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1966 Headlight Relay differences and wiring woes...
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bluexl
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PostPosted: Mon May 02, 2011 6:52 pm    Post subject: 1966 Headlight Relay differences and wiring woes... Reply with quote

OK so I'm having trouble wiring my 66' Hi-Lo relay, my turn signal lever, and then some...

I have the wiring diagrams and I have the instructions that came with the new harness...but my Headlight relays are totally different...and the instructions are throwing me off...

Here are the old and new relays:
Image may have been reduced in size. Click image to view fullscreen.

I am going through a 12V conversion but really stuck on how to wire these things up...

Instructions say:
White Wire: #S Hi-Lo Relay Unit to Fusebox Terminal marked "W". (OK I did that)
Yellow Wire: #54a Hi-Lo Relay Unit to Fusebox terminal "Y". (Problem with that is there is no #54a on either the new or old relay.)
Brown-White from Turn Switch to #S Hi-Lo. (Ok but I'm already using #S with the White Wire...)

And once that is figured out, where does the Brown wire from the turn signal go the flasher???

Here are some other pics just because...

Image may have been reduced in size. Click image to view fullscreen.
Image may have been reduced in size. Click image to view fullscreen.
Image may have been reduced in size. Click image to view fullscreen.


Any help would be so SO appreciated. Brick wall
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Banzai KG
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PostPosted: Mon May 02, 2011 8:03 pm    Post subject: Reply with quote

Does you instruction sheet that came with the relay look like this?:
http://www.oldvolkshome.com/headrelay.pdf
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1964 Karmann Ghia coupe
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bluexl
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PostPosted: Mon May 02, 2011 8:42 pm    Post subject: Reply with quote

Oh that is awesome thanks! My relay came with nothing. It was the new wire harness that came with instruction. And this guy came with instructions too: http://www.airheadparts.com/vintage-vw-parts/flash...11953227-b

Thanks Banzai KG!!! That will get me going for now!
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bluexl
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PostPosted: Mon May 02, 2011 10:13 pm    Post subject: Reply with quote

This 12V Hi-Lo Headlight Relay Wiring Diagram should be of use to all.

Image may have been reduced in size. Click image to view fullscreen.

Now where does the brown and white colored wire from the turn signal lever go?
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bluexl
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PostPosted: Tue May 03, 2011 10:48 am    Post subject: Which Relay Wiring Diagram Is correct? Reply with quote

So which of these is correct if I have a 66' but am doing a 12 Volt Conversion?

This One?
http://www.oldvolkshome.com/headrelay.pdf
This One?
http://www.oldvolkshome.com/6870turnswitcht1_OVH.pdf

Or either of these 2?

Pic One:
Image may have been reduced in size. Click image to view fullscreen.
Pic Two:
Image may have been reduced in size. Click image to view fullscreen.

If Pic One is correct: The brown wire just grounds out?

If Pic Two is correct: Where does the Brown w/White wire go?

Thanks again!
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toddb_67
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PostPosted: Tue May 03, 2011 1:32 pm    Post subject: Reply with quote

I don't mean to hijack this thread but will a defective dimmer relay cause you to have no headlights? Right now my '69 Ghia has no headlights and I just replaced the headlight switch with a new one and cleaned up all of the ground connections and checked all the wiring and it is good. I'm stumped.
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"I fold mine using search and lots of it, a liberal application of search makes almost any job go smoother, infact "I put that #%*@ on everything!"
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Banzai KG
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PostPosted: Tue May 03, 2011 6:14 pm    Post subject: Reply with quote

toddb_67 wrote:
I don't mean to hijack this thread but will a defective dimmer relay cause you to have no headlights? Right now my '69 Ghia has no headlights and I just replaced the headlight switch with a new one and cleaned up all of the ground connections and checked all the wiring and it is good. I'm stumped.

