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pietrzj
Monza


Joined: 19 Mar 2014
Posts: 207



PostPosted: Sun Aug 20, 2017 10:20 pm    Post subject: Poor Headlight connection - Loom or tool out there? Reply with quote

Hi,

I have/had a number of problems related to my OSF headlight:

1. Automatic leveling not working
2. Main bulb not illuminating without a helpful thump

The main reason seems to be that the outside plastic rail was mis aligned and the mating of the connector on headlamp insertion was therefore at an angle and not making a good connection.

Until I found this I had to remove the front wheel and inner arch plastic to assist the mating each time I re-inserted the headlamp unit.

The fix involved a sharp pull of the outside upright metal plate toward the the hood.

The other issues I had were a broken connector (from headlamp unit to loom/harness) and broken location tabs on the socket it connects to (headlamp unit end). I have replaced the socket on the headlamp and I had already bought the pale blue connector to replace the broken one on the harness that mates to the headlamp unit. However, it seems I need a tool to remove the old connector (part number 90006).

I am now left with two options:
1. Try and source the electrical connector seperator tool, or
2. Try and source a used loom (front compartment section), which is about 1 metre long and has a total of 4 connections.

Any advice? Or even parts/tools out there?
 
  
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pietrzj
Monza


Joined: 19 Mar 2014
Posts: 207



PostPosted: Sun Aug 20, 2017 10:28 pm    Post subject: headlamp socket Reply with quote

headlamp socket
 



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pietrzj
Monza


Joined: 19 Mar 2014
Posts: 207



PostPosted: Sun Aug 20, 2017 10:30 pm    Post subject: Reply with quote

New socket (slightly different hole profile, which meant I had to pull the tab out further to stop it pushing back, but the pins are not as protruding as the original socket by a few mm
 



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pietrzj
Monza


Joined: 19 Mar 2014
Posts: 207



PostPosted: Sun Aug 20, 2017 10:31 pm    Post subject: Reply with quote

Broken location tabs on original
 



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pietrzj
Monza


Joined: 19 Mar 2014
Posts: 207



PostPosted: Sun Aug 20, 2017 10:32 pm    Post subject: Reply with quote

This is the connector I need to open up with the tool or replace with a new bit of loom
 



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pietrzj
Monza


Joined: 19 Mar 2014
Posts: 207



PostPosted: Sun Aug 20, 2017 10:38 pm    Post subject: Reply with quote

The new blue connector that will replace the old black one if I use the tool option
 



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Endoman
Imola


Joined: 11 Apr 2011
Posts: 794
Location: Bolton U.K.


PostPosted: Mon Aug 21, 2017 12:22 am    Post subject: Reply with quote

Had the same problem a few years ago. Fitted the new blue socket tool was sourced on ebay, actually a pair with all sorts of tool ends but it can be done with small electrical screwdrivers. Same part on Boxters iirc.
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ms2015
Monza


Joined: 28 Oct 2015
Posts: 166



PostPosted: Mon Aug 21, 2017 2:41 pm    Post subject: Reply with quote

Helped a friend change his headlight connectors just for fun - new blue ones on each side to replace the original white ones - he had the correct tool - If you have the front arch liner off make sure the cable to the headlight unit has a clear path and not crimped or bent anywhere - that was causing his side light to be intermittent- - hope to hear that the new blue connector is the answer to your issue
 
  
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Demort
Paul Ricard


Joined: 21 Mar 2015
Posts: 3258
Location: Sussex


PostPosted: Mon Aug 21, 2017 7:40 pm    Post subject: Reply with quote

A generic set ..

http://www.ebay.co.uk/itm/BERGEN-19pc-Universal-Automotive-Terminal-Release-Tool-Kit-B6645-CAR-WIRING-/182448548705?_trksid=p2141725.m3641.l6368

The pins are not the easiest in the world to get out of a socket but sourceing the pins from porsche is a nightmare .. they are rarely interested in helping .

You can search ebay for car terminal pins and there are various selections but im not sure of the correct ones for that connection .
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Chris993C2
Montreal


Joined: 09 Mar 2010
Posts: 607
Location: South Bucks


PostPosted: Mon Aug 21, 2017 8:40 pm    Post subject: Reply with quote

When I replaced one of mine, I couldn't get the terminals to release - even with the correct tool.

I resorted to using side-cutters to remove the mounting flanges (red), and then melting/cutting along the green lines with a soldering iron, before ripping the connector shell into a gazillion pieces with needle-nosed pliers.

Messy, but cathartic Very Happy
 



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pietrzj
Monza


Joined: 19 Mar 2014
Posts: 207



PostPosted: Tue Aug 22, 2017 9:33 pm    Post subject: Reply with quote

Thanks for the replies. Very useful advice.

I managed to find a loom section from Jasmine for a boxter. Not sure it is identical but prepared to take a gamble. Even if it doesn't fit, I will use it to practice separating the connector as I know that part is identical.

If the loom section is the same (as one of you suggested as well as the original advert I say for the loom), I will just swap the whole section - and tell everyone its the same of course thumbsup

Seems like a bargain at £19.95 for the loom section (used of course), when the tool could be as much as £28.

I will keep you posted

Jan
 
  
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