HELP - Removing pins from headlight plug

gregdaisley · Oct 3, 2012

Hi all!

I have a bit of a problem, I was out at the car last night attempting to retrofit Genuine Bi-Xenon headlights to my FL Leon.

I got as far as removing the pins from the 10 pin halogen plug, which need to be refitted into the 14 pin Xenon plug in a different configuration. I physically could not remove the pins from the plug, using a lot of force. I removed the purple locking collar that is on the plug but that didn't make any difference.

I have done a search and people have been saying it's a pain, but I don't want to damage the wiring on the car.

Can anyone give me some pointers or is it worth taking it to a car electrician and let them do it?

Cheers, Greg.

Nath. · Oct 3, 2012

I've not seen the plugs you are on about but I have removed pins from the horn plugs on a MK4 Ibiza to do a twin horn modification.

The pins were hld in with a barb or tang (like a fishing hook barb) Through a little hole in the plug body I pressed the barb/tang down with the tip of a scriber (you could use a dressmaking pin) and the pin pulled out. When refitting I just teased the barb/tang back out with the tip of my scriber and all was good.

Here is a link to the sort of thing I'm talking about. http://www.pinrepair.com/connect/

Scroll down about half way, there's loads of pics and words that explain it better than I can

Those terminals are branded Molex and you can get different Molex terminal removing tools, I don't know what make of terminals VAG use bit as said I got lucky with a scriber .

Hope that helps.

TarekElsakka · Oct 3, 2012

I use a tiny, thin screwdriver to push in the clip that holds it together. It can be done by hand but is very hard.

gregdaisley · Oct 3, 2012

Unfortunately I'm really struggling with this

Can't seem to get the little buggers out...

Nath. · Oct 3, 2012

Post a pic of the plug body, maybe we can help more.

I bet there is a small hole for each terminal, you push a very small screwdriver or dressmaking pin into the hole to release the barb/tang and the terminal will pull out.

allbutt55 · Oct 3, 2012

If you look at the side of the plug that plugs into the headlight there are little tags in there on the pins to stop them coming out you need to push the tag and pull the pins out from the wire end if that makes sense having the right pin tool is best but you can use a small flat head but you need to hold the screw driver in press the tag and pull at the same time !!
If you were close to me I could do for you

allbutt55 · Oct 3, 2012

See this
http://www.google.co.uk/search?q=co...AQ&biw=603&bih=908#biv=i|13;d|MmeK8OuJM1JhTM:

gregdaisley · Oct 4, 2012

Car is booked in for its first MOT next Tuesday so I won't be touching it until that is done now. I have emailed a German company called Kufatec who make xenon plug adapters for the pre facelift car to see why they won't work on the fl car. The only difference is the high beam is replaced with a DRL. I would just hook the high beam switched live to the shutter and I have an aftermarket DRL relay to fit. Hopefully they'll get back to me soon!

allbutt55 · Oct 4, 2012

All i did was wire the high beam wire to the shutter worked fine

gregdaisley · Oct 4, 2012

Sweet, but what about when the lights are off? No flash?

gregdaisley · Oct 4, 2012

Ps thank Nath! Great info in that link, I think they are very similar to the pins in that diagram. If the adapters don't go to plan, I'll give them a to

allbutt55 · Oct 4, 2012

They still work fine put the high beam in the plug as normal then just take a feed off the wire to i think pin 11 which is the shutter so when you flash or put high beam on the shutter opens too!

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HELP - Removing pins from headlight plug

gregdaisley

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Nath.

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TarekElsakka

gregdaisley

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Nath.

The Gentlemans Express

allbutt55

allbutt55

gregdaisley

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allbutt55

gregdaisley

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gregdaisley

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allbutt55

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