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OBC retrofit questions !!

Laurence Gibbs

Laurence Gibbs

PCGB Member
Member
I have a couple of questions for those who have done this before !
Ok, so all the "how to's" i've read appear to say, fit the pins in the white or grey (depending on year) plug? looking at the white plug's white connector (i have the black white blue combo of plugs on a 2001 car) there appears to be cables already populating the holes where the new cables are mean't to go ?? Do i have the correct plug?? The black plug with incidentally a black connector appear to have the spaces in the right place for the cables . All the pics i've seen show a black (and apparently almost completely un-populated (spare????) connector.
How on earth do i get the pins in the plug without breaking or bending them? what's the secret? They appear to be an extremely tight fit ? I have managed to break two and have a third stuck in the connector sans cable and top half of connector (going to try extraction tool for that). So it's turning into a nightmare !!
 
You need to connect to pins 20, 21, 22 & 25 of the white plug. Those pins should not be populated, so check again. The plugs are marked with tiny numbers moulded in at each corner.

I suspect you are trying to use the VW "009" repair wires, and you need "010" wires to fit the white plug.

I have attached my wiring diagram for that MY.

Download
 
Thanks Richard, my mistake was looking at the plug the wrong way around. All pin holes empty. I will try and get hold of the VW 10 wires. I am a bit surprised as i bought a pre-assembled loom of ebay as i wanted to avoid having to make the thing myself. The pins look ok but just seem to be really tight.
 
eBay. Say no more......

If you order the repair wires from VW, the part numbers now have an "E" added to the end. The wires come with a terminal on each end, so you can cut them in half. Trouble is, I think they come in packs of 5.



 
Here you can see the difference in shape between 009 and 010 terminals, and why one would be a tight fit in the wrong hole:
 
Just out of interest , when you have fitted these, how easy was it to push the terminals into the connector? I will take a pic of the terminals i have , they look closer to 009 than 010 i think.
 
The terminals slide in to the plug easily, with very little effort. Make sure you orientate the terminal so that the tang goes to the outside of the plug. It then engages with the slot you can see from the outside.

The 009 ones are wrong for the white cluster connector. You need the 010 terminals for that end, and the 009's for the stalk plug.
 
They look wrong to me too.

The confusion arises because the later clusters (MY2002-on) use different plugs, and "009" terminals. You can buy the crimp terminals like the ones you have from Porsche (if you can work out what numbers to order). I have always used the VW repair wires because they are convenient, the correct size wire, the terminals are perfectly crimped, and they are a perfect length - especially for the 2002- OBC and cruise retrofits. It is difficult to make a clean crimp on the small terminals without an expensive tool, and if you don't get it right you end up fighting to get them into the plug, or worse still, don't get a good connection.
 
New terminals 010E type did the trick. They slotted into the connector easily, in stark comparison to the ones supplied fitted to the loom. No wonder i was having trouble. Thanks again Richard.
 
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