Wiring a new connector/plug & Radiator Fan problem

[salman]

Hi,
I would really appreciate if someone can help me out here. Basically the fan on my Golf mk 5 SDi, which I recently bought, was on constant. I put it on diagnostics machine (brother's snap-on one) and it said there was an error code which basically meant the ECU was thinking the coolant temp was too high. I couldn't clear the fault code so decide to have a nose around. I realised the plug/connector on the wire to the sensor (I'm guessing its temperature sensing) on the bottom hose (outlet) of the radiator was broken. I went to the dealers but they couldn't even find the plug on their system let alone get me one. I rang up TPS and 15 min later they delivered it to my brother's garage.

Now I have two questions (and I hope I've been clear in the above background paragraph):
1) Does the fault and symptom sound right to everyone or could there be something else causing the fan to be ON constantly?
2) This is probably more important to me, the plug I was supplied with has no pins in there to connect the wires to (apparently that's how they come, how stupid is that??), just the plug housing. The dealers again can't find these pins! Now I have managed pull these out of the broken plug but should I just heat the soldering off and use these or ring up TPS and get new ones??

I know I could just get a plug with wire attached cut from a salvage car but i really didn't want to put any joints in the wires

[phil miller]

hi mate YES what you have said sounds like giving the problems you have, TPS will also be able to supply you with the pins connected to about 5in of wire, all you do is simply push the new pins in to the new plug, then solder the new wires to the old, if you still have the old broken plug it will help you work out which way round they go

[salman]

Cheers Phil, I just wanted to make sure about the cause. I didn't realise you get the wire connected to it, that would make it a lot easier now.

[phil miller]

i forgot to say when you solder them you can get the solder bullets already in heat shrink, most garages should have/get them, you just push one wire in one side and one in the other, warm it up with a heat gun and the solder melts and joins the wires while the heat shrink, shrinks round the wires giving a water proof join

[salman]

Thanks Phil, I didn't use the heat sinks this time but thats a very handy tip for next time.

I managed to solder the new plug on and connect it up and matched what should go where with the last one. The fault codes cleared now but the fan is still staying on constantly. I'm gna have a good look at the wiring going directly to the fan in the morning. Any ideas what else it could be?

Edit: Had it checked out at a VW Specialist. They changed the ambient air temp sensor which wasn't functioning at all and this has cured the problem!