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April 21, 2021, 12:16:26 AM

Headlight relay - flummoxed

This is a discussion for the topic Headlight relay - flummoxed on the board Beach Buggy Electrical Help.

Author Topic: Headlight relay - flummoxed  (Read 1473 times)

this user is offline Paul1953

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Reply #15 on: December 23, 2020, 12:58:47 PM
Have had a few phone calls over the weekend from individuals with headlight wiring issues.... One in particulay really made it clear just what some purchases turn out to be totally messed with..  Beach Buggies from the 70`s must be the most tampered\altered vehicle that exists today.

I cannot stress enough that when you want to purchase a buggy make every effort to see it yourself. Make the number one priority of your checks the electrical system. Check that all items, swicthches, lighting wipers and so on work as they should. If you have little or no experience with auto electrics try to take someone with you who has. If you purchase a so called "barn find" off fleabay be sure you are prepared for the possibility of a nightmarish mess. Snoopy passed comment that a buggy could have had anything from any year fitted. Believe I remember Keith finding one with household cable for a wiring "loom".

VW would change many things each year, even going to the point of challenging the public to see if they could spot the changes. There are many differing style of headlight switches from round push pull to oblong push pull to rotary to rocker in 1303 and so on. Number of contacts varied. Some have dimmers for speedo illumination and some don`t.

One basic difference between VW wiring and other manufacturs is that the +12V feed from battery\starter solenoid is that the cable goes to terminal 30 on the headlight switch and on to the ignition switch. (Terminal identification is standard DIN notification and a full list is available on the internet).

It is really difficult to diagnose\offer advice over the phone to someone hundreds of miles away....

There is a long standing website started by Jim Mais in the US. Jim was involved with aircooled motors from a very young age. To the VW community he became known as "SpeedyJim".  Sadly he died in 2019 from a teminal illness but his website lives on. The website shows all of the electrical wirings of switches etc and even has wiring diagrams and comprehensive operational details of Eberspacher petrol heaters.

This should help most people to understand what goes where and why.....   http://www.speedyjim.net/



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Reply #16 on: December 23, 2020, 01:49:20 PM
I've had the a plastic relay show a fault in 1 buggy but work in another!


this user is offline Paul1953

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Reply #17 on: December 23, 2020, 02:22:58 PM
You can check a relay easily. You should only find normally closed versions if running lights have been fitted.

For normally open relays wire to ground. Touch +12v terminal with supply and you will here the contact latch and again when the +12v is removed. In the VW headlight relay the main beam dip beam can be checked by wiring +12v to terminal 30. Momentarily touch terminal S with negative wire and again and you will hear the relay toggle between main and dipped positions.