 | Home > Technical > 2002 Headlight Issues - main beam always on with ignition |
 
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| Martin Site Admin Member Since: 02 Apr 2007 Location: Hook Norton Posts: 6604   
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OK here goes, a diagram of what's currently going on with the mod fitted:
 Click image to enlarge Hopefully you can see that the mod relay sits in parallel with the lighting switch. What it does is: When the ignition is switched on, the mod relay closes and connects the brown/blue (via black mod wire) to both the red and blue (via the same colours on mod wiring). This puts the vehicle lights on as if the lighting switch was in pos 2 - side lights + head lights. This is how things are now. What I don't understand, is when you simply remove the mod's fuse from the inline holder on the red wire to the fuse tap, which should stop the mod relay operating, why the lights don't then work at all from the lighting switch. The switch does exactly the same as the relay and uses the same input supply (brown/blue) and output wires (red and blue), and these wires are tapped into for the mod right next to the lighting switch connector. A few possibilities why the lights are not under control of the switch 1. the lighting switch is faulty or disconnected - fit switch or use temporary bridging wires 2. or maybe there is something going on with the wires into the lighting switch connector - check with voltmeter and ohmmeter 3. previously something else is being changed not just removing the fuse - check everything in place! So what would be good is to reinstate the mod wiring, connect the lighting switch (preferably your new one, most likely to be working) and ensure nothing else is disconnected - stalk connected etc etc. Leave lighting switch off (pos 0), turn on ignition key to pos 2 - should get lights as powered by the mod relay. Now remove the mod inline fuse from the inline holder, now the lights should be under control of the switch. Expected behaviour is: with ignition key in pos 0 (off) or pos 1, lighting switch pos 1 and pos 2 give sidelights only. With ignition key in pos 2 (gauges and dash warning lights on) - pos 1 side lights, pos 2 side + head. 1988 90 Td5 NAS soft top
2015 D90 XS SW |
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9th Aug 2023 10:26pm |
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| docperio44 Member Since: 08 Aug 2023 Location: Quebec Posts: 21  
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Ok, so when I put it ingnition in position 2 (dash lights up) then pull the mod , you are mostly right except: position 0 - lights are off as they should be. Position 1 - side and head and position 2 is the same (Side and head).
Also note that the headlight leveling motor -- follows that power -- once I pull the mod, it has no power at light switch position zero and powers up at lights position 1 and 2. I believe that makes sense since headlights should not level until there is power to headlights. Is this progress? I think so! |
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10th Aug 2023 12:37am |
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| Martin Site Admin Member Since: 02 Apr 2007 Location: Hook Norton Posts: 6604
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Great progress!
Now remove the blue wire connector from the mod relay (and nothing else at this stage), this should remove the bridge between the side and head in pos 1. 1988 90 Td5 NAS soft top
2015 D90 XS SW |
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10th Aug 2023 6:36am |
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| docperio44 Member Since: 08 Aug 2023 Location: Quebec Posts: 21
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You, my friend, are amazing! 100% working right now!!! Ignition on - 0 is off, 1 - side lights, and 2 - beam on!!!
Thank you so much for following up and taking the time! |
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10th Aug 2023 1:32pm |
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| geobloke Member Since: 06 Nov 2012 Location: Nottinghamshire Posts: 4410
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Booming marvellous
 Well done both
What a strange modification  |
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10th Aug 2023 1:42pm |
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| Martin Site Admin Member Since: 02 Apr 2007 Location: Hook Norton Posts: 6604
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Fantastic, so pleased to finally sort it
And thank you  1988 90 Td5 NAS soft top
2015 D90 XS SW |
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10th Aug 2023 6:48pm |
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| docperio44 Member Since: 08 Aug 2023 Location: Quebec Posts: 21
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Ok, so not sure when this stopped working… but it did. I reset up mod fuse and blue wire and lights come on. If I try and redo our previous successful series of action: ignition 2, pull mod, pull blue - the lights are not responding at all. So that means that switch is not controlling the power. Before I open up panel again, am I missing anything? Why may this stop working?
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17th Aug 2023 1:50am |
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| Martin Site Admin Member Since: 02 Apr 2007 Location: Hook Norton Posts: 6604
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Have you tried your spare switch?
The relay mod switches from the same source and to the same outputs. 1988 90 Td5 NAS soft top
2015 D90 XS SW |
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17th Aug 2023 6:36am |
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| docperio44 Member Since: 08 Aug 2023 Location: Quebec Posts: 21
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Turns out the switch was disconnected. It a tight hole to fit those connections and I didn’t fully click it in! all good! sorry for the bother
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17th Aug 2023 9:17am |
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