Ignition switch

[bonkfrog]

The Alfetta suddenly began to be difficult to start, although it turned over as usual. It was discovered that, if the key was moved in the lock, ignition lights became brighter (sometimes) and it would start.
I reasoned that the LT contact to ignition was faulty within the switch and didn't fancy a couple of additional switches on the dash. So, I was able to source a NOS ignition switch from overseas – around $70 landed for a Magneti Marelli.
Of course, everything was in the way and getting a drill to the security bolt meant  the usual head under the dash and legs over the front seat. After doing this for a while I decided that I could undo the steering wheel rake adjuster bolt & pull the column down as far as it would go; this allowed much better access to the bolt and reduced the need for foul and unnatural language.
Now I got out the Dremel and fitted a small dental burr – need the smaller chuck for this – a few seconds of drilling cut into the bolt and a larger drill allowed an easyout to fit. The bolt came out very quickly and a replacement M6 x 1.0 hex head bolt of approximately the same length was found.
Next, it appeared that an alarm system had been fitted with two additional wires. When I pulled the old switch apart, there was a small two-terminal block to which were attached the "alarm" wires. It all looked standard; was there a special alarm ignition switch? In addition, the green wire from the ignition switch didn't appear to be connected – it was missing. My guess is that it isn't required for electronic ignition systems as there is no ballast resistor on the coil.
A small (very) screwdriver allowed the retaining lugs on the terminals to be flattened & the terminal block to be fitted to the new switch terminals.
Refitting the switch seemed simple, although I took out the lock bolt so as to shorten it to match the original. The most difficult part was re-fitting the steering column shroud pieces but at least they weren't broken as many are!
Reconnected the battery and checked that ignition/handbrake lights came on – much brighter than they have been for some time – started without problem. Celebratory beer.

[bonkfrog]

Nearly forgot: found possibly the largest redback spider living inside the steering column shroud. This is also an optional extra from Alfa Romeo and explains why I haven't had flies inside the car.

[Al Campbell]

Redback!!! Hope you didn't find it while upside down under the dash.

[colcol]

On Alfa Romeo's before the current ones, [pre 97], they had undersize wires and terminals on the ignition switch with too much running through the switch, if possible, put some relays in to take the load off the ignition switch, so its turning on and off a relay, not something with a lot of amps, on my 33 you could smell the ignition switch burning, its the same switch as used on 75's, 90's, GTV6's, ......at least you can buy new ones, Colin.

[ACE]

Another Alfetta Spider!
They seem peculiar to the SE corner State too ... 

[bonkfrog]

Colcol
Quite right. One of the several electrical jobs to be done is to install a relay to the ignition circuit. The wires themselves look quite heavy, but there's still a lot of current going through the switch itself.
BTW I sprayed the s**t out of the spider & the under dash area, cleaned out a mess of eggs & dead beetles. Should go a lot better.

[colcol]

I could actually smell my ignition switch burning, it was most noticeable with the airconditioner on, Alfa Dealer in 1988 took about a week to get a switch in, so i had to rewire it to get me to work until the switch arrived, on-off toggle switch for ignition, push button switch for starter, this ignition switch on 33's, 75's, 90's and GTV6's was such a troublesome item, it is still available new on ebay today, and its not as expensive as it was in 1988, that was in the day's when dealers could charge what they liked, Colin.

[Alfapride]

hi all, i know this is an older thread but I think it's worth adding my similar experience with my alfetta and may assist other people if they are in the same situation and potentially stranded (as I was yesterday!).

It seems the ignition barrel locks up or doesn't make correct electrical contact internally when the key is turned. If your starter motor turns and the the gauges (temp, fuel) don't activate and the handbrake light is dim you can be certain there is an issue with the ignition barrel.

I was able to squirt wd40 into the barrel and used the key to get a lot of gunk out and wiped it with a cotton bud - this seems to have improved the connection inside a lot but if I get time i'll try pull apart the barrel and see if more can be done - if all else fails I'll have to replace the barrel.