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In later (~1990-on) cars, there's another very good reason for relays .... 200

posted by Ken C on Wed Oct 6 09:16 CST 2010
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last visit: Fri Oct 24 11:39 CST 2014

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I've done the conversion: Euroheadlights (Cibie/Volvo) with higher wattage bulbs, Dan Stern's H4 high-temp sockets, but with my own wiring, fuses and relays wired directly to the battery; and like you, I installed inidividual relays on each side for each filament (4 relays).

I never did a right-left comparison test, though, but I'm happy with my results.

However, there's a very good additional reason if you have a later-model year 240. It appears that these last years used a new placement of a headlight relay, located inside the center console (behind the center vents) -- and the connector plug to it tends to melt from too much amperage/heat, breaking the contact and causing the headlights to fail.

Perhaps you've already noticed some posts on this forum relating to this? There have even been pictures of the burned/melted plug posted here.

By having current for the headlights through the custom wiring, only a slight amount of current (just enough to drive the relays) actually flows through that vulnerable OEM plug and relay, thus virtually eliminating this possible (and somewhat too frequent) failure of the headlight system.

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Headlamp Relay modification. A bust IMO [200]
posted by TONY H subscriber on Sun Oct 3 00:20 CST 2010 >

Headlamp Relay modification. A bust IMO [200]
posted by rhaire on Sun Oct 3 02:39 CST 2010 > V
- Headlamp Relay modification. A bust IMO [200]
  posted by scorron subscriber on Sun Oct 3 06:54 CST 2010 > V

Compare the voltage [200]
posted by Art Benstein subscriber on Sun Oct 3 09:13 CST 2010 > V
- Compare the voltage [200]
  posted by TONY H subscriber on Mon Oct 4 01:18 CST 2010 > V
  - Compare the voltage [200]
    posted by scorron subscriber on Mon Oct 4 03:07 CST 2010 > V
    - Compare the voltage [200]
      posted by TONY H subscriber on Mon Oct 4 04:07 CST 2010 > V
      - Compare the voltage [200]
        posted by ZJZ subscriber on Mon Oct 4 05:40 CST 2010 > V
        
        Restore the originals [200]
        posted by jerryc on Mon Oct 4 09:59 CST 2010 > V
        
        Restore the originals [200]
        posted by xmopar on Mon Oct 4 10:58 CST 2010 > V

Headlamp Relay modification. A bust IMO [200]
posted by JimN696 on Mon Oct 4 01:56 CST 2010 > V

Headlamp Relay modification. A bust IMO [200]
posted by David Samuels subscriber on Mon Oct 4 03:46 CST 2010 > V
- Headlamp Relay modification. A bust IMO [200]
  posted by TONY H subscriber on Mon Oct 4 04:28 CST 2010 > V
  - Headlamp Relay modification. A bust IMO [200]
    posted by David Samuels subscriber on Mon Oct 4 04:43 CST 2010 > V

Headlamp Relay modification - DON'T WASTE YOUR TIME [200]
posted by RicoS on Mon Oct 4 04:35 CST 2010 > V
- Headlamp Relay modification - DON'T WASTE YOUR TIME [200]
  posted by Art Benstein subscriber on Mon Oct 4 05:23 CST 2010 > V
- Headlamp Relay modification - DON'T WASTE YOUR TIME [200]
  posted by Ryan_R subscriber on Mon Oct 4 15:08 CST 2010 > V
- Headlamp Relay modification - DON'T WASTE YOUR TIME [200]
  posted by bulletproof subscriber on Wed Oct 6 12:29 CST 2010 > V
  - Headlamp Relay modification - DON'T WASTE YOUR TIME [200]
    posted by Art Benstein subscriber on Wed Oct 6 14:34 CST 2010 > V
    - Headlamp Relay modification - DON'T WASTE YOUR TIME [200]
      posted by bulletproof subscriber on Wed Oct 6 15:21 CST 2010 > V
      - Headlamp Relay modification - DON'T WASTE YOUR TIME [200]
        posted by Art Benstein subscriber on Thu Oct 7 01:44 CST 2010 > V
        
        Headlamp Relay modification - DON'T WASTE YOUR TIME [200]
        posted by bulletproof subscriber on Thu Oct 7 02:38 CST 2010 > V
        
        Headlamp Relay modification - DON'T WASTE YOUR TIME [200]
        posted by V945T on Fri Oct 8 17:00 CST 2010 > V
        
        Headlamp Relay modification - DON'T WASTE YOUR TIME [200]
        posted by bulletproof subscriber on Sat Oct 9 10:18 CST 2010 > V
        
        Headlamp Relay modification - DON'T WASTE YOUR TIME [200]
        posted by V945T on Sat Oct 9 10:27 CST 2010 > V

Headlamp Relay modification. A bust IMO [200]
posted by Ryan_R subscriber on Mon Oct 4 05:41 CST 2010 > V
- Headlamp Relay modification. A bust IMO [200]
  posted by TONY H subscriber on Mon Oct 4 05:55 CST 2010 > V
  - Headlamp Relay modification. A bust IMO [200]
    posted by Ryan_R subscriber on Mon Oct 4 06:12 CST 2010 > V
    - Headlamp Relay modification. A bust IMO [200]
      posted by TONY H subscriber on Mon Oct 4 06:26 CST 2010 > V
      - Headlamp Relay modification. A bust IMO [200]
        posted by daveshan subscriber on Mon Oct 4 09:25 CST 2010 > V

Euro Vs DOT [200]
posted by KlausC subscriber on Mon Oct 4 09:49 CST 2010 > V

In later (~1990-on) cars, there's another very good reason for relays .... [200]
posted by Ken C subscriber on Wed Oct 6 09:16 CST 2010 > V
- In later (~1990-on) cars, there's another very good reason for relays .... [200]
  posted by It Rolls on Wed Oct 6 14:46 CST 2010 > V
  - Well, there's more than just headlight relays .... [200]
    posted by Ken C subscriber on Wed Oct 6 15:11 CST 2010 > V
  - Here's a picture of the front .... [200]
    posted by Ken C subscriber on Thu Oct 7 10:17 CST 2010 > V
    - Here's a picture of the front .... [200]
      posted by It Rolls on Thu Oct 7 13:14 CST 2010 > V
      - Cost (time and $$$) .... [200]
        posted by Ken C subscriber on Thu Oct 7 17:11 CST 2010 > V
- In later (~1990-on) cars, there's another very good reason for relays .... [200]
  posted by TONY H subscriber on Thu Oct 7 01:26 CST 2010 > V

Headlamp Relay modification. A bust IMO [200]
posted by Oleseahorse subscriber on Fri Oct 8 14:39 CST 2010 > V

Headlamp Relay modification. A rambling post about my experiences with E-Code lighting on Volvos [200]
posted by V945T on Fri Oct 8 16:23 CST 2010 > V

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In later (~1990-on) cars, there's another very good reason for relays .... 200