Quantcast
RWD - headlights

Volvo RWD 444-544 Forum

INDEX FOR 7/2019(CURRENT) INDEX FOR 6/2017 444-544 INDEX [<<]  [>>]

THREADED THREADED EXPANDED FLAT PRINT ALL
MESSAGES IN THIS THREAD




  REPLY TO THIS MESSAGE    PRINT   SAVE 

headlights 444-544 1962

1962 12v 544 headlights are not run thru the fusebox? with all fuses out headlights work and the car starts right up, also does the electrical system use a ballast resistor in the ignition system, sum of the wiring is creative,i think I am going to get an education, I am wanting to upgrade the electrical and any advice would b appreciated thanks 2tired





Cut and paste link:



  REPLY TO THIS MESSAGE Replies to this message will be emailed.    PRINT   SAVE 

headlights 444-544 1962

Unable to find a wiring diagram identical to my 1963 544, I resorted to using one of the commonly available 544 wiring diagrams as a basis (the number of fuses did not match and most of the wire colors didn't match). I reused as much of the original wiring as possible preserving about 90 % of the wire colors.
I also added a 20 amp circuit breaker to feed the headlight circuit as opposed to fuses. I now have 6 fuses on the drivers firewall for the original loads and 3 fuses and 2 relays on the passenger firewall for the added loads.

I added A/C and 2 - 8" condenser/ radiator fans and controls (radiator temp sw and trinary A/C pressure sw. with manual toggle sw overide). I also used after market gauges and a GPS Speedo and their connections are shown, not the original as my original instrument panel was in very poor cosmetic condition.

I converted the vertical type wiring diagrams used in the Euro influenced world to a horizontal type wiring diagram more common in the US.

I am not 100% finished but if any of you have Autocad Software I would be glad to email the .dwg file and you could tailor to your car (all in English).





Cut and paste link:



  REPLY TO THIS MESSAGE    PRINT   SAVE 

headlights 444-544 1962

Robert;

Headlights and Ignition, as well as Starting, are considered by vehicle manufacturers (entire industry of the time, not just Volvo) to be "mission critical" (to borrow a term from the military, and reliability engineering)...as such, they are not fused...adding a fuse brings with it wire terminations, and other components (crimps, the fuseholder and fuse itself) all of which are sources of (cost of course) and also points of failure (fact is there is nothing more reliable than an unbroken, continuous piece of wire!).

Regarding your "wiring is creative" comment...it sounds like wiring may even be unmolested...you have not yet mentioned any operation or function that would suggest anything has been changed (or "upgraded" by a previous owner), or is different from the factory original. These cars were absolutely reliable and there is no need to change (improve?) anything...there is however need to bring it back to its original function, before changing it (often incorrectly referred to "upgrading").

Point of information: The fact that the Cigarette Lighter in a 122 for example is not fused is more a function of cost saving than reliability of a "mission critical" function...but if one is going to use the vintage Lighter, adding a fuse IS a sensible upgrade. See: http://www.sw-em.com/Fuses,%20Allocation%20and%20Troubleshooting.htm#Fuse_your_Cigarette_Lighter

Regarding ballasted Ignition Coil...vintage Volvos do not have (or need) one...they do however have a unique Ignition System, with an Armored Cable supplying Ign Power to the Ign Coil, an effective anti-theft measure of its day, and making the so equipped cars IMPOSSIBLE TO HOT-WIRE! Many casual mechanics are quite flustered by these Ign Sw/Ar Cable/Ign Coil Assys...but don't be, these are quite reliable, and often totally needlessly replaced by mechanics who cant (or don't know how to) deal with them, not because they actually failed! See: http://www.sw-em.com/Volvo%20Ignition%20from%20Scratch.htm#Vintage%20Volvo%20Ignition%20system%20and%20the%20Armored%20Cable

