HEADLIGHTS

[TEZ217]

Hi Folks, new to the forum had my bongo 6 months and love it! but need some advice and guidance, came across a problem this evening you may be able to help me with or guide me in right direction-
Normally drive during the day so this could well be a problem that was always there or could have just occured, bongo parked up in my driveway facing my house wall decided to clean the inside, so started the bongo so interior lights did not drain battery at all, on turning on my ignition to warm heater plugs noticed my headlights came on even though switch on headlight stalk was off, turned on headlights they dimmed to park then turned to them to headlights then tried main beam all ok on switch but turned off the switch and lights still on. So to sum things up as soon as I turn on my ignition my headlights come on! Realise it could be a short circuit somewhere or still could be the stalk switch but thought maybe someone had came across this before and could help, (take your time though as in no mood to try owt this evening as its forcast for minus 7 out there)
Regards TEZ

[g8dhe]

What does the High Beam indicator light on your Dashboard show - from what you say I would expect it to be on all the time ?

It could be that your Headlight relay has welded its contacts together, have you had a headlamp blow at any time ?
Try disconnecting the relay its show below, its the back most one if you reach underneath the relay it should be possible to pull the connector off;

With the relay disconnected the Headlights should be OFF, unless you pull the Flash switch on the stalk, when the lights should come on.
There could still be a fault in the wiring however, which is causing the relay to pull in all the time, the best check for that is to measure the resistance across the contacts with the relay disconnected if you have a meter.

[TEZ217]

Hi Geoff, thanks for the speedy reply, having just braved the cold found out the high beam indicator is NOT showing all the time but is working, but believe from your pictures your on the right track heres why, a couple of weeks ago I stupidly left off the expansion bottles cap, found this out some miles down the road when steam and water was escaping, seems like I may have averted any engine damage but from your pictures its obvious what got wet and steamy( yes I was as well but not it seems as much as the pictured relays) many thanks TEZ

[g8dhe]

Well the relays are pretty well encased in there rubber covers but expanding steam and water is a pretty volatile mixture so they could well have had a soaking which may not have been good for them !

[TEZ217]

Hi Geoff, will check the relays tomorrow weather permitting thanks for the pointer in the right(I hope) direction.
cheers TEZ

[TEZ217]

Hi all, well the story so far is checked the two headlight relays next to expansion tank opened them sprayed with electrical cleaner appeared brand new contacts clean and free, put back in place and I thought I had cracked it with Geoff's guidance, turned on ignition NO HEADLIGHTS BRILL tried the stalk switch park ok headlights ok but main beam nothing the flash/pass is fine any ideas? if I remove relays again how would I check the wiring to them and the relay itself I do have a meter cheers TEZ

[g8dhe]

Well the Flash switch by-passes the relay. The relay controls both the High and Low beam, so if the Low beam is working but NOT the high beam then that points at the stalk switch for High/Low beam, here is the diagram if it helps;

Given that the Flash and High beam connections are all made within the stalk switch, that seems to imply that there is a fault within the switch itself.

[TEZ217]

Hi, diagram does'nt help me I'm afraid,! But the headlights came on with the ignition regardless of stalk switch, I have only removed the relays checked them and refitted in there original place now my lights dont come on with the ignition but the main beam is'nt there I would think its still the relays as I hav'nt touched any thing else. need to be able to test the wires to the relay maybe while switching the lights to main beam HOW !!
CAN I SWITCH THE RELAYS WITH EACH OTHER MAYBE AS THERE BOTH THE SAME IT APPEARS

[g8dhe]

Yes you should be able to swap the relays.
The relay doesn't affect the High/Low beam settings at all. It just switches the power to the stalk switches on/off for the Headlights in general.
High/Low beam is controlled by the stalk switches.

Hang on do you have air bags ? Its different if you don't, but in that case you wouldn't have a relay either! but can you confirm which year and month the vehicle is and if it has air bags ?

[TEZ217]

Hi Geoff, its a 1999 with air bags

[g8dhe]

Is that Feb 1999 or newer ? The manuals the club has only go as far as Jan 1999 ..... so it might have changed

[TEZ217]

Its june 1999, actually I have a complete stalk assembly got it off the previous owner he bought it when his horn went off but instead of fitting it the garage simply wired horn to flip swith,
Looks a bit awkward to fit quite a few multi plugs should be straight forward once you get past the airbag and steering wheel removal but that should be fun
swapped the relays did'nt make no difference but could feel the suspect one clicking ok when swapped so guess Geoff is correct its the stalk what do you think!! any guidance with steering wheel and airbag would be helpful

[francophile1947]

Can't help feeling that I've read of other Bongos doing this, but can't find the old threads now Pretty sure it was a deliberate modification.
Was it getting dark as you cleaned the inside (I notice you said interior lights on)? If so, this thread may be relevant http://www.igmaynard.co.uk/bongo/forum/ ... on#p212706

[g8dhe]

I've suggested to Ian it might be worth investigating purchase of the newer manuals, as more and more vehicles are now less than 10 years old.
I seem to remember also that I have seen reference to a light sensor on some models, I know in a Spacewagon we have automatic lights that come on as soon as the light level drops.

[TEZ217]

Hi, I do have the small box dashboard top drivers side but have never touched it at all, was told it was a heat sensor for air con.