the following was courtes=
y of ken wilford.. i was just cleaning out my files and thought some of you =
may benefit from this. i did this to my van and now i can run 80=
/100w H4's in there without melting the headlight switch.. big i=
mprovement!
enjoy..
chris
----------------------------snip-------------------------
How to Wire Headlights with Relays for Higher Wattage Bulbs
Parts you need to do this:
2- 40 Amp Relays
4- Rolls of Different Colored 14 gauge wiring
Box of Female Spade connectors (blue)
2- Fuse Holders for 16 amp fuses
2- 16 amp fuses
2- Ring connectors for battery connection
Run two 14 gauge feed wires from your battery to the fuse panel area. =
Crimp a spade connector to each wire. Hook the power wires to one side=
of the 2 fuse holders. Now make another wire for each fuse holder and ru=
n this to the power side of the relay (pin 30 on the relay)-(I would use red=
wires for this to indicate they are power wires). The relays that I woul=
d recommend would be the 40 amp relay that is used on the Vanagon. These =
are part number 141 951 253B. Now you want to label the two relays: High =
Beam and Low Beam. Now you go to fuse panel. Here you will see the fou=
r fuses at places number 3, 4, 5, 6. Number 3 is low beam left and 4 is l=
ow beam right. Number 5 is highbeam left and 6 is highbeam right. You =
want to unplug the two main feed wires to the four fuses (lowbeam should be =
yellow with a black stripe and highbeam should be white). Plug these powe=
r supply wires into the number 85 pin on your two relays (be sure to plug th=
e proper wire into the properly labeled relay). Now you want to make up t=
wo ground wires for the relays as well. I would use a brown wire for thes=
e as this is typical ground color for VWs. Plug one end of the ground wir=
e into the number 86 pin on the relay and the other end onto the ground star=
connector located behind the fuse panel and to the left. Now you want to=
unplug the four connectors from the fuse panel that feed the lights. The=
se should be white for highbeam left, white with a black stripe for high bea=
m right. Splice these two together by cutting off the two connectors and =
crimping both wires into a single female spade connector. Now do the same=
thing with the low beam wires (should be yellow for low beam left and yello=
w with a black stripe for low beam right). Now plug these wires onto the =
relay pin number 87 on the corresponding relay. You should be done. Te=
st your lights and then secure everything in the dash taking care to tape up=
any exposed connections with electrial tape.
Thanks,
Ken Wilford
John 3:16
www.vanagain.com
Phone: (856)-765-1583
Fax: (856)-327-2242