TeamCapri

Please login or register.

Login with username, password and session length
Advanced search  

News:

New & potential members - due to overwhelming spam registrations, it's been very hard to sort through new registrations. If your account has not been approved, check your spam folder! If not please contact us at admin[AT]teamcapri.com and we'll sort it out for you.

Pages: [1] 2 3

Author Topic: Headlight Troubleshooting - any further tips?  (Read 4913 times)

JimmyGermany

  • Full Member
  • ***
  • Posts: 112
  • On the search for parts less broken than mine :-)
    • 1993 Capri non-turbo
Headlight Troubleshooting - any further tips?
« on: April 02, 2021, 04:10:13 PM »

Gentlemen,

I've got one headlight which has stopped flipping.

Today, I started troubleshooting.
Attached the electric motor directly to the battery, runs non-stop (as expected).
When attached to the plug normally, nothing.
Replaced control unit with a (used) spare - same result.
I cannot measure any signal at the plug when activating the switch. (Should I be able to?)

https://ibb.co/d5HFLwM

This is the connector in question - the previous owner spliced EVERY SINGLE WIRE - this is currently my prime suspect.
Should I be able to measure continuity between the plug contacts and the connections that to TO the control unit?

I'm kind of at a dead end and hoping for a tip.
Happy Easter to all!

Cheers
James
Logged

greywolf27030

  • Old-Timer
  • *****
  • Posts: 1658
    • 1991 XR2, 1992 XR2, 1993 XR2
Re: Headlight Troubleshooting - any further tips?
« Reply #1 on: April 03, 2021, 07:55:00 AM »

There is a clock spring in the light housing that controls the up and down movement. It is packed with grease from the factory and over time it is common for the grease to turn to wax and be non-conductive. A simple disassembly and cleaning gets them back going.
Logged
Jack Byrd

JimmyGermany

  • Full Member
  • ***
  • Posts: 112
  • On the search for parts less broken than mine :-)
    • 1993 Capri non-turbo
Re: Headlight Troubleshooting - any further tips?
« Reply #2 on: April 03, 2021, 11:53:43 AM »

Hello!

Do you mean within the motors? I did that.
Cleared out the gunk and replaced with silicone grease.
The motor runs fine when connected to the battery directly.
There seem to be no current reaching it through the plug.

Should I be to measure the signal from the plug when using either switch? (I tried with the DMM but it shows nothing)

Should I be able to measure continuity from the contacts in the plug to the plug that goes into the control unit?

As a last resort, is it possible to make a new partial wire harness from the control unit to the one headlight? This is my least favourite option, because I’m lazy.

Happy Easter to you ALL!
James
Logged

Rocketman

  • Administrator
  • Old-Timer
  • *****
  • Posts: 5492
    • 91 BPT AWD Capri & 1991 XR2
    • http://www.werbatfik.com
Re: Headlight Troubleshooting - any further tips?
« Reply #3 on: April 03, 2021, 05:05:34 PM »

I think the only thing you'll be able to reliably test is the motor windings thru the plug.

The other contacts in the motor plug are from the rotary switch, and continuity from those will depend on the motor's position.
The plug for the control unit in the vehicle probably won't show you much by probing it. It's going to "Read" the motor position and send power to the motor depending on its position information.

There may be some information, or at least wiring diagrams that can help you in the factory service manual. www.techcapri.com
« Last Edit: April 03, 2021, 05:08:01 PM by Rocketman »
Logged
1.8L Turbo All Wheel Drive Capri... the "GTXR2"


JimmyGermany

  • Full Member
  • ***
  • Posts: 112
  • On the search for parts less broken than mine :-)
    • 1993 Capri non-turbo
Re: Headlight Troubleshooting - any further tips?
« Reply #4 on: April 06, 2021, 02:13:59 PM »

Gentlemen,

Perhaps a silly question: are there different LEFT and RIGHT motors?
And, if yes, how can you tell them apart by looking at them?
I've seen listings mentioning the side, and some saying they are interchangable.

Gonna have to find a Pro to deal with this problem.
I think I've done all the poking I dare to :-)

Cheers
James
Logged

GermanXR2

  • Newbie
  • *
  • Posts: 34
    • XR2 Turbo
Re: Headlight Troubleshooting - any further tips?
« Reply #5 on: July 07, 2022, 04:22:34 AM »

@James

Could you solve the problem?

My both headlights pop up without problems, after switching off the driver side light stays open.

Maybe after 6-8 trys (headlight switch or pop up switch console) it goes down.
Logged

greywolf27030

  • Old-Timer
  • *****
  • Posts: 1658
    • 1991 XR2, 1992 XR2, 1993 XR2
Re: Headlight Troubleshooting - any further tips?
« Reply #6 on: July 07, 2022, 01:38:02 PM »

The common problem with headlights is the hardened lube inside the motor. Corroded grounds are also a problem. I've been trying to get my turn signals working for six months.
Logged
Jack Byrd

GermanXR2

  • Newbie
  • *
  • Posts: 34
    • XR2 Turbo
Re: Headlight Troubleshooting - any further tips?
« Reply #7 on: July 08, 2022, 05:37:31 AM »

@greywolf27030

Thanks for reply, i own the XR2 only a few days and have many question.....

