80-85 Fuse Block

1980-1985 Headlight Relay Installation Troubleshooting

The photo above shows the back side of the 1980-1985 Vanagon fuse block.  The most common mistake when installing relays in an early van is connecting the relays to the wrong side of the fuse.  The line (supply) side of the fuses for the headlights have a solid bridge connecting fuses 3 &4 (low beam) as well as 5 & 6 (high beam).  If the relays are connected to the upper side of the fuse, only one headlight will function (and it will not be powered by the relays).  

For a proper installation, the stock (yellow/black) low beam headlight wire should be removed from the terminal on the lower bridged connection at fuse 3/4 and the thicker yellow wire from the low beam relay harness should be installed in it's place.  The stock (yellow/black) low beam wire is then inserted into the connector with the male blade on the thinner yellow wire of the relay harness, which will now trigger the low beam relay.

For the high beams, the stock (white) high beam headlight wire should be removed from the terminal on the lower bridged connection at fuse 5/6 and the thicker white wire from the high beam relay should be installed in it's place.  The stock (white) high beam wire is then inserted into the connector with the male blade on the thinner white wire of the relay harness, which will now trigger the high beam relay.