80 series headlight headache (1 Viewer)

[Straightfarkin]

Hello

1995 gxl diesel manual 1hz-T

Low and high beams went out after some heavy rain, blue light on dash doesn't light up either.

The relay in the engine bay works fine and the two 15A fuses next to it for LH and RH headlights are not blown.

I have removed all of the interior around the steering stalk/ kick panel and revealed I beleive the DOME metal grey relay just to the right of the accelerator pedal with also works park lights on stalk on it clicks.

The Headlight bulbs aren't blow and work through bypass test I did to rule out bulbs.

The previous owner butchered alot of wiring to install spotties but I jave disconnected them and repaired all visible cuts.


I can not figure out what the problem is?
I am aware they switch on the negative which would explain why i have 12.6V at both terminals for the light bulbs. I understand once the relay is triggered it provides a ground to earth for the bulb... however I jave continuity to ground on both terminals also?


Any help would be appreciated I'm all out of ideas.
Thanks, Chris

 

[Fj80oregon]

Have you tried switching out the fuses? Sometimes fuses can be no good and still look ok. Just a thought.

 

[Straightfarkin]

Yea mate I did

 

[Gerry McGerry]

Low and high beams went out after some heavy rain, blue light on dash doesn't light up either.

Combination switch failed maybe.

The relay in the engine bay works fine and the two 15A fuses next to it for LH and RH headlights are not blown.

Do you mean you've bench tested it and it works or is it when you turn the switch you hear it click?

The previous owner butchered alot of wiring to install spotties but I jave disconnected them and repaired all visible cuts.

If they worked before, hopefully that's not the issue.

I am aware they switch on the negative which would explain why i have 12.6V at both terminals for the light bulbs. I understand once the relay is triggered it provides a ground to earth for the bulb... however I jave continuity to ground on both terminals also?

See diagram below, relay grounds out through the comb. switch (pin 11), but the headlights are grounded through a different wire (pin 9). These all connect in the harness and go to the same earth point behind the right kick panel.

If the headlight relay is still working you could try connecting a wire from any ground point and touching it to the red and yellow wire in the comb. switch plug and report back if that works, should turn on low + high beams. Second image shows plugs with pin numbering. This will rule out if it's the comb. switch or not.

 

[Idaho Savage]

Had a similar situation on my FJ62. Long story short, I replaced the switch (entire "tree"). I believe the connections in there had worn out.

 

[Straightfarkin]

Combination switch failed maybe.


Do you mean you've bench tested it and it works or is it when you turn the switch you hear it click?


If they worked before, hopefully that's not the issue.


See diagram below, relay grounds out through the comb. switch (pin 11), but the headlights are grounded through a different wire (pin 9). These all connect in the harness and go to the same earth point behind the right kick panel.

If the headlight relay is still working you could try connecting a wire from any ground point and touching it to the red and yellow wire in the comb. switch plug and report back if that works, should turn on low + high beams. Second image shows plugs with pin numbering. This will rule out if it's the comb. switch or not.


View attachment 3841380
View attachment 3841387

Thankyou mate. The relay was the issue. It was clicking but not closing the contacts

Beautifully priced genuine Denso single pole relay $65 hahaha

Appreciate the help, have a good one

 

[Straightfarkin]

Gerry what document/ book did you get those drawings from?

I was looking through my Haynes schematics but they aren't as detailed as this one.

Thanks again, Chris

 

[Gerry McGerry]

Thankyou mate. The relay was the issue. It was clicking but not closing the contacts

Happy to help mate, good to hear it's solved. The cheaper relays aren't worth buying, $65 is reasonable these days, sadly.

Gerry what document/ book did you get those drawings from?

The resources section here (top of page) has a lot of diagrams and workshop manuals. I don't think wiring diagram I use is on here, it has every spec (U.K, U.S.A, AUS, G.C.C, JDM etc.) but it's 60mb and I don't know how to upload it. If you know of a way I can send you such a large file I'd be happy to send it your way.

 

[Straightfarkin]

Legend mate cheers ill look through the forum archives in future. I'm not too computer savy anymore bro all I can think of is if you right click on the file and choose "Compress to" and then either ZIP file or 7z and that should make a copy of it just much smaller hopefully enough to send on email.

Don't stress if it's trouble or doesn't work, appreciate the help mate.

 

[Gerry McGerry]

Legend mate cheers ill look through the forum archives in future. I'm not too computer savy anymore bro all I can think of is if you right click on the file and choose "Compress to" and then either ZIP file or 7z and that should make a copy of it just much smaller hopefully enough to send on email.

Don't stress if it's trouble or doesn't work, appreciate the help mate.

Figured it out, shoot me a message on here with your email and I'll share a link to a cloud drive.