In the 'Missing Items' thread I originally suggested buying the connector ant terminals from Volvo (the connector is Volvo part no. 30656844 and the repair terminals are part no.30656669) or going to a breakers and getting the connector with a length of wiring attached from another Volvo.
I then did some research and found who manufactures the connectors. They are made by JAE and both the connectors and contacts are available to the public from the likes of RS and Mouser, and it's probably cheaper and easier to buy from then than it would be from a Volvo dealer or breakers.:
The male connector is 56p from RS as part no. 727-5771:
The contacts for the male connector (you need 2) are IL-AG5-PC1-5000 which are £1.80 for a pack of 50 from RS as their part no. 690-9896:
The Female connector that connects to the LED lamp unit is 56p from RS as part no. 727-5775: You will need 2 of these.
The contacts (you need 2 for each connector, so 4 in total) are IL-AG5-C1-7500, £1.45 for a pack of 50 as RS part code 690-9887:
For Mouser, it's best to search for the JAE part numbers on their site to find them. They have the advantage that the contacts can be ordered in multiples of 1 instead of 50.
You will also need a decent quality crimp tool. It has to be the type that can do uninsulated terminals with strain relief tangs, not the type used for those red./blue/yellow insulated crimp terminals. You want something with 'steps' in the jaws, like this:
The steps' crimp the 2 sections of the terminal at once - the lower one crimps the conductor and the higher one crimps the strain relief tangs.
As well as the connectors, you are goin gto need some wire. It doesn't need to be the same colour as the factory wiring, but you do need 2 separate colours as we are dealing with a polarised component. Unlike bulbs, LEDs only work with the current flowing in one direction (remember the 'D' means diode), and connecting them in reverse will usually result in damage.
The factory cable spec appears to be:
0.35mm Thin Wall Cable
Cross Sectional Area: 0.35mm²
Stranding: 12 x 0.2mm²
Outside Diameter: 1.3mm
Nominal Current Rating: 7.0 Amps
This is thin-wall PVC insulated cable. The 1.3mm OD is the smallest 'thin wall' size used on cars and isn't the easiest to get hold of, but on the Male connector where 2 cables have to be crimped into a single contact it's just at the limit that the JAE crimp contacts will take. You will need 2 x 3 metre lengths of different colours.
The final thing you will need is some loom wrapping tape. I use fibre tape (sometimes called TESA tape after the leading manufacturer) but you could use PVC loom tape (like insulating tape tape, but thinner and less adhesive) too. I wouldn't use insulating tape, as it's too thick and will make the wrapped wiring hard to route and form to the existing loom in the car..