Wacky Headlight issue

[bfrey003]

Not sure if this has happened to anyone else. When i turn on my 91 mk1 and drive for a short time, the head lights will cut off (both regular and highbeams). Some times i can fiddle with the light switch (cut off and on) and make them come back on. The running lights will stay on and i can hold the highbeams lever and they work as long as i hold it back. And its not a set time they got off, it's completely random, sometimes 30secs and sometimes 10 mins. this just started happening about a month or so ago

any guesses???

[CalAltaDubber]

I hate to say it, but I think the fault is in the headlight switch. You will have to replace the switch.
The give away is when you said that you can make the lights come on when you play with the switch.
It is probably a carbon buildup on the contacts inside the switch.

I had one that did the same thing except the running lights were the issue.
The switch actually routes the current to the headlights seperate from the running lights.

I have found them at my local wreckers fairly cheap.

You might also look at German Auto Parts or similar sites online to get one.

The last place to look is a dealership, for some reason (provided that VW still carries them) they are way over priced.

[bfrey003]

yea, sometimes they'll come back on on their own, sometimes i can mess with it.

i figured it was either the headlight relay or the switch itself. just thought it was weird it didnt mess with the running lights...

[Briano1234]

yea, sometimes they'll come back on on their own, sometimes i can mess with it.

i figured it was either the headlight relay or the switch itself. just thought it was weird it didnt mess with the running lights...

After you replace the switch, relay the headlights to shunt the large current off of them, and increase the brightness of your lights as well.



Headlight relay time

I used a set of Honda headlight retractor relays off a 87 accord (they are rubberrized and capable of holding 40amps.) and they have a handy mounting bracket.

Before install 11.6vdc at the headlight.



After the install at the headlight.


Since it was daylight when I did this, the before and after are:
before



after



I used 2 new headlight sockets, 16g wire, 2 20amp fuses, a bunch of solder less 3m connectors.
I only have to make 2 wire cuts, that was the High beam white wire before the hi-beam connector.

Everything is totally reversible in about 3 minutes.

I used spade connectors to insert in to the driver side socket to use to pick the relays.

Circuit design


Some hi-lights

Start with 44 inches of 3 different wires


make the "hi-beam with a pig tail 6" long


Use a good crimping tool



Find and clip the "hi-beam" wire



Attach the pig tail to the White wire.


Heat shrink the bitter end that goes to the socket.


Tape off the original socket


To secure the new harness place it behind the power steering res bracket and under the valance and on the grille side of the a/c condenser bracket

Close the tie-wrap


Insert it in the hole int he valance that is to the left of the a/c condenser mount.



Feed the harness through the hole and tighten



When I am making a ground connection, I stagger the ground to be away from the other connections and tape over all connectors.



I now make the other side of the harness (drivers side) to include the "pick wires" the battery connections, and the relays, Tape the harness to prevent runaway wires, and abrading.

I attach to the bracket and it looks as such. I don't use more than a foot of wires on the drivers side harness. Cut to make pretty and for fitment.



Finished relay bracket and mount. The Bracket is off a 86 honda civic...

[kamzcab86]

i figured it was either the headlight relay or the switch itself. just thought it was weird it didnt mess with the running lights...

The headlights are not relayed in stock form. The headlights, in stock form, are powered through the headlight switch (thanks, VW ), which ends up frying the switch... sometimes even sparking an electrical fire behind the dash. Replace the headlight switch, then add relays:
http://www.cabby-info.com/electrical.htm#Lights (read this link, as it has important info regarding the switch, as well as another relaying guide).

[bfrey003]

So I ordered and replaced the light switch and I now have functioning headlights!!! Used german autoparts and it got here in less than a week. Plus, they also sent a sticker. gotta love free swag!

I'll prolly tackle the relaying the headlights in janurary once my next financial aide installment comes.

Thanks for the help on this!

[CalAltaDubber]

So I ordered and replaced the light switch and I now have functioning headlights!!! Used german autoparts and it got here in less than a week. Plus, they also sent a sticker. gotta love free swag!

I'll prolly tackle the relaying the headlights in janurary once my next financial aide installment comes.

Thanks for the help on this!

Glad to be able to help.