Schematic and guide to fit relays

[Guest]

Yes we have Opel here, in actual fact it is marketed as Vauxhall in the UK, my daughter has an Opel Corsa and I have an Opel Astra and a Opel Corsa ldv.

when i was in europe a couple of years ago, i had an Astra myself (the new one), 1.6 petrol engine and tiptronic 5speed auto gearbox
i really loved the car, especially the gearbox was soooo smart! :-D

 

[focus frenzy]

Focus frenzy,
Thanks for the tip on the double output relays, I am going to try and find some here for a picture and will then add a small schematic to help with connecting up.

it is marketed by tiger accessory group, and the blister package is marked "baja tough" but I have seen the marked as "blazer"

here are a couple pictures.

 

[focus frenzy]

what the &*%$#? those should be page size and have little text boxes and arrows?

 

[Muser3]

Relay Mods

Relay Mods

Thanks Guys,
These mods are so sensible and not really too difficult to do.
I already used one relay to switch the R/R sense wire out of the pos. battery circuit when the bike is switched off. It is mounted to the right of the battery box because it is powered off the brake light circuit. I have the relays ready to go except for the five prong and It will be next. It is so nice of you to share.
Lee :-D

 

[Guest]

just wondering, are these relays water-proof?
i dont think theres enough room in my headlight bucket to fit something of that size

 

[focus frenzy]

just wondering, are these relays water-proof?
i dont think theres enough room in my headlight bucket to fit something of that size

well there are water proof versions made, but most all of them are water resistant, you mount them upright with the contacts pointed down it is very dificult for water to get in them.

I have ridden in the rain many times and yet to have a problem.

for the headlight bucket you need to get a mini relay.
you can get one by asking your auto parts place for a fog light, or headlight relay for a ford focus. (2001) they are half as wide as a regular one and are rated for the same load. you can also run the wiring outside the bucket to a spot under the tank.

I only have the headlight cut out relay in the bucket.
the high low control relay is located under the tank in the space above the coils.
the other relays sit under the left side cover.

 

[Matchless]

Focus,
Thanks for your input. I have managed to get a 5 pin with a double 87 output and have once again updated the schematic in the guide. Yes, installing with the pins down is the correct way to keep water out.
If anyone can post a picture of where they mounted the relays it would help others. The biggest issue here is space.
Miniature relays are also available from electronics supply stores for 12volt, but the current handling of the contacts is important and must exceed the amperage you are switching, a 60W headlamp draws 5 Amp, so any 10 Amp 12 volt relay should in theory do as well.
I will keep updating the guide as more information is forthcoming from any of you. The idea is to then just add the schematic to your wiring diagram to show the modification or modifications done in case some fault finding takes place later on and you have forgotten what was done before.

 

[Guest]

Miniature relays are also available from electronics supply stores for 12volt, but the current handling of the contacts is important and must exceed the amperage you are switching, a 60W headlamp draws 5 Amp, so any 10 Amp 12 volt relay should in theory do as well.

i'm wanting to go ahead with this mod, but the elctrics are not my strong side...
so, what exactly do i ask for at the electronics supply store?
a "10amp 12volt relay"? is that what they re called?

if someone could have a look at the link and make a suggestion, that'd be great :-D
http://www.jaycar.co.nz/productResults.asp?FORM=CAT

 

[Matchless]

Just for info here is a link that gives an easy overview on the relays. http://www.6066gmcguy.org/BoschRelay.htm

Just for clarity two types of relay can be used, a change over contact (usually 5 pin) or a make contact (usually 4 pin). The change over contact can be used in place of the make and the 3rd contact is just left unwired, but the make contact cannot be used in the change over relays place.

To keep it simple at an electronics shop, just ask for a Relay 12volt, 10A or 15 amp with a change over contact. The change over contact is then able to switch on or off when operating the relay. Those available from the electronics shop will require soldering leads to the pins. Only consider these if you can get smaller than the automotive one and do not have space for the one below.

Bosch automotive types are 25mm x 25mm x 25mm from the automotive store without the mounting lug, which is useful, but can be cut off if space is a problem and also without the pin protusions that are about10mm, but get longer with a lug and larger with a plugin base. Buy the 5 pin with pins 85, 86, 30, 87, 87a as these are change over. See my picture in the guide. If you ask them for a 12v horn or foglight relay you will most likely get the 4 pin that is only a make contact which is useful for all the mods except the headlight mod (not the starter, disable headlight mod) which requires a change over.

