Vanagon EuroVan
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Date:         Wed, 24 Oct 2012 09:24:17 -0400
Reply-To:     Jay Brown <badkarma@TTLC.NET>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Jay Brown <badkarma@TTLC.NET>
Subject:      Re: Uninstalling SA headlights
Content-Type: text/plain; format=flowed; charset="iso-8859-1";
              reply-type=original

The South African Grill uses H4 sockets (same as stock connector on the 80-85 Vanagon) for the main 7" round outer lights. Jumper wires for high beam and ground run to the smaller inner lights.

The 86-91 Vanagon uses 9004 sockets for the outer lights and a custom connector for the inner lights (you can substitute 1/4" female disconnect terminals for the stock inner light plug if you don't have the stock wiring). Remove the round white connector on the back of the inner lens by turning it counterclockwise to determine which wire is the ground.

Both types of headlight sockets will be available at most good autoparts stores, or can be found online if you can't source them locally. If you plan on running higher than stock wattage bulbs with either setup, high temp ceramic headlight sockets are highly recommended.

With all model years, the headlight wiring color codes are as follows:

Yellow = Low Beam White = High Beam Brown = Ground

The pinouts for the headlight sockets can be found on my website here: https://sites.google.com/site/vanagonheadlightrelays/helpful-information/lens-bulb-upgrades/headlight-socket-pinouts

Marine style butt connnectors (with built in heat shrink tubing) work well for headlight connections, or you can solder and shrink wrap the wires if you have a decent soldering skills and a good iron.

If you would like to avoid cutting any wires when installing your grill in a different van, you can use one of my plug & play headlight conversion harnesses: https://sites.google.com/site/vanagonheadlightrelays/headlight-wiring-harnesses

Feedback on my products can be found here: http://www.thesamba.com/vw/forum/viewtopic.php?t=377131&highlight=thatvwbusguy+comcast

Hope that helps, Jay Brown '85 Zetec Westfalia


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