This car has been standing around for a year and checking the car over for this years Mot test has revealed some faults, firstly dead battery due to being left discharged over Winter...
I checked the lights and all was good, then the horn, which was silent. Both horns had corroded and no longer made any noise at all. With a bit of percussive treatment I was able to get some life out of them, but further checks revealed both connectors had poor contact, due to corrosion, so cleaning with contact cleaner and then greasing was in order.
Both front and rear washer pumps failed to operate, so I stripped out the left wheelhouse liner and banged each pump. To remove the liners I use a heat gun to soften the plastic so making them easier to unclip without pulling the metal wing flange.
The rear one came back to life but I had to remove the front one from the tank. Lever the pump out of the tank then pull it down.
I checked the resistance of the motor, which was pretty typical, at 17 Ohms.
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I connected a known good fly-lead and connector and saw resistance of 278K Ohms, suggesting there was a high resistance at the connector.
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To remove oxidisation I cleaned the connector pins with contact cleaner, re-connected and saw between 9.8 Ohm and 4 Ohm resistance, indicating a good contact.
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Though the motor ran when the fly-lead was connected to a power source, it wouldn't run when connected back to the correct connector and the washer operated.
I then removed the rear pump also as both front and rear pump harness connectors required the female terminals tightening to make reliable contact with the motor pins. After cleaning with contact cleaner, I used a small pick to crimp the terminals, then applied grease to stop further corrosion.
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Lubricate the pump spigots with soapy water and push them back into the tank bung, being careful to not displace the bung. The front washers then performed perfectly, the rear jet needed cleaning out.
Checking under the car revealed the passenger side steering rack gaiter had come unclipped from the inner end and the track rod end ball-joint cover was split.
The gaiter has become stiff with lack of use and popped off when the steering was turned to full lock. I had originally cable tied the gaiter on, but do recall it was snowing on me when fitting this, so maybe it wasn't as well done as necessary.
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Gaining access to refit the gaiter and add a new cable tie was a real challenge and I found it best to remove the air filter to turbo intake pipe and work from above and below.
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Eventually, the gaiter was on and tied. The air intake ducting was then re-installed.
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Split ball-joint boot, remove, clean off all grease and any dirt, smear in new Molybdenum grease, fit new boot with spring retainer clips.
I have a scissor type ball-joint splitter, which works very well and can part ball-joint tapers without splitting the rubber boot, especially if you grease the tool so it doesn't rub the rubber when being inserted.
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