Volvo Headlight System Malfunction: 2017-2022 S60, V60, S90, V90, XC40, XC60 & XC90

Common Failure Symptoms

When the Headlight Control Module (HCM) begins to fail, you will typically see a warning message in the driver's display. The car's computer is very specific, and diagnosing the problem often starts with reading the exact message.

• "Headlamp System Malfunction, Service Required" Message: This is the most common indicator of a fault within the headlight system. It can point to the module, the headlight level sensor, or the internal components of the headlight itself.
• "Auto High Beam Malfunction" Message: This message appears when the system that automatically switches between high and low beams is not working, often due to a fault in the HCM or the forward-facing camera.
• One or More Lights Stop Working: You may notice that the low beam, high beam, or the 'Thor's Hammer' Daytime Running Light (DRL) is out on one side.
• Flickering or Dim Headlights: The light may flicker, appear dim, or change to a pink or purplish color, which often points to a failing module or LED element.
• Active Bending Lights Stop Working: The headlights may stop swiveling when you turn the steering wheel.
• Related Systems Disabled: A headlight system fault can sometimes cause the vehicle to disable driver assistance systems like Pilot Assist, Adaptive Cruise Control, and Lane Keeping Aid, as they may rely on the same camera and sensors.

Associated OBD-II Trouble Codes

A professional scan tool that can read Volvo-specific codes is necessary for an accurate diagnosis. Generic OBD-II readers may not be able to communicate with the HCM. Look for the following codes:

• U040086: Invalid Data Received from Headlamp Control Module.
• B104321 or HCM-B104312: These codes point specifically to the Headlamp Leveling Sensor (often called the front or rear axle sensor), not the module itself. This sensor tells the HCM the car's angle to aim the lights properly. A failure of this sensor can also trigger a "Headlamp System Malfunction" warning, so it's important to read the codes before replacing the module.

Known Issues, TSBs, and Recalls

There are no active recalls or Technical Service Bulletins (TSBs) from Volvo or the NHTSA for a widespread failure of this specific Headlight Control Module. However, there are related software recalls for these vehicles that owners should be aware of.

• NHTSA Recall 19V-849: Affects many 2019-2020 models, including the S60, V60, XC40, XC60, and XC90. A software issue could prevent the Automatic Emergency Brake (AEB) system from detecting obstacles. Since a headlight malfunction can also disable driver-assist features, it's important to ensure your vehicle's software is up to date.
• NHTSA Recall 18V-800: Affects many 2017-2019 models. A software error in the Vehicle Connectivity Module (VCM) could prevent the vehicle's GPS location from being transmitted in an emergency. The fix was a complete software update for the vehicle.

These recalls are addressed by a Volvo dealer, typically with a free software update.

Programming & Replacement

Replacing the HCM is a two-part process: physical installation and software programming. While a skilled DIY mechanic can perform the physical swap, the software programming is mandatory and requires specialized tools.

Software Programming: A Necessary Step

You cannot simply install a new or used HCM and expect it to work. The module must be loaded with the correct software for your vehicle's specific configuration and then paired to the car.

• Tool Required: This programming is done with Volvo's official diagnostic software, called VIDA (Vehicle Information & Diagnostics for Aftersales).
• Who Can Do It: A Volvo dealership or a qualified independent European auto specialist with a VIDA subscription and a J2534 communication tool can perform the programming.
• The Process: The technician connects to the vehicle and performs a "HCM Software Reload." This process requires information from a data sticker on the headlight assembly itself.
• Voltage is Key: A stable power supply (at least 12.5V, but ideally over 13V) must be connected to the vehicle's battery during the entire software download. A voltage drop can interrupt the process and potentially damage the module.

Physical Replacement Walkthrough

The HCM is bolted directly to the bottom or back of the headlight assembly. To access it, the entire headlight must be removed from the vehicle.

1. Bumper Removal: The front bumper cover must be at least partially, and often fully, removed. This involves releasing numerous plastic push-clips under the hood, Torx screws in the wheel wells, and bolts underneath the car.
2. Headlight Removal: Once the bumper is off, the headlight assembly is typically held in by three T30 Torx bolts.
3. Module Swap: With the headlight assembly on a workbench, the HCM can be unbolted and the electrical connector detached. The new module is then bolted in its place.

Buying a Used Body Control Module

Purchasing a used OEM Headlight Control Module is a great way to save a significant amount of money. However, there are critical factors to consider to ensure you get a good part that can be successfully installed.

• Match the Part Number: It is essential to match the OEM part number on your original module to the used one you are buying. The part number is printed on the module's label, but it may be on the surface facing the headlight, requiring you to remove it to read it. The part numbers covered in this guide are interchangeable.
• Inspect for Damage: Check the connectors for any signs of corrosion (green or white powder) or bent pins. Look at the casing for cracks or signs of water intrusion.
• Factor in Programming Costs: Remember that a used module is just the part. You will still have to pay a dealer or independent shop for 1-2 hours of labor to program it. Factor this cost into your total savings.
• Why Used OEM is a Good Choice: For a complex electronic part like this, a used Genuine Volvo module that has been tested is often more reliable than a cheap, new aftermarket part from an unknown brand. These modules are designed to last the life of the vehicle, so a used unit from a lower-mileage vehicle is typically a safe bet.

Cost Breakdown

Prices can vary by location and supplier, but here is a general estimate for replacing a single Headlight Control Module.

Frequently Asked Questions (FAQ)