In article <vtesu29ird5fca@corp.supernews.com>, Ato_zee@hotmail.com 
says...
> 
> On 10-Dec-2003, "Graham" <glaurenson@lycos.co.uk> wrote:
> 
> > I 'think' the Headlights work through the Ignition switch, and that the
> > contacts in there sometimes corrode/break down, so you might like to check
> > there too.
> > I've heard that you can get a heavier duty switch.
> > Someone else may verify this ?
> >
> > Graham
> 
> I can confirm that the headlight and tail light current
> (which is quite substantial) goes through the ignition switch, so that the
> headlights go off wnen the ignition is off. Worse, to this current is added
> things like heater fan, wipers, rear screen heater - all of which push up
> the amps. The push on quarter in tab carrying this load, not to mention
> the ignition switch itself starts to cook and the switch block on the end
> of the ignition switch turns brown and starts to char. Both Mk1 and Mk2
> Unos are prone to this, particularly if you drive mostly at night, when
> everything is on.
> 
> Having had total failure on the motorway in conditions that needed wipers
> and heater I was not well pleased when all the lights etc went out. Not
> to mention this could be lethal if there was a HGV on your tail.
> 
> It's not a roadside fix, you need to get the steering wheel shroud off,
> plus have a replacement switch to hand. With a bit of luck you may be
> able to swap just the contact block. Replacing the ignition switch
> is a pain in the arse due to it being fixed with break head bolts. I
> can't imagine why, no joy rider is going to the trouble of removing
> it.
> 
> Lets hope you only have an earthing problem. You might also
> check the fuses and fuse box.
> 

Thats interesting to know, at least I now know I'm not looking for a 
relay hidden somewhere inacessible.  I had also considered it could be a 
problem with the the headlamp stalk itself, but I couldn't see why a 
problem with that switch would take out everything, including main beam 
and flash etc.

The car is the girlfriends, and she has a tendancy to leave the lights 
on and turn everything off at the ignition, then restart the car in the 
same way. I can't see that being helpful in this situation. This 
actually explains something odd I found when I was trying to fix it - 
I'd turn the car off, check the fuses, nothing would be wrong, I'd turn 
the ignition on again, and it would work again - it looks like the 
switch.  I assume that not fitting a relay in this circuit was a cost 
option for fiat.  

Anyway, Nothing will be done to it till the weekend then its grab the 
DVM and then, recheck the fuses and then check the earths. Then if no 
joy remove the steering shroud to check the ignition switch and the 
condition of the connectors.  

Luckily it's parked outside her house, so there not a problem in working 
on the car, unluckily she's got mine to drive round in whilst her's 
can't be driven (don't ask how that happened).


Anyway, thanks for the info, I'll let you know what happens...........


Mark