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[EVDL] O.T.: VW Rabbit relay plate problem vis-a-vis headlights

725 Views 0 Replies 1 Participant Last post by  EVDL List
I consider this an off-thread issue, eventhough it has to do with
my electric Rabbit. I thought maybe some of the Rabbit gurus
would have dealt with the relay plate under the dash - that box
that has the fuses in the front. I've had my headlight scene
working fairly well for the last year or so now, once I found the
mis-wired connector that was going over to the pass-side
headlight and causing a number of strange behaviors since the
conversion in '94. However, when I returned to my evening job a
few weeks ago after vacation, at the end of the shift I flipped
on the headlights and got only one low beam. Bah, humbug! I
thought burnt-out headlamp, although only 1.25 years old.
Driver's side. Drive on the high-beams, which are fine. Screwed
around with this about a week ago - headlight is ok. After
studying the wiring diagram in the Bentley manual, pin E10 in the
relay plate Ys to both low-beam fuses, and one leg of the Y was
at infinite resistance (the left one). As I couldn't readily fix
that problem, I put the relay plate back on its hooks (which
requires a fair amount of push with the wiring harness and air
vent hose fighting me). Then I think I had both headlights back
once I put the fuses in. Removed fuses to check the E10 Y and
fell into a random problem of losing headlights. The gremlin has
moved to the connections at the bottom (or outbound downstream)
side of the fuses. My E10 Y legs are now both good, according to
the ohmmeter. But it is my pass-side headlight low beam that is
out now :-( . Almost certainly, I would find an infinite
resistance in the relay plate. BUT, putting it back up on the
hooks might change things...

The flipped connector mentioned above may have caused a greater
than normal current to run on some of these circuits. A symptom
that I had before I found the flipped connector was the pass-side
headlight would sometimes take up to ten or fifteen minutes to
pop on. I believe a welding operation may have been going on in
the relay plate down through the years.

I can drive high-beam for now, I suppose. The lights aren't all
that bright, and we have all these glaring XID headlights
nowadays. Rigging a bypass is not all that hard, although I
really didn't want to do anymore headlight work till I did my
long-term project of running full 14V voltage via large-gauge
wires to better white-light headlamps as Neon John had once
described. (I'd like to do that to my truck too, where I could
really use all the light I can get for being up in the mountains
with those deer and other beasties floating around.)

So anybody been inside one of these relay plates? Are these Ys
little welded together legs, or what does it look like in there?
Reliable replacement plates hard to come by? That looks like a
big wiring job that I could get myself into deep do-do with.

Please reply off-list unless you think maybe the other Rabbit
conversion owners out there might find this useful. Heck,
running Rabbits as EVs - they've got lots of issues. (Bob Rice
comes to mind... :) )


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