Non-bendy LED to Bendy LED headlamps swap

[Power6]

I successfully figured out and completed the swap from my original non-bendy LED headlights, to bendy LED headlights, on my US market 2019 S60 T6 R-Design. Using all used parts. It was a bit of an adventure! Not as easy as it seemed to be, before I started! I was hoping that it would be as simple as swapping the used headlamps, put on the original modules (HCMs) from my existing headlamps, code with OrBit and go! Turns out it's not quite that simple.

BUT this forced me to work out how to do it, and add features to OrBit to support it, so others can do this without all the pain that I went though ;-)

I used part numbers 32342532 and 32342531. There are like a million headlamp part numbers so good luck out there. Bendy lights should be marked "FULL" and the non-bendy "MID" on the parts sticker on the lamp. I used "US" headlamps, variant code is "JB0B". The EU versions are different part numbers and variant code "JB0C". The swapping process is the same no matter whether US/Can or EU/ROW car. 

First a note on software: You will need the HCM software for this, to load to the used modules. Unless you happen to get used HCMs you know are loaded with the correct software (not likely!). I don't have an official stance on this yet for OrBit when it comes to reloading module software and OrBit doesn't distribute it. That's something to work out for the future. For now, if you have an S/V60 like I do, reach out to me and I can get you the software loaded to the HCMs for this. Others are free to ask, I will help if I can, I just don't have the time to do the tedious research needed to figure out all the right softwares currently and I may not have the software files needed anyways. If you can get to VIDA, you may be able to get the HCMs up and running so you can do an official HCM reload.

To keep the long story short, I found out why you can't make a simple headlight swap and config change:

• Used parts vendors always take the HCMs off and sell them separately, because they are dumb and know nothing about Volvos.
  
• Volvo builds cars with "special" parts at the factory, and by special that means cheaper ;-) The HCMs the car is built with won't support the bendy lights. If you buy a new replacement HCM it will support the bendy lights (same part for all cars). But the part the "non-bendy" car is built with, will not.
  
• You must get proper used HCMs, that support the bendy lights, in addition to the headlamps. They are not typically too pricey though.
  
• You will have no idea if the used HCMs are "left" or "right" (HCML or HCMR), or if they are loaded with software for you model, or a different model (see dumb parts vendors)
  
• You will need a way to set the used HCMs to the correct "side", unless you get lucky and get one used HCML and one used HCMR!
  
• You will need to load some HCM software on the used HCMs
  
• You will want to "learn" the headlamp module to the HCM (not critical but should be done)
  

You can only tell the difference between the HCM that supports the bendy lights and one that doesn't, by looking at them physically. The "diagnostic part number" from VIDA or read with OrBit is the same, the software loaded to the HCM will be the same between bendy and non-bendy cars, the replacement HCM part number for bendy vs non-bendy car is the same. Once you know the difference, you can buy these used, confirming you get the right one if you can see an image of the part. 

(NOTE these parts seem to apply up through 2022 SPA. For 2023 SPA models, there looks to be a new HCM hardware used and new software)

HCM from factory non-bendy car - part number stamped 31427787 and marked "MID" - Will not support bendy lights!
   

HCM from bendy light car, or new replacement OEM - part number stamped 31427776 and marked "HIGH" - Will support bendy lights
   

Now that you have used headlamps and good used HCMs, you will need to install them in the car, and configure them. Since you don't know what you are getting when you buy a used HCM (HCML or HCMR, which model, what software loaded?). You will need to deal with each of those things in turn. And you need some software. The steps I would follow:

• Install the used HCMs on to the bendy lights
  
• Remove the bumper
  
• Install the bendy lights but do not reassemble the car yet! You want easy access to the headlight harness plugs for next steps
  
• Plug only one headlight in to the car, so you are working on only one used HCM at a time
  
• Follow the guide for checking in the car for an HCML or HCMR, load HCM software and write the config string: https://forums.spaycetech.com/showthread.php?tid=161
  
• Unplug the completed headlamp module, plug the other one in and go through the above process again for the second headlamp
  
• When complete, plug both healamps in and reassemble the bumper
  
• Change config with OrBit to enable bendy headlamps
  

   


That's all you have to do ;-) Some FAQ here for the effects of this mod with VIDA (from my observations so far, could change):

• Restore OEM as usual before connect to VIDA. I get no codes in my car or any problems with "bending" disabled
  
• The used hardware module is fine, VIDA will update the car HW and SW with the changed HCM
  
• The car should be compatible with software reloads and Total Upgrade for the HCM (the diagnostic part number and software are the same for bendy/non-bendy HCM to VIDA)
  

[afranke]

Very nice, great write up.  Now for Pixels!

