hi TD,
please bear with me a little as this may (a,) sound a bit technical and (b,) take a little time.
I will try to answer your questions in reverse order if thats ok
4. Just our of interest, my parents' caravan in 2001 and therefore would
have post 1998 wiring, would the lead work on their caravan?
no, I doubt it because the pin configuration of their grey plug (post 1998) would be using pin 4 for the positive lead not pin 2 as the lead is set up for. on later grey plugs (post1998) pin 2 is not used as the power comes from pin 4 "the modification would not work on theirs as there are only 2pins in the socket end of the lead and the wrong one is energised for their plug" .
3.The only time I will use the lead would be if the leisure battery has
lost all charge and I'm not on EHU, therefore the fridge will be on gas,
would that be ok still to use the lead?
yes. for two reasons there is no direct electrical link between the van wiring and the fridge, "exept for the fridge light" and I doubt if a 1996 van has a fridge light, (although I could be wrong) but even if it had the small drain of a fridge bulb every time the fridge door was opened would be very small, and as the fridge was being used on gas the 12v switch would be off "as would the 240v" one. not that any of this matters anyway as the only time 12v goes to the fridge from the car is when it is being towed via a smart relay as soon as the engine stops, the power to the fridge is cut off, but this is via a different pin on the 13pin plug which you have not used on the lead.
2. If I have wired the plug incorrectly, will it damage anything or justnot work?
IMHO, it will just not work, as any other pin in the 13pin socket, "on the car" would not send any electrical current up the lead, this is because 7 of the pins are for road lights 3 are earth wires, 1 is not used and that leaves only 2 pins, perminant power pin 9 and the fridge pin 10 now assuming you will be testing the lead in daylight with all the cars electical systems and engine turned off only pin 9 would energise the lead, the only forseeable problem could be if the wires were somehow reversed, this is easy to check with a circuit tester, if you have one, a simple 12v bulb with tails will do, just to make sure that the socket on the lead has power to the right pins. after connecting the lead to the car. it would also assist in making sure there are no breaks in the connections in the lead and also the lead has power before plugging the vans grey plug into the lead.
a tester would also assist with question 1.
1. Am i right in saying that I would need to disconnect the leisure batt from the 'van before the lead would work?
this question could be very problematical because it all depends on how the van is wired up what switches do what? and the type of zig unit fitted, I do not know the schematics for your particular van, in theory it should not matter BUT, if it was me I would disconnect it, to start with and for 2 good reasons.
1. if the battery is connected an has some charge it may not be possible to know if the lead is actually working as power will be drawn from it as soon as the lights are switched on. disconnecting it eliminates this possibility,
there may be a switch in the van that switches from internal power (van battery) to external power source (the lead) but you would have to look for this if it has one, it could have a switched ZIG unit also that senses if there is an external power source instead of a switch. either way if the battery is disconnected, only the power from the lead can power the 12v system.
2. once the lead has been checked and connected, it would be a matter of seeing what works and what does not what switch does what, without the aid of the leisure battery, at this point having establish that the lead is working, with the battery still disconnected you could then use the circuit tester to see if there is any power going down the battery leads of the lesuire battery. I suspect there will not be, but however if there is it will be an indiction that the battery WILL have to be disconnected when you use the lead.
I am afraid there is still a bit of experimentation that yet still has to be done before you have all the answers just take things one step at a time in a logical manner , asking any question you like as you go along it will be worth it in the end if it extends the use of your van.
afterall if you can get the lead to work for the cost of a 13pin plug it will be a darn site cheaper than any of the alternatives on offer wish I could do the same but with having a 2005 bailey theres no chance of that,