Hi John,

As others have already pointed out, there are a few possible suspects to
test in order to diagnose and fix for your headlight problems. To avoid
replacing parts needlessly, one of the easiest ways to test for the root
issue is to check the function of a couple other components and determine
the failure point via the process of elimination.

With the van running (and headlights switched on, but not working) try the
defroster fan and the windshield wipers. If these work fine I would look at
the grounds and the headlight switch as the source of your trouble. If the
fan and wipers are not working either, it is almost definitely the ignition
switch.

Regardless of the part(s) that need to be replaced, it is always a good idea
to clean the grounds. A happy ground point makes for a happy circuit and
this maintenence costs nothing more than a possible skinned knuckle or two.
The headlight grounds can be found on two crown shaped lugs above the fuse
block on the left wall of the van. Give each connector a tug to make sure it
is good and tight and then wiggle the connectors back and forth to insure
good contact. If the grounding lugs are badly corroded it is probably best
to remove all the connectors and clean them up nice and shiny before
reinstalling the grounds.

The Vanagon runs the full electrical load of the headlights thru the
ignition switch. This is generally considered a bad design concept, made
even more confusing when you consider the fact that the Baywindow and
Spitwindow buses came with integrated headlight relays from the factory...

I have been making headlight relays for the Vanagon for several years since
fabricating a set for my '85 Westy. I recently started making a hard start
relay setup for the Vanagon as well after my '87 Wolfsburg started suffering
from week starts with an almost new starter. The addition of these two easy
to install accessories will eliminate two of the major electrical loads from
the ignition switch. The end product will be brighter headlights and better
starting current accompanied by a cooler running ignition switch and
headlight switch, which will generally make them last longer and operate
more efficiently. More info can be found on my website at the following
address: https://sites.google.com/site/vanagonheadlightrelays/

Hope this helps,
Jay Brown
'85 Zetec Westfalia
'87 Zetec Wolfsburg

Date: Sun, 30 Jan 2011 16:15:23 -0600
From: John Rodgers <inua@CHARTER.NET>
Subject: Headlights Out
New experience. Got in the van last night, turned on the headlights.
Nothing! Dash lights OK, driving lights OK, brake lights OK. No
headlights. --