Headlight wiring upgrade

1626 Views 18 Replies 4 Participants Last post by Alfisto Steve, Aug 20, 2015

riveroflava

Discussion Starter · Aug 18, 2015 (Edited)

The other week, my driver's side headlight went dim, and I was wondering why, since I had replaced both lights less than a year ago. Upon inspection, I discovered that the plastic connector was badly burned. I checked the passenger side, and that one was also slightly burned, but nowhere near as bad as the driver's side. Also, I noticed that the driver's side connector (the male end -- the one going into the bulb) was replaced at one point... it was a different color, and the wire splices were a few inches down from it.

Anyway.... I did some research, and decided to replace both connectors with ceramic ones. Also, I discovered, on the driver's side, one of the wires is a much lighter gauge than the others. This must be a factory error... I don't know why anyone would replace the entire set of wires (God knows where they go to!!) and mess up something like this. Two of the wires are 14 gauge, and the other is 18! (On the passenger's side, they are all 14.) Very weird and stupid.

After doing the wiring upgrade, I installed GE Nighthawk Platinum bulbs. Oh, also... there is this black wire on the passenger side, that is held near the relays on the black bracket on top of the light. I don't know what this wire is for, but I found out that if it is disconnected, the passenger headlight will overheat and explode. :grin2:

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riveroflava

Discussion Starter · #2 · Aug 18, 2015

Here are the excellent, high quality ceramic wiring harnesses I bought at buyheadlightbulbs.com:

9004 Heavy Dury Wiring Harness | Plug & Play Headlight Wire Upgrade 9004

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riveroflava

Discussion Starter · #3 · Aug 18, 2015

Pictures of the upgrade

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riveroflava

Discussion Starter · #4 · Aug 18, 2015 (Edited)

They seem brighter.... but I still have yet to see how they are on the road at night! Also, they have these cool blue circles in the middle, but they aren't really visible in these pictures...

Low beams:

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Richard2

· #5 · Aug 18, 2015

Those are pretty nice, and on sale! I just ordered 2 sets

Del

· #6 · Aug 18, 2015

The sockets or the bulbs? Haven't looked yet but will the socket sets work with the Bosch lights?

riveroflava

Discussion Starter · #7 · Aug 18, 2015

I just realized that it would be better if I removed the unnecessary extra wiring harness on each side.... lol. Apparently, my brain wasn't fully operational when I did this little project!!

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riveroflava

Discussion Starter · #8 · Aug 18, 2015

The little blue circle is faintly visible in this picture:

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Alfisto Steve

· #9 · Aug 18, 2015 (Edited)

What kind of GE Nighthawk Platinum 9004 bulb are you using is it a 3200k or 4100 kelvin rated? If you use too high a rating or super blue you may get that blue dot I think. I see they are 65w bulbs.

You didn't tell us year and model but from first picture I see it is either a 94-95 164 as quick release Bosch connector for engine timing RPM crank sensor mounted near right (passenger side LHD) headlight.

riveroflava

Discussion Starter · #10 · Aug 18, 2015

Alfisto Steve said:
What kind of GE Nighthawk Platinum 9004 bulb are you using is it a 3200k or 4100 kelvin rated? If you use too high a rating or super blue you may get that blue dot I think. I see they are 65w bulbs.

Probably 4100. On the product page on Amazon, GE provides a chart, and it shows that the Nighthawk Platinum is far on the blue end of the Kelvin scale.

Also, the blue dot may be intentional...check out the picture attached to this message. Regardless, the faint blue dots look nice.

You didn't tell us year and model but from first picture I see it is either a 94-95 164 as quick release Bosch connector for engine timing RPM crank sensor mounted near right (passenger side LHD) headlight.

You are correct! It is a '94 Quadrifoglio. (I thought I put my year/model in my signature?) Also... are you talking about the black wire that is strapped to the metal plate above the passenger headlight? If we are talking about the same wire, I found out that if that connector is disconnected, the passenger headlight bulb explodes for some reason!

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Alfisto Steve

· #11 · Aug 18, 2015

riveroflava said:
Also... are you talking about the black wire that is strapped to the metal plate above the passenger headlight? If we are talking about the same wire, I found out that if that connector is disconnected, the passenger headlight bulb explodes for some reason!

That has to be weird, are you talking about the spring locking Bosch connector that should be for engine crank sensor on 24v models not headlights?

riveroflava

Discussion Starter · #12 · Aug 18, 2015

Alfisto Steve said:
That has to be weird, are you talking about the spring locking Bosch connector that should be for engine crank sensor on 24v models not headlights?

Lower right in picture below:

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Alfisto Steve

· #13 · Aug 18, 2015

That black ribbed cover unit below Bosch spring lock connector looks like some kind of aftermarket xenon headlight amplifier to me. What is it hooked to? Are you saying if you unhooked Bosch connector in top of picture it blows headlight bulb?

riveroflava

Discussion Starter · #14 · Aug 19, 2015

When I was doing the headlight/wire upgrade, here is how it happened: I decided to do one headlight at a time, and did the passenger side first. After splicing the wires and installing the bulb, I tested the headlight to see if it worked. After pulling my key from the ignition AND about 10 seconds AFTER disconnecting the battery (!) ... the bulb exploded! I then noticed the connector (in my photo, and I guess by what you say it is Bosch) was still disconnected. (I had unplugged it so I had more room to work.) I reconnected it, put in another bulb, and nothing happened the next time I tested it. Nothing has happened since. As for the old bulb that exploded, its connector remained hot for awhile! I kept testing the new bulbs, too see if they were getting hot, out of paranoia, but all was (and still is) ok. Anyway, that's the story. I can't think of any other reason as to why the bulb exploded. There have been no problems since.

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riveroflava

Discussion Starter · #15 · Aug 19, 2015

Also, I don't know where the wires go... I shall check tomorrow

riveroflava

Discussion Starter · #16 · Aug 20, 2015

Steve, the wire initially enters the engine compartment alongside a grouping of wires that comes out of the false firewall, to the left of the oil vapor separator. After going around the metal bracket above the passenger headlamp, it looks like it goes right underneath the timing belt cover, in between that cover and the one below it. After there, who knows!

Alfisto Steve

· #17 · Aug 20, 2015 (Edited)

That is where the front crankshaft pulley timing teeth reside and the RPM/Timing sensor reads opening in thjose teeth to send signal to engine computer. Without that sensor the engine will not run.

Del

· #18 · Aug 20, 2015

"Without that sensor the engine will not ruin"

ruin? Freudian slip, lol?

Alfisto Steve

· #19 · Aug 20, 2015

Del said:
"Without that sensor the engine will not ruin"

ruin? Freudian slip, lol?

Fat finger two key step!

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