Popup Headlight Fix/Mod

Well, I like to keep people updated.

A while back I wrote:
 

>> On a side note, I've got a '84 Celica that the headlights don't
>> operate.  The motors still work, but they won't move with the lights.
>> Has anyone ever torn one of the motors apart to see what's inside?  Or
>> does anyone

Randall Romero <greymatter@mindless.com> suggested:

> If your headlights raise but don't lower when you switch them off, then
> it is the relay control module located on the steering column under the
> dash, near the brake mast. cylinder push rod.  It is in a green plastic
> housing about  2x1.5x1.5. A new one will run you about US$68 plus tax.
> This was the problem with my '83 Celica and now it works fine.  If you
> know someone who is very good with electronics, have him replace what's
> wrong as this module just contains a small circuit borad with some
> transistors and resistors. (I can't see how Toyota can justify 68 bucks
> though).

> This control relay can be tested by first unbolting it from that panel.
> Remove it's metal cover by bending back the lips that hold the cover in
> place and then pulling it off.  Inside, you will see two large magnetic
> relays and a couple of diodes. Use a screwdriver to close the contact on
> one relay at a time.  When you do this, the corresponding motor should
> run continuously, moving the light up and down.  If this doesn't happen
> then the relay is bad and must be changed.  This part unfortunately
> costs about US$100 at your friendly Toyota dealer.

Well, as it turned out, since the last time a checked (about a year or so ago) the relay had
failed to work completely.  So, I went in search of a test light.  After 10 stores and no lights
later, I found a voltage/cont tester at a Radio Shack outlet store for $10.  Time to go check wires.

There was no voltage at the relay, and since this feeds directly off the battery via a fusable link,
I checked there.  +12 volt.  Well, it must be a bad wire or something.

As I unwrap the loom, I'm horrored to find that I was not the first to go hunting in this harnes.
There haev been several splices already, and they all seem to involve the popup headlights.
Well, I find my power wire that had corroded in half and promptly fix it.  I then check all the
other splices (wires twisted together) and find them defective.  I solder new splices in and insulate
everything well.  I then check out all teh wiring and verify that it goes where it is supposed to, and
that I have power once again to the relay.

I plug everything back in and am ready to test.  Switch on.  No action.  Switch off.  No action.
I give up and go look at something else for a few minutes, save I roll the car in the nearest river.
When I come back I grab the control unit and promptly burn myself.  Now I see the problem.

Well, I'm cheap, and am not going to spend 73.78 on a new unit, So I lookinto other things.  I decide
to tear apart one of the motors to see what kind of switch is inside.  It's a simple three prong rotary
switch with two wires going to the contro unit, and one wire going to the motor relay.  This is rather
simple to fix.

What I did:

I went back to my friendly Radio Shack and bought a simple DTSP 12V relay and wired it up in place
of the control unit.  Now, I've killed two birds with one stone.

Now, my lights come up with the headlights, and not with the park lights like factory, and they work again.

All this for under $10 US.

Anyone want a wiring diagram on this?

Happy motoring.

Sean Figgins 1984 Celica GTS Liftback 1997 Celica GT Liftback Tulsa, OK  USA  

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