New headlight loom

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frog hopper

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france
I know this has been done to death, just wanted to give my opinion and a nod to @The Mad Hat Man whose diagram I followed.
200Tdi 90, headlights were not that bad really since fitting Osram Nightbreakers some years ago, however I thought I would give the replacement loom a go to try and get a bit more from the lights and also help protect the lighting switch etc on an aging vehicle.
Tested voltages with engine on tickover and was getting 12.4 volts at the bulb connectors. Bought all the cable/relays/fuse board etc from Vehicle Wireing Products including a crimping tool for doing the non-insulated terminals that fit into the relay carriers. Used MHMs' suggested methods of installation and took feed direct from battery and earths back to battery.
Due to me faffing about getting sidetracked fixing other bits as I went it actually took me about 10 hours to do the job.
After everything completed and checked I put my meter on the bulb connectors again with engine on tickover and am now getting 13.8 volts. I have yet to test drive in the dark but would expect to see a noticable difference, one thing though, there was always a chance that the wipers would join the party when going up and down to main/dip. I know it was more than likely and earth problem somewhere but after many hours faffing I never could totally solve it, so far it seems that problem has gone away at last.
I am handy enough with hand tools but really struggle with bits of wire etc, if I can do this anyone can, and I must say I suprised myself when it came time to test it all and everything worked as it should - well it does so far - so happy bunny. :D:D:D:D:D
 
I know this has been done to death, just wanted to give my opinion and a nod to @The Mad Hat Man whose diagram I followed.
200Tdi 90, headlights were not that bad really since fitting Osram Nightbreakers some years ago, however I thought I would give the replacement loom a go to try and get a bit more from the lights and also help protect the lighting switch etc on an aging vehicle.
Tested voltages with engine on tickover and was getting 12.4 volts at the bulb connectors. Bought all the cable/relays/fuse board etc from Vehicle Wireing Products including a crimping tool for doing the non-insulated terminals that fit into the relay carriers. Used MHMs' suggested methods of installation and took feed direct from battery and earths back to battery.
Due to me faffing about getting sidetracked fixing other bits as I went it actually took me about 10 hours to do the job.
After everything completed and checked I put my meter on the bulb connectors again with engine on tickover and am now getting 13.8 volts. I have yet to test drive in the dark but would expect to see a noticable difference, one thing though, there was always a chance that the wipers would join the party when going up and down to main/dip. I know it was more than likely and earth problem somewhere but after many hours faffing I never could totally solve it, so far it seems that problem has gone away at last.
I am handy enough with hand tools but really struggle with bits of wire etc, if I can do this anyone can, and I must say I suprised myself when it came time to test it all and everything worked as it should - well it does so far - so happy bunny. :D:D:D:D:D
Well done, mate. Sound like a job well done and it's worth doing IMO. :)
 
I need to do something like this.
But I'm lazy and bought the Red Bison kit from Paddocks, which I'm yet to fit.

Glad to see there hear that DIY method worked well though, gives me hope I can get round to using the kit.
 
Thought I should give an update on the job.
Went out in the 90 last night and again tonight for the first time since doing the loom mod.
The lights are much brighter on both main and dip with a much whiter light than before. The dip now has a very noticeable cut-off with a good spread of light into the verge, so far no-one has flashed me so it would appear the dip pattern is alright.
If anyone is thinking of giving this a go then just get on with it, probably the best thing I've done on mine recently. Just give plenty of thought to where you are going to fit the bits and pieces before you start.
As a bonus it would seem that the problem I had with my wipers sometimes giving a sweep as I flicked between main and dip has gone away, I had always assumed there was an earth problem and after trying different things over the last 4 years to solve it I could never find a solution. I am now of the opinion that there must have been some power leakage in the loom somewhere that I have now bypassed.:D:D:D:D
 
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