Mk2 upgraded headlight loom (problems!)

[plasticfantastic]

Hi all,

Well im finally down to the last handfull of niggly jobs, as long as she doesn't throw any more at me!

Im in the middle of testing my upgraded headlight loom and have fun into a few complications! i have adapted danny_p's design from his website.

So far my problems are:

1, Dip beam and side lights have swapped positions on the headlight switch. Dip beam comes on with the first click and then goes to sidelights on the second.

2, When i go from dip beam to main beam all lights come on (dip, main, spots and fogs) this is what i wanted but was hoping this would only happen when the fog switch was on with main beam, but it does it regardless of the fog switch.

3, once i have switched to main beam i can no longer switch back to dip using the stalk, i have to turn the headlight switch to either off or position 2 for sides.

4, drivers front indicator doesnt work. (bulbs fine)

5, Horn is on continuosly (unplugged at the mo)

apart from that everything else works as it should.

there is a vast improvement in the intensity and brightness of the lights and is definately a worthwhile mod, once i sort these problems!

Any help is very much appreciated

cheers

EDIT

I have just been out and disconnected the dim dip resistor as per rubjonny's instructions, and i now have sidelights on both clicks of the headlight switch, and when you click the stalk the main beam, dip and spots all flash up but wont stay on?!

this is confusing the hell out of me!

someone please help!

[Mr Blue]

for the last bit. was your ignition on?

[plasticfantastic]

yes it was, not sure what to try now.

i have disconnected the jumpers the go from pin 30 the output on the main beam relay to pin 87a on both other relays. this stops the dip and fogs being on with the main beam but all other problems still exist?!

cheers

[rubjonny]

1. swap the 2 spade wires round that plug into the headlight plug
2. disconnect and bin the dim-dip resistor, its near driver side headlight, size n shape of a pack o polos with a yellow wire out of each end. follow the loom back and you'll find it plugs into a 2 pin connector
3. possibly casued by 2, if not check the plugs are all ok
4. disconnect the plug behind bumper and check the pins arnt all crudded up
5. take the wheel off and check the metal earth contact hasn't bent and contacted something metal, check all 3 screws holding stalks on are tight, check plugs are all in ok, check wires for damage behind there

[JMallows]

You got a wiring diagram of what you have done?

[plasticfantastic]

it's pretty similar to danny_p's version here:

http://www.dannyp.info/index.php?option=com_content&view=article&id=51&Itemid=58

there is a wiring diagram at the bottom.

the main difference is, i have routed all the headlight wires to by the battery and have all six relays there.

i just cant figure out why the relays wont shut down, from main beam back to dip?! something must be backfeeding the relay?!

cheers

[JMallows]

First thing is to go through the whole lot and check everything is connected correctly.

The thing with the foglights is the way you have wired it. You are using the high beam light as a trigger, so they will come on with high beams, and not the fog light switch. You can change the trigger, but that will involve a re-wire etc...

i dont think having the high beam and low on at the same time is a good idea either. The bulb will get too hot and you could lose both high and low beam, and have to drive home on spots, whihch doesnt work well...

Check the circuit, and let me know what you find, confirm everything is the same as the diagram on the other page, if not - whats different?

[JMallows]

I belive there is also a problem with his diagram... the two outer relays (low and fog) should have 12V connected to 30. though this wouldnt normally be a problem, you cant use 87a in the way he is. 87 and 87a are the NO and NC connections, which should be connected to the two lamps, not one lamp and the battery.

[plasticfantastic]

Im going to have a good go through it tomorrow, and probably have a bit of a rewire to. the more i sit here and think about it the more little changes i want to make!

i'll report back tomorrow!

Cheers,

[plasticfantastic]

any chance you could come up with a diagram of how it should look?!

can i still use the same six relays would you say?

cheers

EDIT: Also what are No and Nc connections?!