Mrmerlin

OK you have an 86 Euro, yes I see your fogs and driving lamps work, I missed that .

try moving the hi beam stalk back and forth after you have sprayed deoxit 100 into the switch contacts.

I had an earlier Euro to fix with the same issue. it turned out that another relay had failed and it took out the feedfor lights on.

Have the relays been removed and the pins had deoxit applied to them?

In my case one of the other relays was failed I thought it was the X bus relay.

So since this didnt fix it (swapping in a new X relay,)
then it would be wise to remove the rest of the relays and test them ,
I was using a 4/5 pin relay tester

wigwampro

Quick update for the day... I removed the relay housing and noticed a substance that seemed more like old soldering resin than oxidation (1st pic) but I was able to clean most of it up. Unfortunately, I ran out of Deoxit so I have to continue tomorrow. I also tested voltage at the female points where the headlight relay plugs into the CE panel and only got 12.6V on 30a and 30b on the left side (2nd pic) with the car off. Finally, I replaced fuse #18 (horn and rear wiper) since it must have recently blown and I found a few “53” relays that had some loose prongs so I replaced those with new Bosch relays. I’ll have to wait until I get my hands on some more Deoxit to test the headlight relay. Thoughts on the power situation until then? Is that normal?

wigwampro

I was able to clean up the internals of the headlight relay with some Deoxit today and it is now clean with no signs of damage. I plugged it in and the same symptoms persist. Lights come up and motor seems to work correctly but no power to the lights.

wigwampro

I was finally able to fish out the 4 connector plug behind the headlight motor. I’m working to clean those up but connections looked clean and wires seemed functional. I’ll update this post with progress this afternoon.


I will clean the 4-connector plug behind headlight motor.

wigwampro

I cleaned up this plug and tried the headlights again. Unfortunately, it did not resolve my issue. I ordered a replacement headlight relay for delivery tomorrow. Fingers crossed. I'd love to find out more about the power situation in the CE panel, though. As mentioned, I had 12.6V to 30a and 30b (picture in post #17 above).

Mrmerlin

please buy a relay tester from amazon under 20.00 then test the relays

wigwampro

Sorry, I forgot to mention that I ordered this today: I'll test all 4/5 pin relays when it arrives.

Alan

I don't like how the relay looks - the circuit board corrosion to me looks reminiscent of "Tin Whiskers", these are conductive strands of tin growth - they can indeed cause functional problems. Someone has tried to address this. But it may not be sufficient. Acid etching (difficult without damage) or replacement may be the only viable options.

12.6V car off is fine

Alan

wigwampro

Great hearing from you, Alan! Thanks for that input. I’d never heard of that before but it certainly didn’t look right. I’ve added another pic here of the whole circuit board. I should have a replacement in my hands tomorrow and will update the group as soon as I test it out.

wigwampro

Sure enough, I replaced the dual headlight relay today and they work fine now! Thanks for all of the advice, team!