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Old 01-13-2019, 11:55 AM   #1
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Join Date: Dec 2018
Location: DC
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Pin terminals on wires in CLU plug

So, I'm going through my '97 986 project.
Cleaning up the immobilizer/CLU system.

I removed the M535 box, and it's actually mint inside. Either it's been recently replaced, or the 1 in 1m chance it somehow didn't get wet.

The black connector is a different story.
The plug had visible corrosion residue on the outside, and the pins inside were discolored.
I bought a pin terminal removal tool, and have removed the individual wires.
Most of them came out fine, but I ruined 3 pins in the process. Additionally, 4-5 pins need replaced.

I cut into one of the wires, and found black copper oxidation even ~8 inches down. I may have to really hack into this harness and replace a bunch of wiring.

The main issue I'm having is how to get new pin connectors. I eventually found a Porsche part #, but they range from $3-7 EACH!
Other, less unique, pin connectors are $3 for a package of 100 or more. This is really a "10 for a penny" item on the Chinese industry market, but I can't find this specific pin (how it's tanged) anywhere else.

Anyone have tips on what I can do to re-construct this harness and retain it's reliability?
Possibly buy an entire pigtail and solder each wire on?









Also, on the other plug going into the CLU (which has about 40 wires), I noticed 2 of them are taped together. Looks like an official job, but I'm hesitant to believe Porsche did this from the factory.
The two wires spliced together are the front-most wires going into the plug that are solid white and solid grey.
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