Headlight Wiring Upgrade Project

[moribundman]

Due to a lack of time this project will take me a few weekends. I will update this thread whenever there is progress.

The goal:

1. Add three relays for low beams, high beams and fog lights to the headlamp/lightswitch circuit.

2. Upgrade the wiring to larger gauge.

3. The added wiring harness must be reversible simply by unplugging it in order to restore wiring to OEM.

4. If reasonably doable, tap into alternator, alternatively, tap into battery.

5. Philips X-Treme H7 bulbs are on the way

The first step is upgrading the the wiring inside the headlamp housings. The first photo shows the lamp housing with the the original wiring, which is relatively skimpy:


A closer look at the original wiring harness from inside the headlamp housing. The pins have been removed from the OEM connector:

This picture shows the OEM pins, which I reused. Note the skimpy OEM wires, which were upgraded:

This picture shows the original harness on the side, while the upgraded harness has been installed:

The new, larger gauge wire was soldered to the pins, shrink tubing/shrink tape was applied, and the pins were inserted into the connector:

I installed the new wiring only in the driver side headlamp housing, and although I have not yet upgraded any other wiring, the left lamps are already considerably brighter, which I find amazing!

The next step will be to repeat this whole procedure on the passenger side headlamp.

Then I will install the already prepared harness that will got to the relays. I have found a good location for the relays. It appears that there is enough space inside my ECU box (under the hood) for the relays. I am hoping the relays' magnetic field will not disturb the ECU, which is shielded.

To be continued....

 

[G-MAN]

Is this on your Audi?

 

[moribundman]

Aye.

The three relays will fit in the ECU box:

 

[moribundman]

G-Man, you would probably like to see the reflectors of my e-codes. As you remember, we were discussing them a while ago.

The H7 with the shroud is the low beam, the bulb (looks dark in the picture) under it is the Euro parking light (not connected). The smaller shrouded bulb at the bottom is the fog light. The not-shrouded H7 is the high beam bulb. The bulb at the very left is just a reflection.

 

[G-MAN]

I wonder if the Audis destined for Europe would need such a wiring upgrade? I suspect not. The ones set up for DOT lights for US delivery probably have a different wiring harness.

 

[moribundman]

The only difference between the two harnesses is the addition of one wire per side for each Euro parking light. The wire gauge is the same. How do I know? My e-codes came with the Euro wiring harness in them.

 

[Jim 5]

I know this is really off topic, but I have observed that you are really good at photography mori.

What are you using as your white background in these photos?

 

[tom slick]

Quote:

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I know this is really off topic, but I have observed that you are really good at photography mori.

What are you using as your white background in these photos?

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I think mori lives in a photography studio

 

[moribundman]

Quote:

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What are you using as your white background in these photos?

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It's a piece of thin white cardboard from an arts&crafts shop.

Studio photography, still lifes and industrial photography do not interest me but bore me to death, so I put no effort in. I just want to get this type photography over with as quickly as possible. My little setup, which includes a small light tent, allows me to take quick snapshots for reference purposes. That's also the only type photography for which I prefer digital. Convenience and speed do count.

 

[moribundman]

I have hit a few snags:

1. Not enough space:

There is no way I can cram three relays and relay mounts safely into the oh-so-so conveniently located ECU box. My attention went then towards the headlight housings, especially the somewhat roomy snap-on rear covers, but the wiring would be messy and not to my liking.

2. Weird OEM relays mounts and connectors:

My car has empty slots in the relay carrier above the dash kick panel. The problem is that this relay carrier uses dedicated VW/Audi relay sockets, which I would have to order, because I have only one spare. The other issue is that these relay sockets require dedicated female crimp-on connectors of to me unknown type.

3. Routing wiring back and forward through two firewalls isn't my idea of an elegant solution:

There are all the positive and negative terminals I could possibly want right by the relay carrier under the dash. There are two "30" terminals (+), but I am not 100% sure that's where the OEM light switch gets power, so I'm hesitant to power the lights via those two terminals.

Arrrrgh!

 

[moribundman]

Winner takes it all!

If I want to use the relay carrier, I have to use OEM relay sockets. I will need three of them plus the correct female locking connnectors. I went to the Audi dealer and when I heard the price, I almost died from laughing up my lungs. Here is the little 1"x1"x1" plastic relay mount in question. I have had that one for years, so I have to buy two more, which will cost me under 3 Euro (under $4) for two at the German dealership. Guess how much the US stealer wants for one!

 

[moribundman]

Okay, I can see you're all hesitant to stick your pretty neck out.

It's over ten bucks per socket! Do I hear $11? Anyone?

 

[moribundman]

No one? Oh well, just FYI, the dealer wants $20 and a few cents for one relay socket. Two female connectors with a short (5 inches or so) length of wire are $8. If I were to buy the required two (Remember, I have one) relay sockets and 16 connectors (8 pairs ), then this would cost me 2x$20+8x$8=$104 plus tax. Maybe the fuchsia color costs extra.

 

[simple_gifts]

Quote:

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Studio photography, still lifes and industrial photography do not interest me but bore me to death, so I put no effort in

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He does, of course, occasionally photograph his buns.

 

[moribundman]

I can't even deny that.

 

[Master ACiD]

looks good. last year i went through something similar but exactly reversed.

how is that possible you ask?
i did what you did, but i did it to my tail lamps

 

[moribundman]

You upgraded the tail lamp wiring? Dare I ask why?

I wish I had an update by now, but I'm still waiting for my OEM relay sockets to come in. Although I'd rather wait two weeks and enjoy the low price, I'm getting a little antsy.

 

[Master ACiD]

i upgraded because with filament bulbs i was getting 10 volts to the tail lamps while the car was idling.

i upgraded the wiring and also went to leds.

 

[moribundman]

Today I got the two OEM relay mounts and correct pigtails wires with connectors for the relay terminals. It took a couple weeks, but at least I paid only about 80 cents per wire (I bought ten, so I have twenty connectors) instead of $8 for each! The two additional relay sockets that I bought were a little under $4 each versus the $20 that the US dealer wanted for each. Hopefully I can finish this project this weekend.

The part numbers are for a '96 A4, but should be good for any A4 (Type 8D aka B5, 1994-2001).