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WIRING HEADLIGHT RELAYS - Convertible Mini
https://www.ausmini.com/forums/viewtopic.php?f=25&t=11529		 Page 1 of 1
Author:  poeee [ Sun Sep 25, 2005 8:37 pm ]
Post subject:  WIRING HEADLIGHT RELAYS - Convertible Mini
WIRING HEADLIGHT RELAYS - Submitted by 'Convertible Mini'

The best way to wire up headlight relays on a Mini is pretty straight forward.

Using Bosch Mini Realys. Disconnect battery negative terminal first. At the driver's side of the car near the clutch end of the engine find the main harness where the headlight wires go to the front and undo the tape or brading. Find the two wires Bleu with red stripe (low beam) and Blue with white stripe (hi beam). Cut the two at a space of about 2 inches apart.

Now, the two wires coming from the front are your headlight wires hi and low and the two coming from the inside of the car end are the switch wires. Extend both the headlight wires coming from the front with a piece of cable preferably a bit heavier solder them and insulate with tape. PS If you don't have the same colours just write what colours you match to what on a note pad so you can refere to it later. Do the same with the two wires coming from the inside being the switch wires but these you don't need heavier wires actuall smaller will do.

Now you need to get a battery feed to supply the relay contacts. Best place for this on the Mini is at the starter solenoid Battery cable side.

Connect two pieces of Minimum 5mm wire to the same terninal lug to connect to battery supply. Each of these wires has to go through a fuse, so you will need a couple of fuse holders. (Do not use those white Radio type ones they can not handle such current).

Find a suitable mounting spot for the relays and make 2 little black lead to go from the relay #86 terminals to earth on their own mounting screw.

Bunch up and tape all the wiring as neat as possible back to form the original harness that we opened up before to find headlight wires and leave the new added on pieces coming on in one branch. Put suitable crimp on terninals on the ends of all the wires at the right length to go on the relays.

Determine which relay is going to be HI and LOW. Starting with the wires from the two fuses we added to the system connect one to each relay terminal marked 30, Next the two headlight wires which should be the heavier ones we added on one to each relay on terminal marked 87. (note here that these relays might have two terminal marked 87 it does not matter which one you use. next the two wires from the switching side to terminals marked 85.

Make sure you refere to the note you made earlier regarding the wire colours. Make sure you use bleu whites and blue reds on the correct relay tocorrecpond with the headlight wires. After all is back in place and no loose ends left connect the battery and try the headlights. Try not to let the Smoke out of the wires or they will not work.
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