From suggestion on the http://www.mirafiori.com Forum first developed I understand by (Canadian Dan) the fix is elegantly simple. Replace the power source to the brown wire coming from the ignition with a new jumper wire from the battery POS or Alternator (closer) post. It suggested by some to use a relay to protect the ignition switch from the high amps of the brown wire. Here is my posting asking some question on wire routing.
Why this works
Because all the voltage comes through the brown wire, if it is low (which it will be). This causes the alternator field voltage to be low and since this is the reference for alternator output. Will cause poor charging. --- Canadian Dan.
The reason I have the steering column off to begin with is to replace the column switch. The headlights will not stay on the switch lever is jammed.
Re: Using Relay for Brown Wire
From: Robert Owsinski
Email: rowsinski@comcast.net
Date: Sun Feb 05 06:19 PST 2006
I decided to try the advised use of a relay to protect the ignition switch from
the high amps coming through the "brown wire". They do recommend a fusible link
to the "battery/Alternator" connection on the standard "painless wirings"
diagram of using a relay. The biggest heavy duty fused connection I found uses
a 12 gauge wire. Wouldn't that defeat the purpose of using a 10 gauge brown
wire to the alternator?
With the relay I tried to add a spaded terminal wire connected to the original
brown wire, at the switch, which then is run to the relay post 87. A new brown
wire is the run from post "30" to the alternator. Another jumper wire is run
from post "86" to the original brown wire connection on the switch. The problem
is the rubber shield will not fit over the new wires. I tried bending the
jumper to 87 brown wire connector put to feed back through the rubber shield but
their is no room. and the bend is very sharp.
Should I just cut the connector of the original brown wire and pull it out above
the rubber shield or use terminal 30 for the feed to the relay and leave the
brown connected. I think I can feed the new 86 wire through the rubber shield
from the top. Will using terminal 30 negate the advantage of the reply.
Any suggestions on routing the wires and connections?
The headlight dimmer will not move. I assume its because of this melted contact terminal to the pink/grey wire.
Or Grey/Pink according to the wiring diagram.
I took the column switch apart to see if I could save the better looking plastic. Not possible. You can see the problem