T25 Transporter Headlight Wiring Upgrade

Also For 1982 to 1989 Golfs (fuse panel 171 941 821D)

 

Parts Required (Genuine VW)
 

4 x 135 937 501A  Relay Bases
2 x 161 937 501     Fuse Holders
4 x 141 951 253B  Relays (or similar aftermarket)
4 x N 904 219 02   Terminals for fuse holder

Other Parts Required

Cable and 6.3mm flat receptacles (std & lanced) as required.

 

Fitting Instructions

*WARNING-Disconnect Battery Before Working on the Electrical System.
Detach the fuse panel from it's mounting and let it hang down so that the coloured plugs at the rear are accessible.
Note; Some cables may need to be lengthened a few cm to reach the relay socket depending on the individual vehicle.
Cut the white (left side high beam) cable at the rear of the fuse box at C17 (Yellow plug C pin 17) and connect with lanced 6.3mm terminals to suit the new relay base.
Connect the cable from C17 to the new relay socket, (relay terminal 85) and the other white headlight cable to the new relay socket, (relay terminal 87)
Cut the white/black (right side high beam) cable at the rear of the fuse box at C16 ( Yellow plug C pin 16) and connect with lanced 6.3mm terminals to suit the new relay base.
Connect the cable from C16 to another new relay socket, (relay terminal 85) and the other white/black headlight cable to the new relay socket, (relay terminal 87)
Cut the yellow (left side low beam) cable at the rear of the fuse box at C5 (Yellow plug C pin 5) and connect with lanced 6.3mm terminals to suit the new relay base.
Connect the cable from C5 to the another new relay socket, (relay terminal 85) and the other yellow headlight cable to the new relay socket, (relay terminal 87)
Cut the yellow/black (right side low beam) cable at the rear of the fuse box at C6 ( Yellow plug C pin 6) and connect with lanced 6.3mm terminals to suit the new relay base.
Connect the cable from C6 to another new relay socket, (relay terminal 85) and the other white/black headlight cable to the new relay socket, (relay terminal 87)

 

Connect two 2.5mm red cables to any spare P terminal at rear of fuse box and run them to the two new fuse holders. Run two 2.5mm red cables from the other side of each new fuse holder to the new relay sockets (relay terminal 30). Connect so that one fuse is for high/low right (relays with black striped cables on terminal 85/87) and the other is for high/low left (relays with plain cables on terminal 85/87). This will ensure that if a fuse blows you will only lose one headlight. 
Connect four brown cables from the relay sockets (relay terminal 86) to an earth point near the fuse box.
Slide the two new fuse holders and the four new relay sockets onto the top of the fuse box until they click into place.
Insert both 15 amp fuses and the four new relays. 
Replace headlight bulbs with a suitable higher wattage and test.

 

 

Wiring Diagram for Left Side Headlight
*This should only be attempted by competent persons who have had previous experience with VW electrical systems and possess the appropriate tools and equipment.
*This should not be attempted by anyone that is really dumb, blonde or is employed by an IT company.