Both headlights are grounded at that one location. That is the problem. Too
much current there. As an upgrade, add another ground connection rith near
the headlights. Use a ring terminal under one of the screws that mount the
headlight housings to the van.

Dennis

>From: John Reynolds <kayakjr@COMCAST.NET>
>Reply-To: kayakjr@COMCAST.NET
>To: vanagon@GERRY.VANAGON.COM
>Subject: Archives (& Dennis Haynes) solves headlight problem
>Date: Mon, 28 Jul 2008 01:52:44 +0000
>
>Had not used my van and noticed it need an inspection sticker - passes
>everything except no headlights at all!
>
>I had just replaced the ignition switch and I had pulled the instrument
>cluster and figured I left a connector off somewhere, but the parking
>lights were working.  I had not used the headlights this year, so I can't
>say they were working before the ignition switch replacement.
>
>Several Archive posts mentioned replacing the ignition switch to solve this
>problem, but Dennis Haynes replied to one who had the same symtoms as me
>that  the head light grounds are at fault  ( all lights except headlight
>work, but blue hi-beam indicator stays on when the headlights are turned
>on)
>
>I  figured my new ignition switch was bad (replaced as preventative
>maintenance) and was going to do the whole affair again to put the old one
>back in, but I followed Dennis's advice and dropped the fuse box and saw
>one double wire ground with corrosion on the  connector.  I cut off the
>end, and crimped two new ends on (one on each wire instead of two into
>one), cleaned the ground spade lug and bingo, headlights now work!
>
>Now I have to locate the other headlight double ground (if there are two)
>and do that as well.
>
>Thanks to the list and especially to Dennis Haynes who has provided much
>good info to the list.
>
>Also glad to see see Dave Beierl back on the list.
>
>John Reynolds
>LiMBO
>86 Wolfsburg Westfalia Weekender