I finally got round to exploring what might be wrong with my headlights (completely nonfunctioning). As Zed has previously commented, it looks like the cheapass that I bought the van off has used a random switch instead of a proper headlight switch, so nothing can really be taken for granted with this wiring. Thank God I'm having the van re-loomed next month. The switch that is fitted has 3 wires going to it on 3 terminals. Cheapass PO had sawn off the other 2 terminals on the back of this switch. On exploration, I traced wire 1 back to the fusebox. Wire 2 went to the lights in the dash cluster, and also split off somewhere else. Wire 3 went to an aftermarket relay screwed to the underneath of the dash, which then disappeared off into the area below the dash, but I have a shelf and kickboards there, so I couldn't see where that went next. When I put wire 1 and wire 2 together, the dash lights, side lights, tail lights and number plate light all come on. So I've put those 2 wires on a switch so I at least have sidelights. Wire 3 is a mystery. The relay it goes to seems to be switched by the ignition, because it has some bigass wires on the other terminals of the relay. I tried connecting wire 2 and wire 3 to see what happened, and with ignition on or off, nothing happens. When I flash the main beams, they work - they stay on when I pull the stalk, but go off when I release it. Any suggestions?
It sounds like his wiring is about right. Wire 1 sounds like the earth, wire 2 is your low beam and 3 is the high beam (running through a relay) Try wire 1 and 3 together to see if you get main beam
As an aside - your main beam should flash off the stalk regardless of the switch, ignition on or off. If you get your hands on the correct switch I think you can connect your PO's wiring straight to it. Failing that you need a 3 position switch which is OFF ON ON, and run a common ground
If it's any help, the sidelights should work with the ignition off, but the headlights only with it on. Sounds like the PO has wired an ignition triggered relay for your main headlights circuit.
Hard to sort out without seeing where all the wires go and to be honest i would rip it all out and get a new switch and wire as per the original wiring diagram it will properly take less time. If you need a diagram of just the headlight wiring let me know
Cant get photobucket working will try again in the morning or if you pm you e-mail and i will send that way
