Square (87 - 91) Vanagon headlights. What is the basic problem?

[Vana Guy]

Why are they so dim. What is the basic problem? Is it the wiring? If I installed heavier gauge wire in a dedicated circuit would that help?

[crazyvwvanman]

Yes, dedicated power wiring helps a lot along with short local grounds for each side.
Upgrading or improving the alternator harness can also make a difference.

I like to run a new #8 power feed from the battery to the area behind the glovebox.
There install 2 relays and fuses, using the existing headlight wires to trigger the relays.

Everything that increases the voltage actually reaching the bulbs will make the lights brighter.
A seemingly small voltage jump can make a surprising difference in light output.

Simply measuring the voltage right at the bulb wires with the engine running and comparing that with what you measure right at the alternator will give you an idea of the voltage increase that could be possible if you do the right things.

Mark

[Wildthings]

The wattage of the low beans is pretty low compared with other styles of headlight bulbs. Not sure why this is so or if there is something that will fit that has a higher output.

[Vana Guy]

I've been thinking about just getting some of those LED driving lights and mounting them under or on top of the front bumper. I never realized how affordable they are.

[jlrftype7]

[Red Ryder]

The glass lens on the Euro-spec (E-code) headlight is also much better than the US-spec (DOT) version. Makes a substantial difference in illumination.
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“Most everyone’s mad here. You may have noticed I am not quite all there myself.” — Cheshire Cat, Adventures of Alice in Wonderland

“Scarlett” — 1990 Vanagon Carat Wolfsburg Edition (Tornado Red)
“Nigel” — 1999 Jaguar XK8 convertible (Alpine Green Metallic)

[djkeev]

The stock headlights are admittedly quite poor.

I sourced a pair of Hella ECodes and fit them into a rectangular US sealed beam headlamp bucket.

I mounted them in place of the outer VW lamp, installed relays and I had amazing light!

Next time I am going to use only the outer lamps ((converted to ECode) for light and rewire the inner high beam as DRL's........
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Ghia
http://www.thesamba.com/vw/forum/viewtopic.php?t=392473

Vanagon
http://www.thesamba.com/vw/forum/viewtopic.php?p=6315537#6315537

Beetle
https://www.thesamba.com/vw/forum/viewtopic.php?t=482968&highlight=74+super+vert

[Sodo]

[crazyvwvanman]

[zerotofifty]

well, you may have low voltage supply, this can result of many things, fuse panel, switch, ground, connectors, etc... The bulb maybe near end of life and hence dim. The lense maybe dirty, the reflector may have lost some of its mirror finish.


When all is working right the lights should be fine, An easy upgrade is an LED bulb replacement for the stock tungsten bulbs.
Beware of high watt tungsten "upgrades" as the switch, and fuse panel often cannot handle the higher load.

first thing for a fix is to examine the lense and reflector for defects, next turn on the lights and determjne what voltage is there, besure to include the ground termjnal. If low voltage then test for where the volts drop is, repair.
I really like the LED bulb that I have, it is in the two large outer housings. I i stalled these after fixing voltage drops. I kept the tungsten bulbs in the small inner housings.
Now my van has lights bright as the modern cars.
No need for expensive euro lamp house " upgrades", nor south african round H4 " upgrades". sure do it if you want to spend a lot, but a simple cheap LED bulb and assuring full voltage will be very impressive in results for little money.

[Wildthings]

[jimf909]

[ZsZ]

A set of new repro H4 unit from Gunzl with Osram nightbreaker +200% bulbs (not sure if they available un the US) and relays give really good results.
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Zoltan
1.9 MTdi 2wd Multivan (ex Caravelle)
Van since 2006, engine since 2008

[Sodo]

Direct power to headlights:
E-Code Square headlights, with relays for 400watts (how-to)
The VW fuseblock power ONLY activates the relays (milliamps).
The real power comes direct from the battery via 2nd fusebock.


Link
Here's a YouTube showing E-codes from Bus Depot with 4x 100watts
driving at night, on the gold '87.

it s GOOD!
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'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb

[zerotofifty]

[Wildthings]

[a914622]

You can also change the buckets to hold a standard seal beam light. That opens up a ton of options. You can use real led with focus lenses and led chips.

I have done that and the light output is unmatched.

I went from stock to “stock H4” to sealed beams to h4 with hid to h4 with leds and finally to led lights like below.

https://www.amazon.com/Philips-Automotive-Lighting...&psc=1
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75 914 getting 2.2t subaru scratch that SVX subaru

[Corwyn]

Basically, a rectangular reflector is not as focused as a round reflector. Some improvements would include:

1. Relay
2. Brighter bulbs
3. E-code lenses

Done. Or you can go down the road of getting a new grill and putting round lenses up front . . . .
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FAS Gen V 2.0
The Annual Baja Rally
https://www.thesamba.com/vw/forum/viewtopic.php?t=604813&highlight=baja

"If anything's" gonna happen, it's gonna happen out there"
~ Captain Ron ~

[Vana Guy]

Does anyone have a headlight wiring diagram for the 1990?

[Chilepines]

FYI - There is another thread covering this topic - https://www.thesamba.com/vw/forum/viewtopic.php?t=787921

I had unacceptably dim lights even with e-code cans, Hella halogen bulbs and GW relays. I assume that was due to inadequate current at some level, as others have alluded to. I recently put in Sylvania H4 LEDs from O'Reilly ($99) and there is a marked improvement. Finding LEDs for the inner high-beams was a little more challenging but they arrived from Amazon yesterday and I'll put them in this weekend.
https://www.amazon.com/dp/B09YLW4KLK

The experience of putting LEDs in the original cans seems to be pretty poor due to the low quality reflector and lens on the original lights.
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White 89 Westy with 2004 Subaru EJ25 and Subarugears 5MT - Betty