those who responded to my cries for help.








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                    Headlight issue on a '68 120-130

                    posted by  Type5314 on  Mon Aug 14 14:44 CST 2017
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                    last visit: Thu Oct 23 13:07 CST 2014
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                    My Swedish build 1968 123 GT does indeed have a factory installed high beam flash feature. When you pull back on the turn indicator stalk, the high beams flash. A rectangular relay just forward of the round, reversing lights relay is involved in this switching. From memory, the relay has 4 terminals. It's a very nice way to signal other approaching vintage Volvos. So I hope the trash has not been picked up yet....








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                      Headlight issue on a '68 120-130

                      posted by  votx on  Mon Aug 14 19:56 CST 2017
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                      last visit: Thu Oct 23 18:48 CST 2014
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                      At this point I'm so glad to have all the lights working properly I think I'll quit while I'm ahead. I need to move on, and finish up a few more details to complete the restoration, so I can hopefully sell it and start my next project. I have a 544 and a '68 1800S awaiting my TLC (time, labor & cash). Haven't decided which one to tackle first. Thanks for your input.








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    Headlight issue on a '68 120-130

    posted by  Ron Kwas on  Wed Jul 26 20:24 CST 2017
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    last visit: Fri Oct 24 04:03 CST 2014
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    Bill;

    If a four terminal relay has been added (by previous owner/you...do give details!), it is likely to incorporate/restore the European Headlight Signaling function (activates Hi-Beams when Stalk is pulled back) as covered here: http://www.sw-em.com/122flasher.htm

    The full relay Headlight control using the bistable relay (6 or 7 terminals) was never originally delivered on Amazons, but can also be retrofit to full European style (with Stalk Headlight flashing when Headlights are OFF, and Hi/Lo-Beam control when Headlights are ON) ...it's a good retrofit and I cover it here: http://www.sw-em.com/headlight_control_upgrade.htm

    In order for me to help, you need to give further info:
    1. Terminal designations on relay (a picture sent to my email if you cant figure out how to post here).
    2. Are there any wires which are or were connected to the relay? What colors?
    3. Is the Footswitch Hi/Lo Beam control still present?

    You're welcome to contact me directly through e-mail...some pix of relay, relay terminals and surrounding area and wiring would help.

    Good Hunting!







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