Date: Sun, 17 Oct 1999 16:44:59 EDT
Reply-To: kenneth d lewis <kdlewis@JUNO.COM>
Sender: Vanagon Mailing List <vanagon@gerry.vanagon.com>
From: kenneth d lewis <kdlewis@JUNO.COM>
Subject: Head light relay modification.
'gonites;
I finally got around to doing this mod, unfortunately it took a
headlight switch melt down to motivate me. I do not now if the round
headlight vans have the switch failure problem, but you will achieve a
voltage gain at the lights. Measuring at the fuses I gained 1.5 volts on
the low beams and 2.5 volts on the HI beams.
I did a good bit of research and came up with a method that has
these benefits:
>Greatly reduce the current flow through the pitiful headlight
switch. The switch will now only carry enough current to operate
the relays instead of the 19 amps of high beam current.
>NONE of the original wires are cut.
>ALL of the original HI and LO beam fuses are still used.
>A noticeable gain in light output.
>My headlites used to dim when I turned on the heater fan. Not
any more!
>It's SANO!
My vehicle is an 86 so all references are made with respect to
it. You will need :
1>two automotive type relays. I purchased mine at Radio Shack,
they were rated at 30 amps.
2> 10 gauge wire, the length depends on how you route it from the
positive battery post.
3>Some wire and female spade connectors to match the gauge you
use. It only has carry enough current to operate the relays.
Reference page 97.78 in the Bentley. I pulled off the large White
and Yellow wires at 56a and 56b on the back of the Headlite Flash/Dim
Switch. You will have to drop the black plastic cover under the steering
wheel column to see them. These wires feed current to the main fuse
block. The current path is then split to the right and left side lites.
The two relays can be mounted on the dash board behind the
steering column. They are nicely concealed by the plastic cover. Mine are
mounted sideways, with terminals facing each other.
Connect the big white wire to one of the relay contacts. The
other relay contact is fed by the 10 gauge wire from the battery post.
Properly fuse it at the battery. The coil of the relay is controlled by
the voltage at terminal 56a. Repeat this procedure for the Yellow wire
except feed it with the same 10 gauge wire from the first one . The
relays are right next to each other so make a small 10 gauge jumper. The
second relay's coil is fed by 56b.
To summarize; instead of directly supplying the current to feed
the headlights, all the switches and connections in the dashboard only
have to energize a relay. This relay is fed by a healthy 10 gauge wire so
parasitic voltage drops are significantly reduced.
A proper crimper greatly enhances things. The Shack also sells
these.
Drive Safely & Good Luck
Ken Lewis<Kernersville,NC>86 VW crewcab;60 T-5 Coupe
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