Headlight controller modification - 800x600 photo heavy

[boyzdad]

After repairing my headlight controller, I decided to address a problem that had been bugging me about the way the controller works.

When the light switch is turned off, from headlights to off, the lights seems to take ages before they go down, ok, not a major problem, but I like to mess about with these things

After studying the controller PCB, I found a couple of components that can be swapped out to give some fun results.

The first is to fix the time delay for the turn off, and the second is a cool (well I think so, others may not!) "wave" effect from the headlights if you just give a quick "blip" on the indicator flash stalk.

To see the lights in action, watch this video CLICKY , sorry about the sound, but it was better than the dog barking in the background!


To do this mod, strip down the controller as shown in my link above, then replace these 2 components shown in this picture.




My PCB after modification.....



Obviously you can choose to change only 1 of the caps if you prefer

Suitable capacitors can be brought very cheaply from RS components, e.g. part number 228-6622
Whilst I had the unit in pieces I added the Jimi mod to allow me to make the headlights go down while the sidelights are still on, I choose to wire my mod slightly differently than Jimi, it meant that I did not have to cut the connector, which I preferred.

My take on the Jimi mod......



A picture of my switch I used....



And finally, re-assembled and fitted to the car



I hope this is of some use to people, I certainly spent a lot longer writing this up than doing it (which is why I normally don't bother as I dont have much spare time)!

[Polypedates]

Very neat. Shame I can't solder for toffee

[Boddney]

That's a good mod for the faster retraction time and I quite fancy doing it. I'm not clear on what the difference is between changing one cap or two. Is it that one cap does the retraction mod and two does the blink mod?
Also I'm not seeing complete pictures and the one of "My take on Jimi's mod" is just a red x in a box.
Cool work there mate. Looking forward to having a go.

Bod

[boyzdad]

That's a good mod for the faster retraction time and I quite fancy doing it. I'm not clear on what the difference is between changing one cap or two. Is it that one cap does the retraction mod and two does the blink mod?
Also I'm not seeing complete pictures and the one of "My take on Jimi's mod" is just a red x in a box.
Cool work there mate. Looking forward to having a go.

Bod

Each capacitor does it's own job, so if you change the left (as shown in the picture) it will shut the lights quicker, and if you change the right hand capacitor it will do the "Wave" mod I.e. to make the lights shut quicker after power off only, just change the left hand capacitor for a 10uF one

The server where the pictures are hosted can be a bit slow sometimes try refreshing the page to see if that helps.

[mrfil13]

Great guide, might give this a go, i need to do the sidelight mod at some point as having the lights up just for the side lights is annoying.

Just need to get a soldering iron now.

[ulysess1966]

I can't see the photos

Is this a simple R/C circuit? I'm wondering if the resisitor could be replaced with a potentiometer to give a variable time.

[boyzdad]

I can't see the photos

Is this a simple R/C circuit? I'm wondering if the resisitor could be replaced with a potentiometer to give a variable time.

Hello, the pics disappeared for a while, doh! They are back now

I am sure that a variable resistor could be used, however I did not have time, or to be honest, the inclinaction to go any further with it

It look like there are 2 x 470R resistors that are related to these capacitors, have a play and let us know

[mulaz]

Got a pack of 10 Miniature Radial Electrolytic Capacitors 10uF 16V for grand total of £1.15 with free postage off fleabay.



i think RS has a minimum order of £5 then a silly delivery charge.

[ulysess1966]

Yeah, the 470R resistors look like the other part of the R/C timer. I might try a switch or 2 with different resistor values.

This is a fun project, the type keeps me amused !

[boyzdad]

Got a pack of 10 Miniature Radial Electrolytic Capacitors 10uF 16V for grand total of £1.15 with free postage off fleabay.



i think RS has a minimum order of £5 then a silly delivery charge.

Sorry, I forgot about the RS carrige, however, if you have a trade account (or know someone who does), then there is no minimum charge, and no delivery charge if ordered online

Yeah, the 470R resistors look like the other part of the R/C timer. I might try a switch or 2 with different resistor values.

This is a fun project, the type keeps me amused [Smile] !

It may be worth getting a variable resistor say 470R (RS# 473-534) and a 120R resistor (RS# 163-448) to prevent dead short to have a play

If you have a Maplin shop near you, you could try them for the components the closet they seem to do is a 500R preset (N38BR £0.49) and the 120R resistor (M120R £0.24 (very expensive for a resistor!)). I have to warn you though every time I go into my local Maplin it's "no we dont have stock of that" so good luck!

Another "bonus" with this mod I discovered is that if the "jimi" mod is active, then putting the light switch into the up-but-off position will give the "lazy-eye" look (easily raised to fully up by a flick of the flasher), this is were more accurate timing (via the variable resistor) would come into its own

This could be an interesting project

I would like to see if its possible to sort the sidelight mod (headlights not up with the sidelights on) without having to use an on/off switch.... Does anyone know where I can get the wiring diagram for the lighting from? I assume they must be slightly different (or the controller) between the mk1a and mk1b as the mk1a does not raise the headlights as standard when the sidelights are put on.

[mulaz]

Workshop manuals with wiring diagrams can be found here http://manual.teq.org/

[jimi]

You won't find UK spec wiring diagrams there

[boyzdad]

You won't find UK spec wiring diagrams there

Thanks Jimi, do you know anywhere I may be able to find it? I have a few little projects I want to play with

[jimi]

Depends what you want, I have 1a diagrams, but 1b are like rocking horse poo the 1a diagrams cover most of the 1b but some bits (especially the bit covering dim/dip) are different

[elbon50]

Is there some way that manuals can be made available on this forum please ?

The forum for my other car (not Toyota) has a section with owners & service manuals together with circuit diagrams for the various models. These are available for members to view or download

The only manuals I have at the mo are the original owners manual, a Mk1a USA spec service manual, published by Haynes, and some extracts from a Euro spec Mk1a service manual

As my car is UK spec Mk1b the above is far less than ideal

Peter

[jimi]

Those manuals are © Mr T
It's technically illegal to copy/host/download them and Mr T's lawyer's have been known to force sites to remove them under threat of legal action.
Having said that if you were to contact the right person they might be able to send you a copy of a disc with all the MR2 technical information they have on it.

[boyzdad]

Those manuals are © Mr T
It's technically illegal to copy/host/download them and Mr T's lawyer's have been known to force sites to remove them under threat of legal action.
Having said that if you were to contact the right person they might be able to send you a copy of a disc with all the MR2 technical information they have on it.

Right person PM'd lol

[BLZ-8027]

Good modification

does anyone know what resistors to use on the MK2 ?

this is what they have standard

[boyzdad]

Good modification

does anyone know what resistors to use on the MK2 ?

this is what they have standard

Well, at the risk of getting shot (or dragged out by my heels - Paul!) by answering a MK2 question, I would suggest that you have a play with the 22uF and 47uF capacitors, try swapping them for 2*10uf and see what happens

Regards


Matt

Without looking at the pcb myself I couldn't say what resistors need changing, they will normally be associated with the capacitors, try looking at the tracks from the capacitors.

I hope this helps....... now get out of here, before someone comes

[Boddney]

Hi Boyzdad,
Bit of a thread revieval. I have bought my 10uf caps to do next week on a weeks hols. My question is, do the caps have a polarity as one leg is longer than the other. I know on LED's this makes a difference and just wondered if these were the same or can they just be put in either way round.
Thanks,
Bod.