Hello!
I have a problem with my low beams not turning off. It doesn't matter if I turn the ignition off before the light or not the low beam is on until the battery dies.
My troubleshooting has consisted of:

1. Looked for drl module as I read that this usually causes problems (the car doesn't seem to be equipped with it, but if anyone knows about German-sold
   jeeps that have this placed somewhere other than the torpedo wall on the passenger side, please let me know!)
2. Change the 10-pin connector left front in the engine compartment (was torn apart)
3. Summed the lamp switch
4. Measure the control current from the ignition switch to the headlamp delay module
5. Took apart the headlamp delay module didn't see anything wrong with soldering etc. in the circuit board, however I saw that a small chip had formed on
   the contact on the relay itself, filed it away but the error still remains.

Wire diagram:



What I would like to do now is to bypass this headlamp delay module in order to rule out that it is the fault. When I look at similar threads, it seems that you
should only be able to disconnect the module, but when I do this, the low beams die completely. Any tips on where to proceed?

Thanks in advance!

 

Had that with another car (coincidentally in Sweden): it was a retrofitted relay suffering from water ingress.

 

Did you unplug the delay module and try?

Here's the delay module wiring from the '93 FSM. The Tan/BLK (cut off in the pic) comes from the headlight switch.

 

I have tried to unplug it but when i do the headlights canīt be turned on.

 

I see. Iīve followed the cables as far as I can and from what I can see it doesn't seem to be a retrofitted relay but will have an extra look tomorrow when I get to the workshop!

 

Can anyone confirm that the headlights should work with the headlight delay module disconnected?

 

By looking at both the '90 and '95 diagrams, (so easy to assume it's the same for a '92) yes, the headlights should work with the module disconnected. Have you checked your fuses, both under hood PDC and interior fuse panel? Do you get hi beams if you flash your stalk?

I'm going to suspect the delay module is faulty and you also have a supply issue to your headlight switch, especially if you don't get a hi beam flash; or maybe even a burnt out headlight switch/connector.

This is a '95 diagram so fuse numbers and sizes are very likely different, but these diagrams are the nicest to look at, and I don't have the '92 stuff. Red is your headlight switch feed/output, yellow is delay module and green the hi beam.

 

Any relay can fail for that (or another) reason. The fact that mine was aftermarket isn't really relevant, so no need to have mentioned it, sorry for any confusion.

 

If you look at the schematic Boxburn posted, the delay module is connected in parallel to the headlamp switch with both connecting to the dimmer switch (aka Beam Select Sw). The diagram you posted shows the same but is a bit tricky to follow. The fuse numbers don't match though. Where did you get this diagram?

The delay module knows the key is on from the "telltale connector" (Ign Off Signal in the '93 FSM) and the lights are on from the "yellow" wire (Lights On Signal in '93 FSM). The . The headlights get normal power from the headlamp switch through the dimmer switch.

If you turn the headlights off, then turn off the key, the delay module contact remains open and the lights go out as soon as you switch the headlamps off.

If you turn the key to off, then headlamps, the delay module contact remains closed and the lights are fed through the delay module (yellow line). Once the "timer" runs out, the contact opens and the light go out.

Bottom line, the lights should still work with the delay module disconnected. Don't know about the DRL. There maybe some differences due to being a Germany made vehicle. The '93 FSM say the DRL module is "On right rear of engine
compartment, near firewall".

What "10 pin connector" did you fix?

 

That makes sense! Thank you so much for the super clear explanation, i will look into this the next time i'm in the workshop.

 

Got that diagram from googleling around, the wire colors and fuses seems to be the same as my vehicle but not sure if it is for a -92.

As you said it was not super clear if the delay relay is connected in serial or parallel to the headlamp switch but boxburn cleared that up.

That’s where i have looked for the DRL unit so I’m guessing it’s not equipped with that.

The 10 pin connector i fixed goes to the headlight panel located in the front left corner in the engine compartment.

 

Go to Cruiser54's site: https://cruiser54.com/?page_id=365

Download the '93 FSM and the '95 FSM. The '93 should most closely match yours and the diagrams are 1 page which makes following the circuit easier. However, it does not indicate connectors, splices, grounds and their locations as plainly as the 95 does.

 

Wow! Helpful stuff big thanks!

 

Carefully check that 10 pin connector you worked on earlier. Since that goes to the headlights, I suspect you may have some other damage there or possibly a crossed connection.

 

I’ve changed out the 10 pin connector to a more modern VAG style connector (more weatherproof than the OEM one) so that should be fine now.

I checked the power supply to the headlight switch yesterday and and was surprised that i had battery voltage. Tried bringing between power supply and headlight and boom it worked. So i put the headlight switch in the test bench at work and saw that it failed under load… My guess is that the previous bad connection in that 10 pin connector (and the headlight connectors) burned out the headlight switch.

The connector to the headlight switch still looks good but there might have been some heat buildup there as well so I’m thinking of changing that to (if i find one that ships to sweden)

Thank you so much for all the help! It was the multiple power-supplies to the headlights that confused me!