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

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

    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
    '91 2.0 8v GTI

    Originally posted by DubSteve
    I have wood thinking about you

  • #2
    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
    Velly
    '91 2.0 8v GTI

    Originally posted by DubSteve
    I have wood thinking about you

    Comment


    • #3
      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
      MK1 4door
      MK2VR6
      MK3VR6
      Transporter
      1st place, stock MK3VR6. Vw nationals 07
      2nd place, mod MK2VR6. Vw nationals 09
      and untold wrecks

      Comment


      • #4
        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
        Last edited by Peter Jones; 28-03-2009, 09:47 PM.

        Comment


        • #5
          I have no idea what that guy just said.
          1986 MkII Golf GTI 16V (Sold), 2005 MkV Golf GTI (Sold), 2007 Polo GTI (Sold), 2011 Polo 66TDI (Selling), 2012 Passat 125 TDI Bluemotion, 2013 Scirocco R (Due October!)

          Comment


          • #6
            Originally posted by anarchycamp View Post
            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
            79 MK1 Golf Wreck to Race / 79 MK1 Golf The Red Thread / 76 MK1 Golf Kamei Race Car
            7? MK1 Caddy
            79 B1 Passat Dasher Project
            12 Amarok

            Comment


            • #7
              Nice one Pete.

              .. that text was so bad I think it gave me cancer
              sigpic
              76' 2dr Kjet

              Comment


              • #8
                and those the haters

                Pictures of the differences:
                Normal Dipped


                With Loom Dipped


                Normal Hi-Beams


                With Loom Hi-Beams



                be safe....be seen!
                Velly
                '91 2.0 8v GTI

                Originally posted by DubSteve
                I have wood thinking about you

                Comment


                • #9
                  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.


                  i like volkswagens
                  My blog: http://garagefiftythree.blogspot.com.au/

                  Comment


                  • #10
                    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)
                    Velly
                    '91 2.0 8v GTI

                    Originally posted by DubSteve
                    I have wood thinking about you

                    Comment


                    • #11
                      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.
                      Last edited by Spyda; 16-07-2009, 11:15 AM.
                      MK1 GLS 3door
                      A4 B7 2.0T

                      Comment


                      • #12
                        cheers fella, i was looking to go HID...so will do the replays first
                        Velly
                        '91 2.0 8v GTI

                        Originally posted by DubSteve
                        I have wood thinking about you

                        Comment


                        • #13
                          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.


                          i like volkswagens
                          My blog: http://garagefiftythree.blogspot.com.au/

                          Comment


                          • #14
                            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
                            sigpic

                            Comment


                            • #15
                              Originally posted by RedMk2Gti View Post
                              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
                              Velly
                              '91 2.0 8v GTI

                              Originally posted by DubSteve
                              I have wood thinking about you

                              Comment

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