mk1 and mk2 Headlamp Wiring upgrade...this is a MUST!

[velly_16v_cab]

W3LSH’s how to on uprated headlight loom

I thought it was about time I uprated the headlight loom on my mk2 golf again after changing my original cars loom from pre 90spec to 90spec with the g60 conversion.

I’ve take some pics along the way to make a ‘simple how to’ for anyone who may want to do the same

The difference is incredible too

Parts needed
1. A Relay with 30-amp switching capacity


2. 20-amp fuse
3. Quality fuse holder


4. Blade connectors, blue & yellow type
5. Ring connectors to connect to the battery
6. Suitable cable
Total cost? Under a tenner (uk money)

To start with you need to find the wire that provides the input voltage to the lights


I then cut this wire to have the required input and output for the relay


spade connecters were then added


I quickly measured out the cable I would need to go from the battery (+ve and –ve) along a hidden route on top of my intercooler so the loom would not be visible

The two battery ring connecters, fuse holder, and relays were added


After the wiring was put in place, all I had to do was connect the two connectors I had cut earlier to the relay


Here’s a simple pin diagram of this


By running the wires across the top of the intercooler (or rad) the loom is also not on display - but gives a different result to standard


Hope some people find this useful

[velly_16v_cab]

here is a text way of going it, you really shopuld get the picture by now!
Vel

Headlamp High Powered Loom !

This mod is DEFINITELY REQUIRED.

Why?

Because if you get your voltmeters out and just check the voltage
on the standard headlight connectors.
Main headlight is 12.5V and high beam is only 10.2V !!!
A pure voltage drop!!!!! I knew there was a voltage drop but not THAT much !
The standard loom is poor.

I don't know if it was just my car or all VW's, because of this, not even
your standard bulbs are being lit up to the max.

You're losing about 8W of power on full beam PER BULB !

With the mod, you get a full 13.7V for both main and high beam !
So even your standard bulbs will be brighter.

Another advantage is the power is taken direct from battery, the rest of the
cars electric's have less strain so they have more power.
- electric windows, bass on full etc etc.

Its been safely tested for couple of years on long motorway journeys.
At first I was a bit dubious as to whether the system would heat up.
But not even warm!
The standard loom gets warm but this was freezing even after 5 hours
continuous use!
Thats why best to use 30 Amp gear rather than 20 Amp which BRM (should I say
that) provide.

Dead easy to do:

Kit
----
30A Wiring (6 meters) - 4 quid
Battery connectors - 3 quid
30A Fused relays * 2 - 3.5 each
(Get these so you don't have to buy inline fuse holders)
2 headlight connecters from scrappies (Off any big Audi or BMW cos
they're 30 Amp standard)

Thats it !

This kit is rated for up to 180W main beam and 180W high beam bulbs.
Giving a total of 720W lighting power!
(Standard is just 60/55*2 = 220W - Voltage drop = 204W)
I've got 100/80W bulbs. Any more and you might get pulled so best not
to go over 100, or 120W maximum.

Wiring is a piece of cake.

Just got to be careful how you wire the relay up.

Looking at the relay pins

Pin 30 - common goes to the battery +
Pin 84 - open feed, switch which will go to the connectors
Pin 85 and 86 power this will be taken from the original headlamp
connector.


NOTE : Don't cut your original headlamp connectors !


Headlamp connector wires

Looking and starting from the left standing in front of the car the top of
the reversed T shape has yellow (low beam) and if you remove the plug from
the lamp and look at it with the wires facing you the right has white (high
beam) and the left has brown (negative).


Relay one (High beam)

Pin 30 goes to the battery
Pin 84 goes to the white wire on the new connector (the one you've got from
the breakers) Don't forget you've got to parallel it for the otherside.
Pin 85 goes to the original connector white wire (I used the passenger side
headlamp connector, nearest to the wire.
Pin 86 goes to the original connector brown wire (I used the passenger side
headlamp connector also.

Relay two (low beam)

Pin 30 goes to the battery
Pin 84 goes to the yellow wire on the new connector (the one you've got
from the breakers) Don't forget you've got to parallel it for the
otherside.
Pin 85 goes to the original connector yellow wire (I used the passenger
side headlamp connector.
Pin 86 goes to the original connector brown wire (I used the passenger side
headlamp connector.

The only wire missing from the (breakers) connector is the brown, just
take the feed from negative terminal.
1

[DVR68U]

good write up, a great mod to do. it was even worse on old beetles lol . but the mk1+2 can deff do with the upgrade. and thats how easy it is to run another set of spoties too.
cheers brenton

[rs.led]

Found this on addition appointment - achievement it helps. It ability able-bodied boldness the aqueous headlight bung botheration and, because the headlight ability is beeline from the battery, will ensure best ability goes to the lights.the base diagram aloft is for a all-encompassing headlight base approach up brand and will plan for both absolute and abrogating switched headlight systems.

If the new approach is fabricated to the diagram’s set up and access fabricated to the vehicle’s absolute headlight sockets, again there will be no charge to cut into or adapt the vehicle’s base in any way.

Once the new approach is installed, the cars headlight globes will now be absolute about-face no amount what polarity the vehicle’s headlight about-face plan by.

The acumen for application 4 individual pole relays instead of 2 bifold poled headlight broadcast is to access safety. If accepted bifold poled headlight relays are acclimated and a agglutinate assault or a broadcast fails, you can apart either both low axle or both top axle at the aforementioned time.

BY:
LED Flashlight

[anarchycamp]

I have no idea what that guy just said.

[Peter Jones]

I have no idea what that guy just said.

That's because he's a spammer. The diagram is actually plausible though and the text is just so funny that I'm inclined to leave it there.

I've removed the link to his website to comply with our advertising rules and for everyone's safety.

Pete

[dub be good to me]

Nice one Pete.

.. that text was so bad I think it gave me cancer

[velly_16v_cab]

and those the haters

Pictures of the differences:
Normal Dipped


With Loom Dipped


Normal Hi-Beams


With Loom Hi-Beams



be safe....be seen!

[Jarred]

Will the upgrade shown in the first post, just upgrade the low beam, or the high beam lights as well?

I'm planning on doing this mod tomorrow, all being well.

[velly_16v_cab]

i think my one just does low beam....but the diagram posted below will do both (i am sure mr jones will correct me if i am wrong lol)

[Spyda]

Heres the diagram i followed and got great results.



You can also use 4 relays instead of 2 realys. One pair of relays for driving lights and the other pair for the high beams, regardless if you have a double or single light grill set up.



This pic might also help:


If you are going to install a HID kit in to you mk1 or mk2 you MUST do the upgrade.

I've also done the upgrade with great results on light output and voltage.

For the 2 relay upgrade will all the wires and fuze holder it will cost about $20-25 for Jaycar and 4 realy upgrade is aditional ~$10.

[velly_16v_cab]

cheers fella, i was looking to go HID...so will do the replays first

[Jarred]

just did that first, simpler upgrade from the first page, seems to have worked so far. Just need to wait till it's night really.

[RedMk2Gti]

villy_16V, did you actually measure the relay terminal 87 output voltage ? do you get 13.7V ?
I've done this 'upgrade' last month, I still only get 12.?V in terminal 87 but I feel the headlight is brighter

[velly_16v_cab]

villy_16V, did you actually measure the relay terminal 87 output voltage ? do you get 13.7V ?
I've done this 'upgrade' last month, I still only get 12.?V in terminal 87 but I feel the headlight is brighter

the write up is from a post off clubgti years ago...i didnt take the readings sorry....but if they are brighter...who cares lol