I've been having trouble with the heater blower so I attemped to replace the resistor today and discovered the issue.  The connections to the 4-pin terminal were completely rusted and the single pin terminal had burned through.  The latter obviously causing my some worry.

In order to remove both I needed to pry them out with a screwdriver so now need to replace them.  

 

Re the 4-pin connector (191972754):  As you can see in the pic it's horrendous.  The plan is to buy another part however the only ones I can find have the wires still attached.  I couldn't bring myself to splice this into the existing loom so ideally I'd like to disconnect the wires, clean them up and plug them into the new (second-hand) connector.  The other pic (attached) looks as though a little lid flips up allowing this. Please confirm.

 

Re the single pin connector: I cannot see a single reference to this anywhere (even on my new favourite site https://7zap.com/en/).  This is the one that melted so also needs replacing if I can locate the part number.

 

4-pin connector

 

 

Single pin connector

 

 

New 4 pin connector with access panel to connections?

 

Which plug into this. 4-pin up the top, single pin on bottom.

 

Edited 5 January, 20206 yr by PoloMM

As to why I can't just check myself, I have now taped the connections up quite thoroughly.

 

Edited 5 January, 20206 yr by PoloMM

The Housing part # 1J0 972 754 or 191 972 754

Then have a look at this for the contacts

 f

Hi Nige,

 

Thanks for your reply. It well help with the contacts but I did already know this part number.  I'm more interested in the one in the second pic which I'm unable to read because it has melted.

 

 

This is the only single pin housing I can find ?

flat contact housing connection piece thermostat 1 pin

Code: 111 971 921 B

Hmmmmm, that's weird (and annoying).  I don't think it's that one.

 

The only thing I can think of is that's a 2 pin connector with only one input for some reason.  I'll need to untape it all and double check tomorrow.

There is a 2 pin listed but that's for the fan motor ?

Yes, that's exactly where it goes. As you can see from the pic the red wire goes to the left toward the fan motor.

 

Must be the one. What's that part number?

flat contact housing connection piece fan motor 2 pin

Code: 1J0 972 752 or 191 972 752 

2 minutes ago, nige8021 said:

flat contact housing connection piece fan motor 2 pin

Code: 1J0 972 752 or 191 972 752 

That isn't it but amazingly the search brought up 191 972 751 which is it, and one pin afterall.  So yeah, I'm baffled.

Very strange ?? so your fan motor has only one wire connection ? 

Evidently yes, but I'm not sure how that's possible.

3 minutes ago, PoloMM said:

Evidently yes, but I'm not sure how that's possible.

 

Very strange then ???

And of course I can't find somewhere to buy the bloody part.

 

Any recommendations? Do VW still stock 20 year old parts?

1 minute ago, PoloMM said:

And of course I can't find somewhere to buy the bloody part.

 

Any recommendations? Do VW still stock 20 year old parts?

 

From experience don't bother with your local stealership, if you have a TPS local to you and they don't all accept private customers, they tend to be able to get out of current production bits and there is a company on eBay that seems to stock a lot of VW connectors https://www.ebay.co.uk/sch/3waycomp/m.html?_nkw=&_armrs=1&_ipg=&_from= I think the contacts in those housings use the Junior power timer contacts and they are readily available online from Vehicle wiring Products, Autoelectrical supplies and again eBay

Fantastic.  I'll search through their (huge) catalogue and see if I can find them. Otherwise will message them.

 

Thanks again.

I’m loathe to start cutting up my loom so I had a bit of a lightbulb moment.

 

What if I disconnected my battery and then dipped the connector in a bowl of vinegar overnight? It would definitely clear up the rust and shouldn’t cause any shorts if the battery was disconnected and then left to dry for another day or so before being started.