The only lights directly powered by the headlight switch (assuming the
relays are installed properly) are the marker/instrument/running lights and
the relays (control current only) themselves.  This shouldn't be a
significant draw, and shouldn't cause the headlight switch to heat up,
unless you are getting heat from the control for the instrument light
control, or you have some poor connections causing a large resistance.

I would check the current draw with a ammeter, to find out just how much
current is running through the switch, could be you have corrosion on your
running or marker lights that is drawing too much current.

Don in Reidsville, NC
1987 Vanagon GL Syncro (Suzie) - For Sale!
1988 Vanagon GL (Sylvia)
----- Original Message -----
From: "No Name Available" <Trvlr2001@AOL.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Tue 25 January 2005 10:24
Subject: Re: front headlights not working.... (long winded again)

> In a message dated 1/25/2005 7:15:54 AM Pacific Standard Time,
> Don_Dixon@BELLSOUTH.NET writes:
> The final part of this repair should be to install separate headlight
> relays
> to eliminate the wiring issue that causes these components to fail.  The
> headlight relays use a small amount of current from the headlight/ignition
> switch to "signal" them to close, and they supply the needed current to
> power the lights.
> Hi Folks,
> Even with two headlight relays my light switch get warm?
> Is there a way to upgrade the switch?
> John C...