Thread: Another version of a headlight upgrade - Tdi's only

I don't want to put the HL upgrade people out of business- but I had a few spaces in the engine bay fusebox, so I put them to use:




Now in a MA TDi Disco, there isn't ABS, nor an electrical fuel pump nor electrical injectors. So that's three blade fuses that can handle 30-15-20amp, and a main fuse of 40amp. (Nice to know if you somehow blow one of the others you can use it as a spare)



Using plain brass female spade crimp terminals, I replaced the wires for the fuel pump and ABS -they fit into the original plastic sheath( there's no wire for injectors), and led the wires out to near the glow plug timer relay. I haven't used the main fuse yet - I might hook up my monster spotlights with it.


Using relay holders from an old rangie ( anything you can screw to the metal is fine - this was neater) the brass crimp terminals pop into the holders, heavy gauge wires lead out under the box to the d/s headlight and across the front using the grommets for the horns to the p/s headlight. lighter wires lead to old d/s headlight connector, and ground is provided by 1 wire ganged from each relay and to the earth point under the fusebox. I used 3 because I have fog lights. The glowplug timer gets moved to the side with a selftapping screw, and that other fuse holder is for my interior accessories. To do it nice and neat, you need to take the fuse box and the battery out, but there is plenty of space within the grommets to slip extra wires through. I used an old volvo wiring loom for the heavy gauge wire and headlight connectors - connectors are a speciality item. Some deft soldering and heatshrink later - voilia - headlight upgrade TDi style.

And, for the people considering buying an upgrade - it's well worth it. The increase in brightness is very noticable. You can also put in better H4 bulbs and not have to worry about melting wires.

For His Highness the Sultan ( Just joking) I'll work on it..

For Mr WayneP - they are just LR rubber mounts from an old rangie, various bits were mounted that way- the compressor is actually from a rangie with air suspension.