Headlight Relay Kit Instructions

Headlight Relay Kit

These instructions are based upon installing this kit into an MGB.

The original loom colours and joint locations on your vehicle may be different.

• Disconnect your vehicle’s battery
• Locate the headlight wiring.  On an MGB, this can  be identified by blue/white (main beam) and blue/red (dipped) cables going into 4 way Lucas bullet connectors.  On other vehicles, you just need to identify which wires run from the headlight switch to the headlights and find the junctions in them.
• Identify a suitable place for the relay box to be securely mounted that won’t interfere with any other functions of the vehicle and is within the reach of the connections identified above.  You can either use self tapping screws (not provided) or rivnuts and bolts to mount the box.  Make sure to check behind the panel you are mounting to before drilling through it.
• Locate a suitable 12v power feed.  A piggy back terminal is provided to make this easier.
• Locate a suitable ground point.  The sleeving over the power and ground wires can be cut back if required.  It is a split sleeve design so one wire can be slipped out easily further up the length.
• Run the headlight relay kit wires to the loom headlight junction location and secure the new loom securely.  Make sure you leave enough length to attach the new connectors.
• Identify which of the original cables go to the headlights and which go to the headlight switch.
• Using the original 4 way Lucas Connectors and the two connectors included with the kit, connect up the wires in the following order.
  • Blue/Red Dipped Beam to Switch – Purple
  • Blue/Red Dipped Beam to Headlight – Green
  • Blue/White Main Beam to Switch – Yellow
  • Blue/White Main Beam to Headlight – Blue
• Reconnect the vehicle battery and test the functionality of the relays.  You should hear a ‘click’ when you turn the lights on and flash main beam.

Included are Lucas Bullet connectors and crimps as well as 6.3mm spade connectors/adapters to allow connection of the plugpal Headlight Relay Kit into your vehicle loom.