84, 633CSi Headlight upgrade (sealed beam to H4)?

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KINGJOHN808
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84, 633CSi Headlight upgrade (sealed beam to H4)?

Post by KINGJOHN808 »

Aloha all, tried the search feature but couldn’t come up with a definitive answer. I recently changed out my original sealed units (35 watt) and replaced them with Hella H4 units (55/60 watt). Haven’t plugged them in yet because I was told that the old wiring would melt when I ran the headlights for any duration of time. Also told that the existing switch may not be able to handle the additional load/current as well.

With that said, must I add relays and run power directly off the battery to each headlight (via relay terminal; one relay per headlight) using the existing headlight switch and wiring to activate the relays so not to draw excessive current?

Mahalo’z in advance.
Ewa Kai, Hawai’i
1984 633CSi
1983 633CSi (wreckers)

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Ralph in Socal Online
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Re: 84, 633CSi Headlight upgrade (sealed beam to H4)?

Post by Ralph in Socal »

I run all stock wiring in several cars with the H4/H1 Hellas. No warning light, no melting wires, no burnt fuses, no issues. I run just the 55/60 typical H4 bulb by Osram. Higher wattage bulbs will likely require the wiring upgrade.

You will probably get better light with upgraded wires and relays but I’m satisfied with the marked improvement. I’ve seen 100/90 and 130/90 Watt H4 bulbs so pay attention to what’s going in

Actually having to replace a set on the 86 535 as both H4 lenses are broken but bulbs are still good

Ralph
There is a very fine line between "Hobby" and Mental Illness.

85 635csi Zinno Auto
84 528i Euro
83 635 Euro Arktik
81 528i Kastanien 5-speed
88 528e Bronzit (Granpa Car)
86 535i Auto (For Sale)
81 633 csi (retired)
KINGJOHN808
Posts: 127
Joined: Sat Feb 16, 2019 2:27 am
Location: Ewa Kai

Re: 84, 633CSi Headlight upgrade (sealed beam to H4)?

Post by KINGJOHN808 »

Mahalo’z Ralph. That’s the information and reassurance that I was looking for. I’ve changed bulbs in other cars but never in a BMW so was afraid that I would have issues with the wiring and switches.

Have a great weekend!
Ewa Kai, Hawai’i
1984 633CSi
1983 633CSi (wreckers)

“Aloha and have a great day!”
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Re: 84, 633CSi Headlight upgrade (sealed beam to H4)?

Post by bpoliakoff »

Susquehana Motor Sports has a schematic which allows all 6 filaments to light at once. I re wired my harness with 14 gauge wire and a new relay from them I bought my H1-H4 lights from them as well. Prices are great and they have a good size stock of Hella's
81 Euro 635 M90 with motronic. Currently under a complete nut and bolt restoration. Pictures at
flickr.com/photos/bertsphotos.
KINGJOHN808
Posts: 127
Joined: Sat Feb 16, 2019 2:27 am
Location: Ewa Kai

Re: 84, 633CSi Headlight upgrade (sealed beam to H4)?

Post by KINGJOHN808 »

Mahalo’z! Just installed and tested out my H4 (9003) Silverstars. Really like the color and image. I’ve always run Silverstars in all my other cars, but was more concerned about the wiring melting or causing an issue with the switch.

Car is still in the building phase so haven’t taken it out of the road yet. Just mainly sitting in the driveway playing the radio and drinking beer. 🤣
Ewa Kai, Hawai’i
1984 633CSi
1983 633CSi (wreckers)

“Aloha and have a great day!”
Jlc
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Re: 84, 633CSi Headlight upgrade (sealed beam to H4)?

Post by Jlc »

Ralph in Socal wrote: Fri Jun 18, 2021 5:49 am I run all stock wiring in several cars with the H4/H1 Hellas. No warning light, no melting wires, no burnt fuses, no issues. I run just the 55/60 typical H4 bulb by Osram. Higher wattage bulbs will likely require the wiring upgrade.
Ralph,

How do you aim them? I’ve seen the flat surface 25 ft way but do not have access to that.
85 635CSi Bronzit
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Ralph in Socal Online
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Re: 84, 633CSi Headlight upgrade (sealed beam to H4)?

Post by Ralph in Socal »

To adjust headlights: On level ground, park about 25-30 ft away from a flat wall with good reflection. Usually a building wall in a parking lot. Project parallel straight lines from the car sides to the wall for lateral adjustment and adjust to 6 inches below the height of the bulbs.

The H4s have very clear illumination lines so it’s easy to see what you’re doing

Ralph
There is a very fine line between "Hobby" and Mental Illness.

85 635csi Zinno Auto
84 528i Euro
83 635 Euro Arktik
81 528i Kastanien 5-speed
88 528e Bronzit (Granpa Car)
86 535i Auto (For Sale)
81 633 csi (retired)
Jlc
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Joined: Sun Sep 27, 2020 5:27 pm
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Re: 84, 633CSi Headlight upgrade (sealed beam to H4)?

Post by Jlc »

Ralph in Socal wrote: Thu Jun 24, 2021 10:44 pm To adjust headlights: On level ground, park about 25-30 ft away from a flat wall with good reflection. Usually a building wall in a parking lot. Project parallel straight lines from the car sides to the wall for lateral adjustment and adjust to 6 inches below the height of the bulbs.

The H4s have very clear illumination lines so it’s easy to see what you’re doing

Ralph
Thanks.
I will try to find a spot. If I can't I can probably do the math to find the height adjustments for 8 feet.
85 635CSi Bronzit
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