29 Oct 2020 - headlight lamp upgrade/replacement

Purchased four LED lamps and H4 5001, H5004 assemblies.  The plan is to start with replacing the low beam headlamps then the high beam headlamps.  If I run out of time, I'll just install the low beam lights and do the high beams later.

 

23 oct 2020 - Headlight Harness Mod

 I created a replacement passenger side headlight harness and installed it today.  I tested it and the voltages are good at each headlight.  Hi/Lo changes the proper headlights.

I will continue to test these replacement wiring harnesses and at some point I will wrap the wiring with tesa tape.

Wiring color mapping from old wire harness to new wiring harness

Driver side replacement wiring harness

Driver side replacement wiring harness

Passenger side original wiring harness

Passenger side original wiring harness

Passenger side original wiring harness

Passenger side original wiring harness

Passenger side replacement wiring harness

Driver side replacement wiring harness

Driver side replacement wiring harness

Passenger side replacement wiring harness

Passenger side replacement wiring harness

Passenger side factory original headlight harness removed

gratuitous grill shot

20 Oct 2020 - headlight harness mod parts

Vendor/Parts listing

Amazon

x002du7y0f

female ceramic H4 socket, 2 per pack

Amazon

x0026rql3l

1 1/4" rubber, body panel/sheet metal plugs

TE Connectivity

42663-2

H4 female terminal

DelCity

74385

female 3 way molded flat connector with 48" wires

18 Oct 2020 - Headlight harness mod

I completed the driver side headlight harness today.  It is installed and has been tested in the garage.  The voltage checks are good, so I will be keeping the harness installed to test and make sure there are no issues.  I did put the original harness in the trunk in case there is a problem.

 

The 3 wire flat connector that I am using appears to be the same brand/company.  The colors match from the installed mod to the headlight harness that I created.

The yellow and green wires from the high beam lamp to the low beam lamp will be about 1" longer on the next wiring harness I build.

Once this harness tests as good, I will wrap the wiring with tessa tap to keep the wires protected and it will look better.

 

5 October 2020 - headlight wiring harness upgrade

 Yesterday, made some progress with a harness.  Tie wrapped the wires to get head light to headlight distance.  Also added H4 female terminals to a couple of wires.  Found out that the TE Connectivity brand of H4 female terminals have to be modified to fit in the ceramic H4 receptacles.  The tab on the H4 terminal that keeps the piece in place in the H4 receptacle is too long, preventing proper seating. So after figuring out how much of the tab to remove, then the terminals seated properly.

I have made the wiring for this harness two inches longer than stock at the flat plug to car harness connection.

2 Oct 2020 - headlight harness wiring

I have all the parts and tools to build headlight harnesses.  The crimping tool has several dies and two of them seem to be what I need to use. I need to keep practicing wth the crimper tool to get the best results. So far there seem to be 3 slots that fit the H4 open barrel terminal.