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Old 11-12-2009, 06:48 AM   #1 (permalink)
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Default Headlight relay #1 location?

My headlights are dead, but the high beams work fine. After testing everything else, the headlight relay #1 is the main suspect. Where exactly is it located? I attached a part of diagram that shows the relay.

Thanks,
Milo
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Headlight relay #1 location?-picture-2.png  
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1996 X90 4WD, 4sp. 1,6L 16v

16' rims, 235 tires, TV/DVD/GPS/Satellite Radio, 16' woofer, 500W amplifier, alarm/remote start, HID lights, blue instrument backlight, K&N filter, remote winch, class A hitch.
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Old 11-12-2009, 05:29 PM   #2 (permalink)
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you for got to say the magic word.
DRL
most kicks here, have no relay. but all drl, do.

if have a 96FSM and a 96kick with drl
so
the answer is.

fsm,pg,81-10203
"head light relay1 center i/p, behind bblower seed selector switch."
the trouble shooting chart is 37 steps
using NAvy binary search methods., 2 or 3 reading max , the answer.




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Old 11-12-2009, 05:32 PM   #3 (permalink)
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your dwg is wrong btw for 96, colors and pins.



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Old 11-12-2009, 06:14 PM   #4 (permalink)
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thanks Jerry, I was able to locate it this evening, but it seems to be working fine. I am back to sq1.

I bypassed the DRL some time back. Everything worked fine until one light died. A week or so later the other one became dim. It must be the + feed to the fuses after all, but who knows...
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1996 X90 4WD, 4sp. 1,6L 16v

16' rims, 235 tires, TV/DVD/GPS/Satellite Radio, 16' woofer, 500W amplifier, alarm/remote start, HID lights, blue instrument backlight, K&N filter, remote winch, class A hitch.
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Old 11-12-2009, 07:37 PM   #5 (permalink)
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volt meter

black lead to minus post of battery
then walk the red lead from the fuse to HL
then from the other side of LH filaments to the relay or switch.

key points.
full power to both lamps , on.
then
good ground (0v) to the low side of lamps ( the low beams or highs , depending on your switch selection)

using the battery Minus lug will show the true error in the whole system.
then with a bad reading , we can work that.

eg: 10v at head lights or
or 3 volt for the low side grounds.

the errow and the cuprits can be found, i promise.

cheers



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Old 11-13-2009, 09:30 AM   #6 (permalink)
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So far, I was able to test the relay, and the + feed on both fuses. Everything is in order. Since the relay 'clicks' I guess my combo switch works OK too.

It must be the ground then. Where exactly is the G202?

Thanks!
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16' rims, 235 tires, TV/DVD/GPS/Satellite Radio, 16' woofer, 500W amplifier, alarm/remote start, HID lights, blue instrument backlight, K&N filter, remote winch, class A hitch.
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Old 11-13-2009, 08:14 PM   #7 (permalink)
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good, g202
pg.8a-102-3
"behind center I/P on bulkhead (firewall)



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Old 11-13-2009, 08:37 PM   #8 (permalink)
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the voltage on the lamp will tell which side is bad, and never ever lie.
The meter is an invaluable tool . You can actually see the illegal resistance in the wire. All it takes is an illegal 1 Ohm illegal resistance and the lights will dim below 1/2.

THE TEST:
minus meter lead to battery minus center term. on battery
red lead to HL.
turn on HL. ( however after mod, not sure, how you do that.)
red lead to wht/red HL wire. must be 12.5v or exact battery voltage, 12v is ok.
if low then the power feed is faulty !! move meter backward towards the HL fuse until voltage rises to 12v min. spec. , see.
the point between the good and the bad is the bad circuit.
NEXT: (above passes)
now move red meter lead to the other side of the filaments. (keep meter on battery neg. minus battery term)
you have 2 wires, one for high one for low beams.

red wire is high beam
R/W is low beam.
lets say, you have Low beams activated. (and failing , dim or out..)
so the R/W must be at 0v (ideal)
move the red meter wire lest to the R/W wire,

if it reads 0v perfect.
if it reads 1 v bad. (spec is 0.5v) max.
if meter reads 2v. its real bad. move meter closer to the Combo switch.

there ,2 simple tests and no guessing at all , no question which side bad.

all the above done to the bad HL.

attached is what your car USED to have.

when we find which side is bad ,2 more readings will tell me exactly the failing node. this is called nodal analysis.
there is normal drops in the system.
the main power feed will drop a half volt and so will the ground feed.
total drop on lamp 1v. (1/2 for high side, 1/2 for low side)
this will give you worse case 11.5v to HL not motor running.
and 14.2-0.5v for 13:7Vdc running motor.

this is due to the copper resistance on the power feeds.
not all that much extra on any Suzuki.

attachments (2 pages in one file)




Last edited by kick_fix; 11-21-2009 at 01:52 PM.
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Old 11-14-2009, 12:56 AM   #9 (permalink)
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Without further ado - it was the G202.

These cars have such a poor ground! The voltmeter showed almost 10 KOhms from the bulb negative pin to the ground. The HIDs are very sensitive to a bad ground. The ballasts will not work if the total resistance (actually impedance) is not within several Ohms, hence the dimmed lights.

Thanks so much for the thorough test procedure Jerry!

Milo.
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Old 11-14-2009, 11:46 AM   #10 (permalink)
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Great ! well done.

yes, but all grounds on this car are subject to fail. ( and is a bad design)
all need to be cleaned and then greased with sil. grease (or spec. elect. greases) (at least one time)

just knowing what side is failing is so helpful to the repair person.
just be sure the meter MINUS is touching the Minus battery terminal and that therminal is spic and span clean (inside) and then you see the truth every time.

no car should use the body ground for:
EFI
sensors
ECU.
PUmp
Actuators.

None ! a real bad idea. and most car companies had to learn this through angry customers. sadly.

I'd add HL and TL to the list for safety.

HAPPY TRAILS !!!



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