Is there (except the Manual) any repair instruction maybe with pictures avaliable?
How to deinstall the motor/gear? How to open and clean?

This would be a great help.

Thanks!
Logged

greywolf27030

  • Old-Timer
  • *****
  • Posts: 1658
    • 1991 XR2, 1992 XR2, 1993 XR2
Re: Headlight Troubleshooting - any further tips?
« Reply #8 on: July 08, 2022, 08:47:44 AM »

@greywolf27030

Thanks for reply, i own the XR2 only a few days and have many question.....

Is there (except the Manual) any repair instruction maybe with pictures avaliable?
How to deinstall the motor/gear? How to open and clean?

This would be a great help.

Thanks!

https://www.facebook.com/groups/210318449008872/permalink/755517504488961

Hope this helps.
Logged
Jack Byrd

GermanXR2

  • Newbie
  • *
  • Posts: 34
    • XR2 Turbo
Re: Headlight Troubleshooting - any further tips?
« Reply #9 on: July 08, 2022, 10:15:32 AM »

PERFECT, Thank you!

Greetings from Germany!
Logged

GermanXR2

  • Newbie
  • *
  • Posts: 34
    • XR2 Turbo
Grease? Re: Headlight Troubleshooting - any further tips?
« Reply #10 on: July 10, 2022, 08:19:14 AM »

I disassemble the headlight motor/gear.
At first view it looks like that some grooves are on the disk, but with thinner you could nearly remove it.
With 600 sandpaper I clean the disk and the three fingers.
Question to the grease, actual only at the gear worm and the teeth of the plastic disc is grease.
The metal disc and the three fingers are without?
Which parts should be geased? And what is the best grease?
Metal disk and metal fingers with only with electric contact spray?

Logged

GermanXR2

  • Newbie
  • *
  • Posts: 34
    • XR2 Turbo
Re: Headlight Troubleshooting - any further tips?
« Reply #11 on: July 10, 2022, 09:53:52 AM »

Here some Pictures

« Last Edit: July 10, 2022, 09:56:01 AM by GermanXR2 »
Logged

greywolf27030

  • Old-Timer
  • *****
  • Posts: 1658
    • 1991 XR2, 1992 XR2, 1993 XR2
Re: Headlight Troubleshooting - any further tips?
« Reply #12 on: July 11, 2022, 08:35:01 AM »

Excellent, I use lithium grease on the gears and bulb grease on the contact plate.
Logged
Jack Byrd

GermanXR2

  • Newbie
  • *
  • Posts: 34
    • XR2 Turbo
Re: Headlight Troubleshooting - any further tips?
« Reply #13 on: July 11, 2022, 01:46:28 PM »

I complete the gear with white grease, worm gear and theeth, put everything together.....and nothing  >:(   
Same as before.... Fxck

This is now my status:
If i turn the knob of the left headlight down (by hand), use the switch at the center console, both headlights pop up.
But if i press the button again, only the right headlight close. The left headlight stays open.

I try to check the motor:
White plug disconnected, to connect with external power:

As i understood to open the headlight:
brown wire is 12V voltage, green wire is ground.
->To close, reverse the wires.

But, if i connect green and brown at the motor plug, the lamp goes up an down, up and down....
Based on another thread, the headlight should goes only up with this connection (brown wire is voltage, green wire is ground)

Is this a normal behavior? that is turns and turns and turns.....
_____________________________________________

Another question:
Is the position of the cooper disk with the cut out's important? I assume, because of the three fingers on the cover:

Headlight modul got 12V power via switch (headlights on)
Send 12V to headlight motor
Motor turns, until a cut out was reached, connection disrupted (by one of the three fingers), Motor stops.
Headlights open

The same to close:
Switch send 12V to the motor
Gear wheel turns until a cut out is reached
Power connection interrupted, headlight in parking position.

I contact the previous owner, he told me that several workshop masters try to solve the problem without success. I open the gearbox, mark the position of the gearwheel with a pen, as reminder when i put everything together. My fear is, during a previous repair try, the gearwheel was misaligned and now the headlight does not reach the end switch.

I hope my description was understandable.....

Thanks!


« Last Edit: July 11, 2022, 04:09:37 PM by GermanXR2 »
Logged

greywolf27030

  • Old-Timer
  • *****
  • Posts: 1658
    • 1991 XR2, 1992 XR2, 1993 XR2
Re: Headlight Troubleshooting - any further tips?
« Reply #14 on: July 12, 2022, 08:18:29 AM »

That is how I perceive the light operating. I've never had to deal with it so can't really help. Have you tried swapping the motors to see if the problem changes sides?
Logged
Jack Byrd
Pages: [1] 2 3