Yes that lit up

 

OK that tells us that you have power and ground to the HL SW for the headlight functions.

Carefully take a paper clip to use as a jumper wire and connect the white wire to the small orange wire at the disconnected connector behind the HL SW with both fuses in and see if your headlights come on. Once again be very careful not to cross anythingand dont push the paper clip all the way in if its a tight fit. You dont want to loosen those sockets. You can also back probe the connector where the wires go in


George

 

No headlights

 

Are both fuses still intact?

Next reconnect the HL SW and pull the Headlamp Power relay. Turn the HL SW all the way clockwise to the manual HL on position and measure the voltage on the white wire at the back of the HL SW by back probing the wire with the connector plugged in.


George

 

In addition, back probe the small orange wire after the white wire to measure DCV


George

 

Both fuses intact. Headlamp relay pulled, switch still connected and turned in on position. White wire read 12.4DCV and small orange 12.35DCV

 

Ok that tells us that the power and ground to the HL SW are good and the HL SW works in manual mode and is requesting headlamps on the white wire to the relay.

Does the headlamp power relay have the pins marked on the bottom? I don't mean the circuit diagram on the top cover but the actual pin locations of 30, 85, 86 and 87?


George

 

like this?

 

OK good. Imagine that relay flipped back over to be inserted in the socket and draw out the pin locations and numbers for the socket (not the relay).

85 and 86 are for the relay coil to energize the relay to send power to the headlights but we need to figure which side is power and which side is ground. Fuses in, HL SW connected, relay removed, HL SW in the manual on mode fully clockwise test the voltage of relay socket 85 and again 86.

Next up, 30 and 87 are the relay contacts that send power to the headlights once the relay turns on but again we dont know which pin is power and which one is the headlight (load) side. Relay still removed test 30 and then 87 with your meter again on DCV.


George

 

I just realized that the pinout of that relay does not look keyed, hard to tell because of the lighting but can it be inserted either way?

George