 

[Matchless]

Looking at the Bosch relays, there are may variations and maybe someone could help with the Bosch part numbers as stamped on the relays. These may a bit, but cannot conform that they are correct:
0 332 019 150 SPST (NO) 5 pin 87+87 Bracket mount (Confirmed)
0 332 019 151 SPDT (NO) 5 pin 87+87 No Bracket
0 332 209 150 SPDT (CO) 5 pin 87+87a Bracket mount
0 332 209 151 SPDT (CO) 5 pin 87+87a No bracket
0 332 017 302 SPST (NO) 4 pin 87 micro Bracket mount
0 332 207 307 SPST (NO) 4 pin 87 micro No bracket
0 332 019 110 SPST (NO) 4 pin 87 Bracket

It seems like their are 100's of equivalents and numbers that have been replaced by others and also other equivalent makes.

 

[focus frenzy]

If anyone can post a picture of where they mounted the relays it would help others.

here is the ignition relay on my 1100E

excuse the mess (need to do some cleaning up) this is the ignition relay and horn relay(in front of ignition relay) on my 80 1000G, this is also the aftermarket fuse panel, I did this a couple years ago and it has not missed a beat.

you can also see the inline fuse holders for the main relay and the headlight power relay

the gray object is the headlight switchover relay and controls low and high beam, the ignition relay controls power to the 30 terminal of the switchover relay.

this is mounted under front of tank in front of coils on right side and is a epoxy sealed water proof relay.
the black box in front of the coils is a integrator module and allows the front turn signals to act like running lights (dim) and turn signals (bright) using the standard single filament bulbs.

 

[focus frenzy]

this is the relay to get if space is a issue or if you want a relay that can handle the same load as the standard square relay but in a smaller size.

this is in the power train fuse box on a Ford Focus.
as the focus is sold around the world, it is a easy relay to get as you just have to go to the dealer or local parts dealer and ask for a headlight relay for a Ford Focus. mine is a 2001 ZX3

note it is sitting above a regular square relay for size comparison.

 

[Matchless]

Focus,
Thanks that should some of the terror factor out of it for those who are hesitant to try it.

 

[Guest]

asked this in another thread but got no reply so far, so trying my luck here [-o<

being "down under", my bike has a functional headlight switch (on/off) and the headlight is NOT permanently on

what do i need to do when installing headlight relay(s) to still be able to use both the on/off switch AND the low/high beam switch?

help appreciated :-D

 

[Matchless]

Hi psyguy,
That configuration is in the 1st and 2nd schematic, last pages of my guide, see first post. On the 2nd the D3 diode is optional between the relays, and there you will need two relays. The first schematic uses one relay.

 

[Guest]

Hi psyguy,
That configuration is in the 2nd schematic, last page of my guide, see first post. The D3 diode is optional between the relays, and you will need two relays. You could also combine the two battery feed wires into one.

thanks matchless :-D

 

[rafael garza]

how can i get a copy of that schematic

 

[rafael garza]

cane veiw schematic

cane veiw schematic

that media fire is awful. is there another way to get a copy

 

[PAULYBOY]

this is the relay to get if space is a issue or if you want a relay that can handle the same load as the standard square relay but in a smaller size.

this is in the power train fuse box on a Ford Focus.
as the focus is sold around the world, it is a easy relay to get as you just have to go to the dealer or local parts dealer and ask for a headlight relay for a Ford Focus. mine is a 2001 ZX3

note it is sitting above a regular square relay for size comparison.

I was at Autozone the other day and saw that exact relay in a blister pack marked as a Ford Focus relay.
I just got a package from the store in Ohio, from a weblink in this thread, with 2 5 pin relays with mounting ear/lug/hole, and 2 wiring pigtails. Awesome!

 

[Matchless]

Hi psyguy,
That configuration is in the 1st and 2nd schematic, last pages of my guide, see first post. On the 2nd the D3 diode is optional between the relays, and there you will need two relays. The first schematic uses one relay.

Sorry did not give you the correct reply, I think I had a case of Altzheimers light at the time!

rafael garza,
I will try and email you a copy or see if I can post it in this thread