Square headlight wiring

[JeffRoo]

Hi All, slowly going through my new van and fixing things. One of the jobs was adjusting the headlights. New adjusters now on order, but when removing the headlight units I have found that the inner headlights were not even connected! I'm guessing this is because the van is '82 and should have had round headlights.
Anyway as The square ones came with the van, I'd like them to work . Now my questions:
1. Does anyone know how to connect them, Wiring diagram?
2. Can I just use spade connectors or do I need to use the correct connector on the inner headlights
3. If yes to correct connect, ay ideas where to get one?
4. As the van was round headlight, and now I use the inner high beams as well (I hope),do I need to upgrade the relay? If so which one and to what?

Pictures to help

IMG_0697.JPG

IMG_0698.JPG

Apologies for the many questions.

[ZsZ]

1. just in german: http://vwt3.hu/files/egyeb/Stromlaufpla ... 6-1992.pdf" onclick="window.open(this.href);return false;
but the original design just connect the inner bulb to the wires of the high beam of H4
2. you can, but better to have plastic protectors to prevent/delay corrosion
4. in the original design the wire thickness at the lamp switch was increased. I have melted a switch so adding a relay to the lamp wiring is highly reccommended.

[petethefeet]

Hi,
Sounds like the right time to at least do a relay conversion, if not the full up grade to the power feed directly from the battery. Loads of info in wiki.
I did the relay upgrade and my headlamp switch no longer gets warm and the lights are brighter, also did the heavy duty power feed to the fuse box.

[CovKid]

Agree. If you've doing headlight work, do it properly: https://club8090.co.uk/wiki/VW ... ry_to_dash" onclick="window.open(this.href);return false;

[JeffRoo]

Thanks CovKid, your link looks great. just one question on the larger wiring. your article on Wiki shows the red cable passing by the headlight, but where does this go?

[CovKid]

It was just simplest route to go from battery to dash (via rubber grommets) rather than across the floor. It terminates in a similar junction box to the one I used at battery, behind the existing fusebox. From there you have a nice fat cable to supply headlight relays, rad fan, blower, anything heavy. The existing 6mm cable at fusebox is fine for everything else.

[R0B]

I have two round to square headlight conversion looms if your interested.

[CovKid]

You keep some odd stuff Rob

[R0B]

I know.The missus is always telling me the same thing.

[R0B]

Looms now sold