Hi all, been a while. Finally getting a chance to look over the Zed again.

Aswell as the brake system needing looking at (at least 1 burst pipe) I have no headlights!

Car is a UK 2+2

PFA of the one of the last times I drove it. a few years ago now.

I could do with some advice or a steer in the right direction.

At some point someone has fitted HID's to the car and done what looks like the earth mod so the flashers don't turn off the headlights.

About 2 years ago I had 1 headlight randomly stop working, bulb was fine so I just fed a wire from the working one to the other and that worked for a year or so.

Now I have none.

The dash switch turns on the sidelights, no flashers, and no headlights.

All the bulbs are fine as I have jumped the relays to get various combinations working.

First step was looking at this thread

But my relays are different to these to start with. I have a twin switch brown relay under headlamp LH position. and a black one under headlamp RH position.

I understand they are supposed to turn on the headlamps dim with the sidelights on but that doesn't work either.

Ill get a picture in a bit to show you all how it looks.

Any help would be massively appreciated as id like to drive this car this year and no headlights = no mot.

Cheers

3 hours ago, Sparkysparks said:

Car is a UK 2+2

But my relays are different to these to start with. I have a twin switch brown relay under headlamp LH position. and a black one under headlamp RH position.

Headlamp fuses all checked? My '94 UK spec has the relays you describe:

 

That's the layout yes.

I have checked all those fused in the bay. The large fuses on the drivers side (Bay side) and the fuses in the drivers footwell also.

The switch itself seems to look ok. I continuity tested it and tbh I couldn't figure out its workings, but I could see no sign or smell of broken wiring / board issues.

As I said. If I jump the relays about they all work somehow, just not as desired. Its pointing me to a break from the switch to the relays. But I still don't understand how only 1 side would go, then a while later the other side.

Do you have the FSM pages for the headlight system?

it could be the connector in the passenger footwell, where the wooden floor cover is over the Ecu, there will be some connector plugs to the upper left, the large (green I think) multi plug suffers corrosion, especially if you have had targa leaks in that area. had to bypass some of the connector on mine, because one headlight wasn't working and the horn also wasn't working. just check you have voltage to the 'switching' contacts on the relays (pins 1&2 I think). the pins will be indicated on the relay by a picture of a coil between the 2 pins. 

dim dip I believe the unit for that is in the passenger wheel arch from memory, but was probably bypassed when the hid kits were fitted. 

Excellent info. I don't have the fsm. Is it available online? 

I'll have a look at that tonight. I did have a look down there but I was only searching for fuses and relays. I did see connectors. I even took the glove box out for access. 

Interestingly my horn stopped working as well but a clean earth sorted that out

These are the scanned pages from my UK/Euro FSM.

EL-39+.pdf

 

Perfect. Exactly what I needed. I've been looking online for pictures of harnesses and all sorts haha. 

I'll have a look tonight and see what i can find. Thanks all

I have just found the fsm app. Whoever created this is a person sent from above. 

Also available here for different years https://conceptzperformance.com/wiki/index.php/Factory_Service_Manual

Thanks Chris

I have some pictures of that "green" plug, I cant see how to upload on here. So I need to be a subscribed member?

It is indeed knackered on that plug and 1 wire was broken out. Looks like it had already been repaired with a bit of speaker cable, that had also broken. I stuck a pin in it and tried to see if I had anything. But guesse what. Dead battery. And the battery charger just gave up aswell.

So this will be on hold for a while.

Ill concentrate on the engine harness, currently taking out unused plugs and I will be putting in new injector and coil plugs, aswell as relocating the ptu somewhere out of sight. Theres a lot of cables im not sure about. 1 being the one hanging from under the relay box to the underside of the car. Ive not got it in the air to look yet, but looks like my issue bundle of wires.

Thanks all

13 hours ago, Sparkysparks said:

Thanks Chris

I have some pictures of that "green" plug, I cant see how to upload on here. So I need to be a subscribed member?

It is indeed knackered on that plug and 1 wire was broken out. Looks like it had already been repaired with a bit of speaker cable, that had also broken. I stuck a pin in it and tried to see if I had anything. But guesse what. Dead battery. And the battery charger just gave up aswell.

So this will be on hold for a while.

Ill concentrate on the engine harness, currently taking out unused plugs and I will be putting in new injector and coil plugs, aswell as relocating the ptu somewhere out of sight. Theres a lot of cables im not sure about. 1 being the one hanging from under the relay box to the underside of the car. Ive not got it in the air to look yet, but looks like my issue bundle of wires.

Thanks all

when I repaired the green plug on mine, I removed the wires from both plug & socket and joined them with a new piece of wire soldered in. 

Might have to bypass the whole plug. It's all a bit manky and brittle. I have to dig underneath to see if it is the loom I think it is.

Im back on this after renewing most of the connectors on the efi loom. Now I have another issue. But I think it's probably a vac leak. It idles for about 10 secs. Then revs drop lower and lower and stall. I've wound the icv out but that's for another day. 

This connector pretty much fell apart as I got it all accessible. Pins fell out. Connections fell out. But. After bypassing temporarily, I still couldn't get the results I wanted. I can get main beams to work if I earth the purple blue wire. But thats obviously not correct. How do I get pics on here? 

Subscribed members can upload photos, I guess maybe standard members have to host on another site and link?

I see. I'll have to subscribe up then. I need to share these pictures

1 hour ago, Sparkysparks said:

I see. I'll have to subscribe up then. I need to share these pictures

Best £20 you will ever spend.

Subbed as you all need to see this.

Might be out of correct order. But this is what I saw. 

I have cut the plug out and hard connected all the wiring. It all works now. So happy!

This has stumped me for years.

Thanks all. Onto the next issue. 

Feels good to be working in the zed again

I'll start a new thread. 

Always satisfying when you finally fix something!

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