No $ for real relay..please help me wire this one

[anglodeutsch4]

Hi there!

Yeah, I had the problem with the headlight dipper relay getting full of water too, it took replacing the windshield gasket to FINALLY fix the water leak.

Here's the way I'd test a non-functioning VW 411/412 headlight system, in general.

On the dipper relay, "J" in the above diagram, check for around 12V with the headlight switch pulled out ("ON") at Terminal 56, Black with White tracer.

If no 12V, it's the headlight switch or the "X" contact of the ignition switch...check at the "X" contact of the ignition switch for 12V, the Black wire with Yellow tracer. If no 12V, check the "30" terminal of the ignition switch, Red wire. If no 12V here, it's the Red wire that goes to the fusebox and connects to the Red wire with White tracer coming from the battery. Figure out where and what it is. Note that the Red/White wire carries all the juice for the ignition switch, so if it's dead at the battery, you get nothing anywhere.

Assuming you've got 12V on terminal 56 of the dipper relay, momentarily short terminal "S" to ground. You should hear the relay click. It's a latching relay, so each click toggles from high to low beam or low to high beam. The click means the relay is mechanically working. It may still have bad contacts, either low beam or high or both. Also check the dipper switch on the turn signal to see if it causes the relay to click, if so, the switch and Brown wire with White tracer are OK. If not, track down the problem with the switch circuit. It could be a bad column switch ground, BTW, or (most likely) dirty switch contacts on the turn signal.

Next check for 12V on the outout side. Check 56a (HIGH beam, White wire) and 56b (LOW beam, Yellow wire), one should have 12V as long as the ignition switch is "on" and the headlight switch is pulled out. If neither does, pulse the relay again, and check both again. If still no 12V on either, it's a bad relay, both contacts. If you got one but not the other, it's a bad relay contact for the missing position.

Assuming you got 12V on both 56a and 56b, move on to the headlamp circuits. LOW beam (56b, Yellow) goes to Fuses 3 and 4, and turns into Yellow and Yellow with Black tracer, each going to a headlamp LOW beam filament on one of the dual-beam lamps. HIGH beam (56a, White) goes to Fuses 5 and 6, and turns into White and White with Black tracer, each going to a high beam lamp, and to the HIGH beam filament on one dual-beam lamp. If still no light, check the grounds at the headlamps (Brown wires), and the lamps themselves.

Good luck!
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Lane
MGVWFAN (STF)
anglodeutsch4 (Samba)
73 VW 412 (the Nomad, dropped valve seat land now, argh!)
67 MGB (Runs like a scalded dog)
76 Plymouth Duster /6 (runs like a top)
02 Intrepid 2.7L (leaks more than my MGB!)
90 Ramcharger 318 (soon to be son's car, fried A518)

[sharkskinman]

i got a couple relays that are correct

my lows come on and i hear the relay click when i pull the turn switch
Regardless of the relay

i also cleaned the terminals on the wire ends
both for the Fuse box and the back of the Fusebox (where relays are)

None of my highs work
Inner or outer

but i know atleast there is a ground problem
as my dash turn lights are on
untill i (push) tilt the wheel up
then they go out
(probably NOT an issue with the highs tho it doesnt affect the lights when they are on))
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4/71 ~311 "Bettie" (F.I./Auto)

[ALLWAGONS]

Unless your wiring was messed around with by PO I guarantee you its a faulty relay.
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Cancer, You have claimed another beautiful life, but You will be defeated....

I rather have a profitable than a sustainable lifestyle

I recycle old cars and parts, other than when I rot, that's as Green as I am going to get.

[sharkskinman]

im so absent minded
someone on here sent me a couple relays
(i still ahvent had the $ to pay for them !! )

but wether its ones i got off a later model VW
or the couple stock ones i have now
I Always hear a click

but Nothing

im going to try them again
and test them as i go
i dont remember if i took the headlight or E switch out
but had to crimp it down after cleaning it

ive rebuilt a couple dozen or so of those switches
im secure in my skills
so it has to be a relay or a wire problem
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4/71 ~311 "Bettie" (F.I./Auto)

[raygreenwood]