As you may know, running a higher than specified fuse is asking for trouble.

Headlight fuses are shown in Bentley P97.56 as S3, 4, 5, 6, all 8 Amp. If
you have an owners manual, that info should be listed there.

If you choose to trouble shoot, disconnect the battery (and aux. battery(s)
if you're not certain it's properly separated from starter battery. Make
sure removed connector(s) can't fall against the battery post accidentally).
Though it's been working for a couple years, I'd double check your work
first. First look for obvious signs of a short. Melted stuff, discoloured
wire casings, signs of arcing (burn marks)

Are the newer relays for higher wattage headlights?

Neil.

On Sun, Apr 3, 2011 at 2:57 PM, Leo Lipert <leolipert@gmail.com> wrote:

> Hello All,
>
>    I have a puzzling situation. A couple of years ago I relayed the
> headlights and have enjoyed zero problems related to them until lately.
> I've
> been smelling something hot with the headlights on, and when I feel the
> fuse
> panel, something is very hot. Due to melting of the plastic fuse panell,
> I've had to replace the ceramic fuse with the following:
>
> *http://tinyurl.com/4xwylgo*
>
> It came with a 30 amp fuse, so that's what I've been running. When I put a
> 10amp fuse in, it blows.
>
> I have a meter, but this electrical stuff can be a real challenge for me.
>
> What size fuse should I be using, and where should I look for potential
> short circuits?
>
> Thanks, Leo
>

--
Neil Nicholson '81 VanaJetta 2.0 "Jaco"

http://tubaneil.googlepages.com/

http://groups.google.com/group/vanagons-with-vw-inline-4-cylinder-gas-engines