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I decided to upgrade the headlights on my 60 with Koito semi-sealed beam (H4//H1) headlights. Mine is a 1989 so has four headlights, like a US FJ62. I made a simple harness which is driven by the old headlight connectors on the LH side (passenger side) of the wiring harness. I have three relay-driven circuits: Outer dipped beam, outer main beam and inner main beam. Each relay's trigger circuit is driven by the original wire in the harness, and the trigger circuit is earthed back to the earths in the original headlight connectors.
The relays switch from the battery, through to new headlight connectors (which are connected to the new headlights) and back to battery.
The issue I have is as follows:
When I turn headlights on (dipped beam), they come on normally.
If I flash the high beams (stalk towards myself), they stay on when the stalk returns to the dipped beam position. They only go off when I turn the headlights off at the stalk (switch back to side lights/parking lights).
If I turn the headlight on and push the stalk forward to main beam, the main beams come on, with the dipped beams, and won't switch off when I return the stalk to dipped beam.
If I run an LED in the main beam switch, it flickers on for a split second when the main beams come on. If I run the original incandescent bulb, nothing.
The above symptoms happen whether I have an LED, incandescent, or no bulb at all in the high beam indicator.
I'm not great at electrics, but I suspect that the issue is due to me not understanding how the original headlights are switched. There is a single relay switching the headlights on/off and somehow from dipped to main, even though there is only one, single circuit headlight relay in the vehicle. I suspect that the main beam circuit is somehow earthing from both ends and staying on even when there should not be current to the main beam wires. Would it help if I earthed the trigger circuits for my relays to the body, and not to the headlight circuit?
Thanks for reading this far, I'm hoping someone better at electrics than I can suggest what has gone wrong!
EO
The relays switch from the battery, through to new headlight connectors (which are connected to the new headlights) and back to battery.
The issue I have is as follows:
When I turn headlights on (dipped beam), they come on normally.
If I flash the high beams (stalk towards myself), they stay on when the stalk returns to the dipped beam position. They only go off when I turn the headlights off at the stalk (switch back to side lights/parking lights).
If I turn the headlight on and push the stalk forward to main beam, the main beams come on, with the dipped beams, and won't switch off when I return the stalk to dipped beam.
If I run an LED in the main beam switch, it flickers on for a split second when the main beams come on. If I run the original incandescent bulb, nothing.
The above symptoms happen whether I have an LED, incandescent, or no bulb at all in the high beam indicator.
I'm not great at electrics, but I suspect that the issue is due to me not understanding how the original headlights are switched. There is a single relay switching the headlights on/off and somehow from dipped to main, even though there is only one, single circuit headlight relay in the vehicle. I suspect that the main beam circuit is somehow earthing from both ends and staying on even when there should not be current to the main beam wires. Would it help if I earthed the trigger circuits for my relays to the body, and not to the headlight circuit?
Thanks for reading this far, I'm hoping someone better at electrics than I can suggest what has gone wrong!
EO