Results 1 to 8 of 8

Thread: Headlight rewiring guide (headlight relay plug melting)

  1. #1
    Forum Newbie
    My Van(s):
    1985 2wd
    Join Date
    Nov 2014
    Location
    Berkeley, CA
    Posts
    7
    Rep Power
    0

    Exclamation Headlight rewiring guide (headlight relay plug melting)

    In reading the threads, it seems the headlight relays are a common point of failure, with melted wires and fuse box plugs. (Discovered this after the wires into my own relay heated to smoking hot)

    Id like to create a resource guide to wire in aftermarket relays and harness/wiring blocks.

    i have a couple questions to get started.

    I haven't been able to source a wiring diagram. Does anyone know the color codes of the high beam and low beam control wires?

  2. #2
    Van Fan terrence's Avatar
    My Van(s):
    1987
    Join Date
    Mar 2015
    Location
    Greensboro, NC
    Posts
    95
    Rep Power
    1

    Re: Headlight rewiring guide (headlight relay plug melting)

    Here is the wiring diagram, headlights towards the bottom:

    http://toyotavans.org/community/tips...NGDIAGRAMS.PDF

  3. #3
    Forum Newbie
    My Van(s):
    1985 2wd
    Join Date
    Nov 2014
    Location
    Berkeley, CA
    Posts
    7
    Rep Power
    0

    Re: Headlight rewiring guide (headlight relay plug melting)

    Many thanks Terrence! and thanks for the patience- van life has been on hold as I moved everything I own from Oakland back to Portland! And damn it feels good to be home again!

    I took apart the dashboard today and dove into it- but I think I'm missing something about the way these 3 prong relays work. Does anyone grasp how the red-white wire is modulating the high beams?

    I tried it a couple different ways (connecting the red wire to the red-white wire directly to then use the red-yellow and red-green wires as signal wires for the new relays.... but smoke started coming up from the steering column almost immediately... so... don't do that, fellas.)

    Presently, I wired in a new switch between the red power wire and the red-black power to the headlights. This gives me low beams, but no way to switch on the high beams. Does anyone have a firm grasp on how to use the current headlight switch to actuate new relays?

  4. #4
    Van Enthusiast boogieman's Avatar
    My Van(s):
    1989 4x4 5 speed dlx 1987 4x4 5 speed cargo 1987 4x4 5 speed LE 1987 2wd 5 speed cargo conversion 1989 2wd auto cargo parts van
    Join Date
    Feb 2017
    Location
    abq, nm
    Posts
    235
    Rep Power
    1

    Re: Headlight rewiring guide (headlight relay plug melting)

    i recently picked up an '87 that had fuse box issues, both a burned heater motor lead and headlight relay/fuses....the previous owner had a shop rewire a relay and two fuses for the headlights. it looks correct but the problem is i get all 4 lights on for low beam and the outside ones change for high beams....i tried another combo switch and same result...not sure what im missing, Name:  20170705_180642.jpg
Views: 197
Size:  98.9 KB

  5. #5
    Van Enthusiast boogieman's Avatar
    My Van(s):
    1989 4x4 5 speed dlx 1987 4x4 5 speed cargo 1987 4x4 5 speed LE 1987 2wd 5 speed cargo conversion 1989 2wd auto cargo parts van
    Join Date
    Feb 2017
    Location
    abq, nm
    Posts
    235
    Rep Power
    1

    Re: Headlight rewiring guide (headlight relay plug melting)

    Name:  20170707_131655.jpg
Views: 161
Size:  89.4 KB

    well thats annoying, why is it always the last place you look? after ripping apart the fusebox and dash and checking the switch 3 times i was gonna disconnect the highbeams until i could figure it out...

    i guess this was some sort of fix before the headlight relay/fuses were corrected...?

  6. #6
    Forum Newbie
    My Van(s):
    1987 Toyota Master Ace Surf
    Join Date
    May 2020
    Location
    New Zealand
    Posts
    8
    Rep Power
    0

    Re: Headlight rewiring guide (headlight relay plug melting)

    Boogieman I know its been years but did you ever figure out why all 4 lights were on for low beam and outside one changing for high beam? I am having the same issue and I also noticed someone had rewired the headlight relay. Interested to know what the problem was. Thanks.

    I have a 1987 Master Ace Surf.

  7. #7
    Van Enthusiast boogieman's Avatar
    My Van(s):
    1989 4x4 5 speed dlx 1987 4x4 5 speed cargo 1987 4x4 5 speed LE 1987 2wd 5 speed cargo conversion 1989 2wd auto cargo parts van
    Join Date
    Feb 2017
    Location
    abq, nm
    Posts
    235
    Rep Power
    1

    Re: Headlight rewiring guide (headlight relay plug melting)

    they added that ground in the second pic..maybe it was done before the fuses had been rewired to make them work period but im not sure...when i undid the ground all was back to normal

  8. #8
    Forum Newbie
    My Van(s):
    1987 Toyota Master Ace Surf
    Join Date
    May 2020
    Location
    New Zealand
    Posts
    8
    Rep Power
    0

    Re: Headlight rewiring guide (headlight relay plug melting)

    Thanks boogieman. I appreciate your response. Glad you figured it out.

Tags for this Thread

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •