Originally Posted by Aliaka1373
As far as I know the lights haven’t been changed much from factory standards , but I’m not sure .
Currently when the headlights go off they flicker but very very very low light ever 3-4 seconds but barely visible .
Do you think it would be an overloaded circuit from the sounds of it ??
Yes, to get that hot it has to be, but that could include a short circuit somewhere along the line.
If it was me (and I can be pretty stupid at times), I'd get someone to stand out front and watch the headlights as I fed +12v (with an inline 30A fuse) to that yellow lead for a second. If you get wild sparks and no headlights, you have a short somewhere in the yellow wire. If you get headlights and the wire doesn't get hot right away, you have over-watt headlights.
I'm betting on the over-watt headlights. the OEM 55W halogen's of that day were awful! I have put 100W halogens in there many times. Thing is, I did it through a relay and just used the OEM headlight plug as the relay trigger signal.
I don't understand that short connection from the large white connector either. It looks like the PO substituted a different headlight switch for the OEM one that plugged into that big white connector. I hate PO electrical ****ery because it's always undocumented. Probably the OEM lightswitch was expensive and the PO subbed in a cheaper car one. That could explain why it's not capable of carrying the current and melted the plug. Might also explain why you have some apparent switch functions that don't do anything.
I would really seek out the OEM light switch and see if it plugs into that big white connector. You might be surprised at what suddenly works like it is supposed to work!