
Re: RH Main beam and indicator headlamp issue
So today I removed the wiring loom and unraveled all the electrical tape around the wiring harness which took about 30 to 45 minutes!
I opened up a can of worms! It's actually a good thing that my headlamp was giving me problems because I discovered some things. For starters, look at the first photo.
Someone has replaced about a foot of every green wire above the heat exchanger with black wiring.
My guess would be one of three things happened, One of the wires shorted out and caught the other wires on fire. Maybe one of the headlamps which is unprotected?
Maybe the air cleaner was off and the car backfired and spewed petrol on the wiring?
Or the heat exchanger got hot enough to melt the wiring? Is that possible?
What really concerned me was the thick yellow wire that goes to the alternator. Someone had replaced it with a section of thicker red wiring but then those two connectors had got hot and corroded sometime after the repair.
In the second photo there are two brown and two green wires all connected together.
How were these insulated from the factory? Just electrical tape? Or was some kind of plastic shield supposed to have went around them? Like those clamp shell protectors used on old FIATs and other Italian cars?
When I unraveled the tape to this point, I checked the RH main beam headlamp and now it and the dash indicator are working. Yet the connection looks OK. When I touch my test light to these four wires with the main beams on, my test light lights up and goes on on dipped beam. The wiring diagram for the main beams does not show these two green and two brown wires being connected. BTW, this must be the non UK diagram not showing the resistor and relay set.
So now I'm going to check and replace every connector which looks suspicious. Now maybe a good time to add four independent in-line fuses for the headlamps.
OK some questions:
Can the heat exchanger get hot enough to melt these wires? Do I need to get some of that insulation wrap to go over the wiring where it touches? Like this stuff:

What was used from the factory? The loom the PO installed had been touching the heat exchanger and it showed no signs of melting.
Was the wiring wrapped up with electrical tape or that cloth style tape stuff?
Rather than re-wrapping all of these wires with tape, I'm going to secure them with those nylon cable ties. Just in case I have to deal with this again.
But I think it would be a good idea to protect this section of the wiring harness.
Also best I can tell the earths for EVERYTHING under the bonnet connect to thicker wire to a stud on the bulkhead next to the battery (LHD). There is also a redundant wire coming off the negative battery cable which also connects to this same threaded stud.
The bullet style connectors that are used on the headlamps and park lamps are in bad shape. I'm going to replace those while I'm at it.