I recommend you get a Wiring Diagram for YOUR vehicle (be advised that a number of changes of harness from 6V to 12V from early to late for 544 vehicles exist, so be certain you have a WD versions for your chassis No. vehicle. For example link to a 544 12V version: http://www.sw-em.com/544%20Wiring%20Diagram.jpg Remember: Color code on these WDs is your friend!), learn how to read it, study it, appreciate its simplicity(!), and ask here when in doubt. I recommend bringing components and connection back to their as-new function before "upgrading" and needlessly changing things (then, you're the one introducing "creative wiring"!)...fact is, wire does not go bad!...terminations, crimps, and connections do! Clean, refurbish the existing, and protect all with ACZP. See: http://www.sw-em.com/anti_corrosive_paste.htm

Finally, there are two places of known weaknesses, where changes (yes, true UPGRADES!) for the sake of reliability and safety should be considered. 1. Ignition Switch momentary switch to eliminate broken Ign Keys. See: http://www.sw-em.com/ignition_switch_key_breakage_tech_article.htm ...and 2. Changing Brake Light Switch from Hydraulic Pressure Sensing type to Pedal Position Sensing type. See: http://www.sw-em.com/safety_bulletin_1.htm

Please take this info and advice in the spirit it is given...don't let it scare or offend, but help.

Cheers






Cut and paste link:



  REPLY TO THIS MESSAGE    PRINT   SAVE 

headlights 444-544 1962

thanks to all for your responses,the main problem is weak headlights and that red light on the dash telling me low charge,will go with your advice and clean everything first thanks again 2tired





Cut and paste link:



  REPLY TO THIS MESSAGE    PRINT   SAVE 

headlights 444-544 1962

If you are still using a 35 amp generator, you should consider upgrading to a higher output alternator.

I prefer using Bosch alternators with external voltage regulators especially when the engine is a B20 or a late B18, both of which already have a threaded hole in the block to bolt on a Bosch alternator.


--
Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
hiperformanceautoservice.com or oldvolvosonly.com





Cut and paste link:



  REPLY TO THIS MESSAGE    PRINT   SAVE 

Voltage Drops and AMP Indicator ON 444-544 1962

Robert;

ALL Connections and connectors in the current path should be clean and tight to minimize voltage drops along the way, and which will result in decrease voltage at ALL loads, including headlights...and with 6V elec sys, its even more important not to loose a tenth of a volt here and there, because there's not many tenths of a volt to begin with!! Use ACZP after cleaning and checking connections!

"red light on the dash telling me low charge" is not correct, sorry...AMP Indicator ON is a well known and understood (and explained by me) phenomenon, see: http://www.sw-em.com/AMP_Indicator_ON.htm

Cheers





Cut and paste link:



  REPLY TO THIS MESSAGE    PRINT   SAVE 

headlights 444-544 1962

A good wiring diagram is essential.





Cut and paste link:



  REPLY TO THIS MESSAGE    PRINT   SAVE 

headlights 444-544 1962

The headlights on most cars are not protected with a fuse, mostly due to the high amperage draw. The starter and the stock ignition system are also not fused on your Volvo.

Although some of the later Volvos are known to have wiring problems related to the wire insulation flaking off, is your wiring damaged or deteriorated?

Is there a need for an upgrade, IE stereo, A/C or electric windows?


--
Eric
Hi Performance Automotive Service (formerly OVO or Old Volvos Only)
Torrance, CA 90502
hiperformanceautoservice.com or oldvolvosonly.com





Cut and paste link:


<< < > >>


Users marked in green are currently online.

©Jarrod Stenberg 1997-2016. All material except where indicated.


Brickboard.com is not affiliated with nor sponsored by AB Volvo, Volvo Car Corporation, Volvo Cars of North America, Inc. Brickboard.com is a Volvo owner/enthusiast site, similar to a club, and does not intend to pose as an official Volvo site. The official Volvo site can be found here.

All participants agree to these terms.
Powered by Denizen - Custom Software for Enthusiasts