Only thing I can think of is use a voltmeter and check for around 12v at the headlight socket; if you're not getting 12v from the socket...then check for voltage at the relay. Then the headlight switch, fuse block, etc...
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Sunnyvale (near San Jose), CA
1964 Karmann Ghia coupe
V.V.W.C.A. - Golden Gate Chapter: http://www.ggcvvwca.org/
B.L.T.N. (Better Late Than Never) late model VW Club (San Jose/Santa Clara, CA): http://www.bltnvw.com
NorCal Aircooled Group (NAG) Facebook Page: https://www.facebook.com/NAGVW
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toddb_67
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PostPosted: Wed May 04, 2011 6:35 am    Post subject: Reply with quote

This is where I am stumped. I suspect I have a bad headlight switch right out of the box, it is brand new from CIP1. I am getting 12 volts at the #30 connection on the switch but when I pull out the headlight switch I am not getting 12 volts to the #56 on the relay. I tried bypassing the switch and jumping 12 volts straight to the relay and still no lights. The only way I can get the lights to work at all is to bypass all of the relays and switches and just apply 12 volts to directly to the white headlight wires. So I know I have good wiring going to the lights and good grounding, I just can't figure out if I have a bad switch or a bad relay or both?
Any ideas?
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1971 Super Beetle Convertible (under construction) http://www.thesamba.com/vw/forum/viewtopic.php?t=582365&highlight=

busdaddy wrote:
Quote:
"I fold mine using search and lots of it, a liberal application of search makes almost any job go smoother, infact "I put that #%*@ on everything!"
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toddb_67
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PostPosted: Sat May 07, 2011 6:51 am    Post subject: Reply with quote

Can anyone chime in on my dimmer relay issue. I have searched and could not come up with an answer.
My main question at this point is, can a bad dimmer relay cause you to have NO headlights?
I hate to keep throwing parts at this problem. I'm hoping I don't have a bad headlight switch right out of the box! Mad
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1970 Pastel White Westfalia
1971 Super Beetle Convertible (under construction) http://www.thesamba.com/vw/forum/viewtopic.php?t=582365&highlight=

busdaddy wrote:
Quote:
"I fold mine using search and lots of it, a liberal application of search makes almost any job go smoother, infact "I put that #%*@ on everything!"
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ovghiaguy
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PostPosted: Sat May 07, 2011 7:42 am    Post subject: Reply with quote

toddb_67 wrote:
Can anyone chime in on my dimmer relay issue. I have searched and could not come up with an answer.
My main question at this point is, can a bad dimmer relay cause you to have NO headlights?
I hate to keep throwing parts at this problem. I'm hoping I don't have a bad headlight switch right out of the box! Mad
not likely a bad relay, but possible.most likely an error at headlight switch.(either the switch itself or hookups) I had a brand new (made in china headlight switch ) fail right out of the box. KGPR replaced it no questions asked. 1 click on switch should give parklights, and second click give park and headlights.if you don't have power @ 56 on relay headlight won't work. need to have power from 56 on headlight switch to 56 on relay. a jumper on 56 terminal of relay should give power to 56A or F terminals on relay. it sounds like you might have 2 different issues
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toddb_67
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PostPosted: Sat May 07, 2011 8:34 am    Post subject: Reply with quote

Yeah, my first thought was that it was both the switch and the relay. The switch is not getting 12V to 56 but is getting it to the park lights and 56b (the dash lights). I tried jumping 12V to the 56 post on the relay and still not headlights, very frustrating! I was hoping someone had a similar issue and could tell me a easy way to test them both but I think I already know my answer, bad switch and bad relay.
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1970 Pastel White Westfalia
1971 Super Beetle Convertible (under construction) http://www.thesamba.com/vw/forum/viewtopic.php?t=582365&highlight=

busdaddy wrote:
Quote:
"I fold mine using search and lots of it, a liberal application of search makes almost any job go smoother, infact "I put that #%*@ on everything!"
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SuperOldSchool
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PostPosted: Wed Nov 14, 2012 4:34 am    Post subject: Reply with quote

So what is the final verdict on Bluexl's question??

Where do the brown ( or brown and white ) wires go to? Are they just ground?

I just bought a 66 a ghia and will be doing a 12v switch this winter, but am unsure how to handle the headlight switch in the turn signal stalk.

Thanks
Jack
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