SPECIAL NOTE

Your plan of attack for installing the very useful headlight relays into your vanagon will be fully dependant on your approach to life. I've done the job in 2 different ways - the first, more difficult DIY method requires harvesting bits and pieces and doing a lot of soldering. Some instructions for that method are below.

The second, much easier method involves purchasing a very high quality relay kit from Jay Brown and following his easy to read and follow instructions that come with his kit. Jay offers two different kits, one with relays that you secure somewhere near your vanagon fuse panel yourself, and a second one that comes with relays which clip right onto your vanagon fuse panel - just like stock. Both are bargains at $28.50 and $37.50 plus shipping (as of Jan 2014). They come pre-wired with quality parts, and will ensure that your upgrade is successful. Jay is a super helpful, knowledgeable vanagon dude and will support even the most inane questions.
Here's his site: Vanagon Headlight Relays

DIY METHOD

Do not use higher wattage globes without independent relays providing direct current to the lamps or you will burn out your ignition switch, fuse box or dimmer switch.

From An Article By P. Lander

PARTS REQUIRED

• 2 x 135 937 501A Relay Bases
• 2 x 161 937 501 Fuse Holders
• 2 x 141 951 253B Relay
• 4 x N 904 219 02 Terminals for Fuse Holder
• 2 x 55/100 Watt H4 P43t Globes (Bosch 41210055/HellaXD1210055)
• Cable and 6.3mm flat receptacles (std and lanced) as required.

ASSEMBLY DIRECTIONS

1. Cut the White cable from the rear of the relay plate at C17 (yellow housing) and connect with lanced 6.3mm terminals to the new relay base.
2. Connect the cable from C17 to relay terminal 85 and the other (headlight wire) to 87.
3. Cut the White/Black cable from the rear of the relay plate at C16 (yellow housing) and connect with lanced 6.3mm terminals to the new relay base.
4. The cable from C16 to relay terminal 85 and the other (headlight wire) to 87.
5. Connect two 2.5min Red cables to any spare P terminal and run them to the new fuse holders.
6. Run two 2.5-nm Red cables from the other fuse holder terminals to terminal 30 at the new relay socket.
7. Then run two brown wires from terminal 86 to the earth point next to the relay board.
8. Slide the relay sockets and fuse holders onto the top of the relay board to a suitable position and replace the fuses and relays.
9. Replace the original headlight globes with the higher wattage globes and check the alignment.
10. A third relay/fuse holder could also be added if required for driving lights.