A610 Pop-up headlight problem

Just thought I would post this as it may be of interest at some point to any A610’s owners who have a problem with their electrics.
When I started my car in preparation for the journey down to Silverstone for the WSR on the Friday evening, I put the headlights on to find just one pop-up headlight working. I first of all did the obvious fix of loosening the manual adjuster which I am told is the normal problem with the mechanism. This did not work. As I didn’t have time to look into the problem, I drove down to Silverstone with the non-working light put up manually. I noticed when I got to the hotel that when I turned the lights off the mechanism retracted the headlight as normal. I did at this point try the headlights again but found it still wasn’t raising the headlamp.
Anyway, last week I had some time to look into the problem. After taking the cover off the back of the headlights, I first checked the mechanism but couldn’t see anything obvious.

Next thing to check was the control module as this is often the problem with pop-up headlights. Fortunately, the part is exactly the same part as used on the Lotus Esprit (which I just happen to have parked next to the 610 at the moment) so tried the 610’s module in the Esprit. It worked fine. I also managed to get hold of another module which also worked fine in the Esprit but didn’t work in the 610. So that was ruled out as the problem. Incidentally, if anybody does need a reconditioned control module then I can get them done considerably cheaper than a new one would cost.


The relays and fuses were checked but weren’t the problem. Next up was the motor. This is also shared with the Esprit so had access to a new one to test. Didn’t think it was the motor though and it wasn’t. So all that ruled out.
I then had another problem develop. The front left indicator stopped working whilst driving the car. Coincidence? Checked the bulb and wiring and everything was fine but the unit wasn’t getting enough power to light the bulb. Looking at the wiring diagrams, it became obvious that there was another set of connections somewhere. Eventually found it by the brake reservoir/fuel tank.

Undid the clip, disconnected the plug and found this


Used some decent contact cleaner and both problems sorted. Hope if anybody else has the problem, it may help save some time in identifying the problem. Cheers

Thanks!

Your advice was much appreciated as always Lee.

Thanks!

Rather than start a new thread, I thought I'd add to this one....
As these cars are 20 years old some things aren't as reliable as they used to be...are they?
So last weekend before going to the weald of Kent event, I noticed the right headlight was a bit slow on the up, and the motor kept running when it got to the top...
Unfortunately I kept on trying it and it then stopped altogether, never mind it was a sunny day and the car has fog lights for the Dartford Tunnel...
I had a look today and this is what I found (after a fight to get the cover out behind the ABS and airhorn pumps) ...not a broken gear, but pulverised drive grommets, the bit that is supposed to break first if someone sits on the headlights.
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There is something missing....



Fortunately I have a spare set of motors so all OK today, but I like to fix what I break and it turns out that the parts are common to the Lotus Esprit and most Elan (FWD) cars, kits are available in the USA, but I am waiting to see if I can avoid importing the parts by using the lotus specialist route.
(Corvette C4 and many others use the same internals so the spares kits from the USA work...if you don't mind £35 postage and some duty~ £100 for the pair delivered...).
When I have a decent source I'll post up the details..

Now the LHS is slower than the right...I expect that will need doing too.

It is a common problem but we re-con them regularly for Lotus cars. Price is £65 + VAT each all in if I remember correctly.

If anyone needs one doing, contact me and I'll give you the details of where to send your broken unit.

Well I have sourced a complete kit in the UK from SJ Sportscars, delivery in a week or so. The refurb kit is enough for both motors, and comes out around £32 inc postage as these prices are ex VAT. If you need the gear, they can get you that too.
Honestly if you can get the motors out, you can do this repair simply as the removal is harder than the repair. There are even links on the web to show you how.
Removal is much more time consuming and complex, especially if the bolts are rusted in (surely not I hear you all say) .
If you'd like new motors (or complete headlight) , I have some available....

https://www.sjsportscars.co.uk/index.php?mod=10

[phildini]

Very interesting Lee, thanks for that.