Yesterday I installed my second set of the DJ Auto E-Code headlamps and wanted to post some brief impressions for those unsure of whether to make the leap.

I have been fairly well impressed with the quality of construction on these headlamps - the entire assembly. Many people have reported that the assembly does not sit flush with the sheet metal, thus, there is a possibility of pulling the mounting studs from the plastic. I found that to be the case on my '92 wagon that had had the fender replaced, but not on my '93 sedan. I used washers between the headlamp and the sheet metal the first time, but left them out the second; no regrets. Either the manufacturer has improved their molds, or the reported poor fit was more attributable to slightly wonky sheet metal from 22+ years of rough roads.

The light quality is much improved over the plastic headlamps (I did not add relays), but has some spottiness. Nothing I can't live with. Beam pattern lilts off to the right, making them brighter while at the same time not blinding oncoming drivers.

I have found two shortcomings with the aftermarket e-codes that irritate me, only one with the headlamp: the rubber dust boots which cover the back of the bulb/bucket don't fit very well and have a habit of trying to push themselves off.

My second complaint is with the turn signals (mine made by DEPO): the turn signal connectors are the worst pieces of trash I have ever seen. Not only do the connectors pull off the wires, and the wires not stay in the insulating ends, but they are not long enough, by far, to reach the connector on the passenger side.

Conclusion: I highly recommend the aftermarket e-codes, but do yourself a favor and clip the Volvo turn signal connectors to solder or crimp onto the aftermarket turn signals.

Even if the light output was not better with these headlamps they'd be worth buying, just because they will never yellow and dull leaving the front-end of your car looking old and tired.

Sourcing notes:

As of the time of writing (this, for posterity) even the aftermarket e-codes are hard to come by. They never seem to be in stock with anyone in the US of A. A few months ago, I had to email Pro Parts Sweden to inquire when the "brow" trim would be available here, and which distributors would have it. I got an email soon thereafter from FCP saying "thanks for the email, we're getting a shipment in a couple weeks." Must've spurred someone to action.

I had to buy my second set of turn signals from Lithuania (eBay) but even with the cost of shipping, they were the same price as FCP. Note that the DEPO turn signals come with the trim/moulding; the DJ Auto branded turn signals do not (at least, mine didn't; FCP sent me one of each the first time).

I highly recommend buying the H4 bulbs and connectors separately. You can find very nice ceramic connectors on Amazon.com for about $5 (a pair) and Hella bulbs for about $5 each.

I got the headlamp assemblies from FCP, the turn signals from eBay, and the connectors and bulbs from Amazon.com.

Headlamps - $93/ea x2 = $186
Turn Signals - $30/pr + $30 shipping = $60
Hella H4 Bulbs - $7/ea x2 = $14
H4 Connectors - $5/pr = $5
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Total: $265

I cut and re-used the "brow" moulding from the US plastic headlamps on the first set, but I don't recommend it if you're anything like me. While the double sided tape I used to attach it is holding strong, it gives me a dirty feeling knowing that I hacked it.

The second go-round I bought some used e-code trim (the older style that wrapped around the side of the lens) and while it fit the aftermarket headlamp, the screw holes didn't line up perfectly.

Good upgrade, glad I finally had the disposable income and time to get it done, and I regret spending so much time in the past polishing out plastic headlights and hoarding good, semi-clear lenses.