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Headlight wiring upgrade

 
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Ozzie  



Joined: 12 Mar 2005
Posts: 4238
Location: Townsville, Qld. Australia

PostPosted: Mon Jun 30, 2008 12:28 am    Post subject: Headlight wiring upgrade Reply with quote

Well my LH headlight wiring is FUBAR. I believe it is the terminal in the fuse panel on Multiplug A terminal 19.

As I want to upgrade to brighter bulbs and this area is a weak point as well as the 8Amp fuse restricting me to 96W max then this is the solution.

You'll need two 30A relays, plenty of wire (4 different colours), crimp lugs and an inline 30A fuse.

First off raise & remove both headlights, (disconnect motor) disconnect the wiring at the plug and put to one side. Pull the wiring back to reach the relays. Terminate the yellow and black wires on the side with no relays. You wont need them.

Fit the two relays near the headlight on one side. I used the RH cos the LH side is not working but either is fine.

Fit the yellow wire to 86 on one relay and the white to 86 on the other.
Fit the brown to 85 on both relays.

Using 4mm wire run from pin 87 on both relays to the battery with an inline fuse. (I used one wire and jumpered at the relays)
Pin 30 on the relays goes to the headlights. Use 2.5mm wire and run two wires from 30 on each relay, one to each headlight.
You'll have to run two wires around to the other headlight.
Each relay does both headlights and allows up to 15Amps each
12Volts X 15A =180 Watts.
Fit the new H4 bulbs and test Depending on the law in your country put in the maximum you need.
The fact that you are fitting heavier wire, direct connect to the battery via relays will give your standard bulbs a boost anyway.

I used a new earth wire on each light and bolted it to the main earth point near the headlight on each side.
For those that can follow wiring diagrams.

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Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance
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00Smurf  



Joined: 29 Jun 2008
Posts: 60
Location: Canal Winchester, Ohio

PostPosted: Sat Jul 05, 2008 12:00 pm    Post subject: Reply with quote

I'm confused on the 30 bit. You run 2 wires from 30 on one relay to one head light, then 2 wires from 30 on the other relay to the other headlight. Or do you run 2 wires from each 30 pin on each realy to each headlight? And where to you attach the 2 wires 2?
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Ozzie  



Joined: 12 Mar 2005
Posts: 4238
Location: Townsville, Qld. Australia

PostPosted: Sat Jul 05, 2008 10:21 pm    Post subject: Reply with quote

One relay is for low beam, the other for high beam.

30 being the switched 12 volts.

Each relay has to supply both headlights with power for low and high beams.

Behind the headlights is a 3 pin plug with spade terminals.
I connected the wires here and a heavier earth wire direct to the earth point on the chassis.
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Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance
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00Smurf  



Joined: 29 Jun 2008
Posts: 60
Location: Canal Winchester, Ohio

PostPosted: Sat Jul 05, 2008 11:10 pm    Post subject: Reply with quote

Ozzie wrote:
One relay is for low beam, the other for high beam.

30 being the switched 12 volts.

Each relay has to supply both headlights with power for low and high beams.

Behind the headlights is a 3 pin plug with spade terminals.
I connected the wires here and a heavier earth wire direct to the earth point on the chassis.


Where on the 3 prong connector did you attach the wires? Just any of the 3 wires, or one in specific?
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Ozzie  



Joined: 12 Mar 2005
Posts: 4238
Location: Townsville, Qld. Australia

PostPosted: Sat Jul 19, 2008 10:54 am    Post subject: Reply with quote

If you follow the wiring diagram the yellow and yellow/black wires are one beam (low IIRC) and the white and white/black the other (high)
I used green and blue from 30 because it was what I had laying around.
The wiring on the plug at the headlight is the same color (yellow and white)
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Porsche 924 1984 (UK import) NA
Its AUTO and its BLACK
Montego Black on black/red
Engineer of Electro/Mechanical Systems Maintenance
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Adismo  



Joined: 05 Oct 2008
Posts: 71
Location: Guatemala

PostPosted: Mon Oct 20, 2008 2:01 pm    Post subject: Reply with quote

Thanks for the info dude, works perfect i will post the pics
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tyfighter123  



Joined: 19 Jan 2010
Posts: 517
Location: Colorado

PostPosted: Fri Oct 08, 2010 7:06 am    Post subject: Reply with quote

He never posted pics!
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Porsche 924S 1987 (parts car)(cut up and recycled)
Porsche 911S 1976
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