Editing Z31/Headlamps php (section)

=== Action Taken: ===

Cleaned contact points with fine grit sandpaper to remove corrosion. Carefully re-adjust contact fingers.

After a few years, this started giving me intermittent failures. I cleaned and re-adjusted it twice before I sought out a replacement at the junkyard. Some owners have good luck with cleaning them, for others it's more of a temporary solution.

When cleaning the contacts, use fine grit sandpaper. Try not to remove too much material or you may need to readjust the contact fingers.

Re-adjusting them is a hit or miss affair and I would try to avoid the trial and error, which is why I got a replacement after two temporary fixes.

Clean both the upper and lower contact surfaces. Blow out any excess debris.

https://dev.z31library.com/xenonzcar_archive/z31/images/headlamprepair/cleaningcontacts.png

https://dev.z31library.com/xenonzcar_archive/z31/images/headlamprepair/contactslabled.png

==== Intermittent interior lighting and exterior marker lighting failures ====

This is not as common as the first failure but it does happen from time to time.

'''Symptom:''' Occasional burning smell. Fuses all look good.

'''Reason:''' Corrosion on light switch connector #12 causing poor connectivity and overheating.

https://dev.z31library.com/xenonzcar_archive/z31/images/headlamprepair/normal_DSC06523cr.png

https://dev.z31library.com/xenonzcar_archive/z31/images/headlamprepair/Plug2.png

'''Action Taken:'''

Cleaned plug male connector with fine grit sandpaper.

Harness female connector was beyond repair and further damaged trying to extract it from the plug.

The female connector was cut off and the wire was cut back and stripped.

A new female connector was soldered in place.

These connectors can be replaced with a little effort, instead of using a poor aftermarket crimp connector.

Artists rendering of connector replacement:

https://dev.z31library.com/xenonzcar_archive/z31/images/headlamprepair/plug-replacement.png

==== Rebuilding 1988-1989 Switches with new contacts ====

As many know, the 1988-89 300ZX headlight switch assembly differs from the 1984-87 switch, primarily in that the connectors on the 88-89 switch differ from the 84-87 switch, the turn signal cancelling mechanism is different between the two, and more to the point, the 88-89 switch is no longer available from Nissan and not available from the after-market.

I did some research and have confirmed that the switch contacts body (self contained) is the exact same between the 1989 Nissan 240SX and the 88-89 300ZX.

You are going to buy a complete, new, 1989 240SX headlight switch assembly and remove the switch pack from it and transplant it over to the 88-89 headlamp switch.

First off, here's a pic of the back of the 88-89 headlight switch showing the connectors:

https://dev.z31library.com/xenonzcar_archive/z31/images/headlamprepair/GBkoukiswitchrebuild1.jpg

Here's a couple of pics showing the 1989 240SX switch (front, side/signal cancelling, back with connectors):

https://dev.z31library.com/xenonzcar_archive/z31/images/headlamprepair/GBkoukiswitchrebuild2.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/headlamprepair/GBkoukiswitchrebuild3.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/headlamprepair/GBkoukiswitchrebuild4.jpg

Here's a side-by-side of the switch packs out of the 240SX (left) and 300ZX (right) - identical:

https://dev.z31library.com/xenonzcar_archive/z31/images/headlamprepair/GBkoukiswitchrebuild5.jpg

https://dev.z31library.com/xenonzcar_archive/z31/images/headlamprepair/GBkoukiswitchrebuild6.jpg