Hi Steffen and all, finally got my act together and documented the
starter relay mod. on my 82 604 TD. Go to::
http://www.geocities.com/firepiston/505ignrelay2.JPG
You will see a photo and wiring diagram of a mod. to fix a common 505/
604 ignition switch start problem. You can use one relay but I chose to
use 2, a 9 volt 18 ma relay (Radio Shack 275-005A) to turn on a bigger
relay (any of the green relays in 505s), which in turn supply current to
the starter solenoid. This mod should bring a very marginal ign. switch
back to life since all it has to do now is supply 9 volts at 18 ma
instead of 12 volts at 6 amps to the solenoid.
It's been working hard, give your ign sw. a break with this mod. and it
may live forever. I soldered everything to eliminate connectors except
for connections to the battery and the splice to the solenoid/ key
switch. Use 12 gauge wire, use lugs on the +12 and neg 12 connections
and go right to the battery. I crazy glued the 2 relays together and
attached it with velcro to the brake fluid reservoir (flipped upside down
for the picture).
After you have the relays wired up to + and - 12 at the battery, cut the
wire to the starter solenoid (smallest wire at the starter), splice the
pigtail from the solenoid to the wire marked "to starter solenoid" on the
diagram. The other pigtail is the key switch, splice it to the wire
marked "to key switch" on the diagram and you're done. Make sure your
car is in neutral when you do this just in case you may have miswired the
circuit so you don't get pinned to the wall. Have fun.
This archive was generated by hypermail 2b29 : Tue 01 Aug 2000 - 03:03:12 UTC
