What they're referring to about bad connectors has to do when something overheats. Most of the time arced internal switch contacts build up heat that further degrades those contacts. That causes more heat build-up until the contacts fail. By that time the heat has migrated out to the connector terminals and caused the same problem there. Most commonly you'll see the switch has turned to charcoal around the rivets on two of the terminals, and the plastic connector body will be melted around the two mating terminals. The proper repair for that is obviously to replace the switch, but you also have to cut out and replace the two blackened terminals. There's more to it than that, and I can fill in the details if that becomes necessary.
For now, since you have the diagram and appear to know which wires are for what, start by bypassing the switch to verify everything else works. Jump the tan wire to the red wire. The low beam lights should work.
Is this a new switch or a used one?
Saturday, February 15th, 2014 AT 5:12 PM