On another note, do you think there is anything needed to replace the JB0B with the JB0C?

[glennda5id]

Should it be possible to swap newer year headlights? As far as I can tell, Volvo continued to improve the light output of the lights in XC90. There appear to be differences between 2016-mid2017, Mid 2017 to 2018 and 2019+

[Power6]

Yes should be fine using newer headlamp units. I used headlamps mfr'd in 2022 on my 2019 S60 here. I did for the same reason, looked for later headlights updated to perform better on the IIHS tests. While there appears to be a change in the HCM hardware for 2023, it looks like you are safe up to 2022.

[glennda5id]

Yes should be fine using newer headlamp units. I used headlamps mfr'd in 2022 on my 2019 S60 here. I did for the same reason, looked for later headlights updated to perform better on the IIHS tests. While there appears to be a change in the HCM hardware for 2023, it looks like you are safe up to 2022.

Very good to know. And I would just use my existing HCM modules? 
Would any programming even be nessecary?

[Power6]

What you need to do, will depend on the specific swap! I can tell you generally what to consider, if you got some specifics bring them and I will help as much as I can.

• As noted above with my case, the headlamp modules were functionally the same, but the hardware differences required the swap of the modules (bendy vs non-bendy).
  
• I have been dealing with a 2019 S60, where all the available headlamps were LED. I think earlier years, like XC90s where some headlamps were halogen, you may have to consider what is different to those models, some may not have an HCM, the wiring in the car could be different, something to consider for a swap. But I think as long as the wiring is generally the same, you could put together a set of HCMs and Headlamps that will work.
  
• There is the possibility that you need no software loaded and just the config change if swapping the lights type (i.e. non-bendy to bendy). The only way to guarantee that, is to buy the headlamps complete with the HCMs attached. Pairing, config, software etc. should all be matched on the HCMs as installed in the previous car they came from. If you buy an HCM on it's own, you don't know what is loaded on it, could be an HCML o HCMR, could be loaded with XC60 software and you have an XC90.
  
• The functions and abilities of OrBit around the HCMs are really to get around the case where the headlamps and the HCMs you have, did not come from the same car. As this seems extremely common, junkyards/breakers like to remove the HCM from the lamp and sell parts separately, it can be difficult or costly to purchase a set of used headlamps, removed from a car, with the original HCMs intact. OrBit can help you by allowing you to install, config and load used HCMs that you don't know where they came from and what they are loaded with.
  

[glennda5id]

Great info. In my case, I have a 2016 and I already have bendy lights, but I am interested in going to the newer lights which have better output, or if I have a failure and need to replace my light assembly. Can I just by a 2019+ bendy light and use it with my 2016 HCM?

[Power6]

Depends what HCM you have! Can you read it in OrBit and see? ECU Tools, change Active ECU to HCML (or HCMR), find the data ID for F120 - Application Diagnostic Database Part number and click "Send to ECU" to read it. If it's 31427777 you should be good, for headlights all the way up through 2022 I believe.

   

[glennda5id]

Depends what HCM you have! Can you read it in OrBit and see? ECU Tools, change Active ECU to HCML (or HCMR), find the data ID for F120 - Application Diagnostic Database Part number and click "Send to ECU" to read it. If it's 31427777 you should be good, for headlights all the way up through 2022 I believe.

Strange, I do not have either ECU's listed. They also do not show up in Vdash.

[Power6]

You could have a "non HCM" car, what is your current config showing in OrBit, for item 106 HEADLIGHTS, TYPE? I don't know which units, though I assume halogen lights, may not use the HCM, the CEM manages them in that case. There are other config items there for LED without HCM as well.