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

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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