Headlight issues

[Rascal21]

Hi all

I`m having problems with the headlights.
I know for a fact that Flash does not work.

Heres how they work right now:



If dimmer-handle (On steering column) is pointing all the way away from me, and I turn the dash-switch all the way over, I get headlights like you see on the picture.

If I turn dash-switch only one notch (Instead of the full two notches), I do not get headlights like you see on the picture.

I can only use either switch or dimmer-handle to get headlights like you see on the picture, both at the same time yields no results as to getting low-high beam/flash working.



Flash does not work at all (Can hear no relay)
High-beam indicator does not work.
High-beam does not work (Unless thats what we see on the picture)

Headlights are grounded directly @ chassis.

At least I got headlights working to SOME degree, as I found that the non-West Germany cars are not supposed to have a Dimmer-relay, instead they are supposed to have short-pin between #3 and #4 female pins for where the Dimmer-relay would be.

But I can`t get any further than this.. I have only theories but no facts to back them up, as to what the problem could be!
(For example, I see a black wire sticking out underneath the fusebox, could that be for headlight ground i.e High-beam/flash?)


I feel this is best left answered by someone with more experience than me!

Getting really close to a road worthy car now, this headlight issue and distorted rear brake discs+leaky differential is all that stands in the way of a EU-approval

[Rascal21]

Alright, I figured out that the low-beam on Left side headlight and Right side headlights are both supposed to be Red-Yellow for high-beam, on my car, Red-Yellow and Red-Yellow goes to Left side headlight only.
Red-Black and Red-White goes to Right side headlight only..

This is completely opposite to everything the manual states, AND the manual does not hint as to what wire color is for earth circuit (For High Beam), nor where it would connect..

Makes no sense to me..

[Ivan141]

Is your wiring tampered with or original? Those wire colors you mention are unusual indeed.

Maybe you are misunderstanding the dimmer and light switch functionality. AFAIK, both german and european models use the same switches. The light switch only switches between off, tail and head.
The dimmer switch on the steering column has 3 positions IIRC:
mid = high beam OFF.
away from driver = high beam ON
pull toward driver = flash.

EU models have power to the headlights switched on the moment you turn the switch to the HEAD position (fully on) OR when you pull the column lever to FLASH.

What type of wiring do you have? German type with 4 fuses, dimmer relay and switched 12v signal to the bulbs, or EU spec with 2 fuses and switched ground through the light switch. Should be relatively easy to figure out.

[Rascal21]

It has previously been tampered with:
Aftermarket 30A relays on 12v terminal, using red-black & red-green wires (Which in this case is for high-beam/flash I think?) for switch rather than power.
And they are earthed directly to chassis as well.
There are two wires under the engine bay fusebox which has been tampered with, a black-orange wire has been cut off and taped, and another one which color I cant remember and it has has been spliced and earthed.
Other than this all seems Original, including the different wires that goes to the Right side headlight.

Mine is a 1984 EDM Zenki Levin Coupè, and I am pretty sure it`s not a ex-German car (Short-pin in place of the Dimmer relay, normal 3-pin headlight relay where it should be)

Thx a lot for answering! You`re way more experienced at this than I am.
This is one problem I just cant wrap my head around.

[Ivan141]

Just try to narrow it down. Find yourself a multimeter and try to chart out what is happening with the switches + relays.
Easiest way is to just jot down a table with the 3 rotary lightswitch positions on one axis, and the 3 high-beam stalk positions on the other axis.
Then for each possible combination note what the headlights are doing, and which relays are switching.

Just to make sure: are your bulbs good & of the correct type?
No point fussing if both low beam coils are burnt out.

[Rascal21]

Well, switch and handle delivers power to the headlight, the current passes through the short-pin next to the headlight relay then goes out the fusebox through aforementioned wires and to the low-beam coils.

No power getting to the high beam coils at all and I hear nor feel any relay clicking (But I do know the relays are functional, thats the weird thing)

Lights are of normal Bosch H4 type and I have checked several times that no coils are burnt out.

I don`t know which wire on the fusebox is for high-beam, and everyone says that when you use flash/high beam all the handle does is connect the earth to the headlight or something like that (Reversed earth connection or whatever they call it).

Thats why I`m highly sceptical to the fact that right now, each of my head lights are ground right on chassis right next to the lights, on the fender bolts, rather than going all the way to the handle on the steering column, and there are no wires cut at the steering column switch assembly, there is however, as I mentioned, a black & orange wire that has been cut-off and taped underneath the fusebox in the engine bay.

[Rascal21]

Quick update as to what the problem can be here:

When the handle is left in center (For no lights at all) it turns on when I turn on the kill switch!
I.e, once the car has power from battery, the lights turn on, even if light switch on dash is at ""zero""

When I manipulate the handle either away from me, or towards me, the lights go dark..

I also tried an (I think) AE82 fusebox, it looks the same as the ae86 one I have now except different brackets, same problem with that as well..