Section C

SECTION C - REPAIR PROCEDURE
Water Ingress Precautions

CAUTION:
Certain of the following operations specify the application of a Spray Grease (Part No. JLM 11472). This product is contained in a pump-type dispensing container. The basic grease is already mixed with a volatile solvent to promote mobility of the grease over the surfaces onto which it may be sprayed.
While the product is non-toxic, prolonged contact between the spray grease and the skin should be avoided. It is strongly recommended that PVC or Nitrile Rubber gloves are worn when using this product. It is also prudent to perform ALL operations involving the use of products containing solvents in a well- ventilated work area. Ensure that spray grease does not contaminate carpets, plastic trim or upholstery. Where necessary, shield the surrounding area in which the spray grease is being applied.

Properties Of Spray Grease

The spray grease has the properties of dispelling moisture from electrical contacts and providing a protective film guarding against corrosion.

Applying Spray Grease

^ Nozzle should be 1/4" from face of connector.
^ Wait 15 seconds before reconnecting assembly.

1. Open the front passenger side door for access.
2. From the "A" post extract the front end of the corrugated cable gaiter, which encloses the cable harness between the "A" post and interior of the front door.




3. Carefully pull on the harness at the "A" post until the two harness interface connectors can be extracted through the opening in the "A" post. (Connectors LB 082, LB 083 - 20 way Black, 6 way White). See Fig. 1.
4. Disconnect each connector. Apply spray grease to both mating faces of each connector (see note at start of the procedure). Allow 15 seconds for solvent to evaporate before reconnecting each connector.
5. Apply a generous amount of spray grease to the REAR faces (the "harness entry" faces) of both connectors.
6. Carefully pass the two connectors forwards into the "A" post opening, toward their original locations.
7. Use cleaning solvent to remove all traces of grease from the groove at the forward end of the corrugated gaiter and from the aperture in the "A" post into which it fits.




8. Allow the solvent to evaporate, then apply a bead of Mastic sealer (JLM 11548) to the full circumference of the forward groove of the corrugated gaiter to completely fill the groove with sealer. Twist the gaiter in each direction to obtain the required access. See Fig.2.
9. Refit the corrugated gaiter to the "A" post. Twist the gaiter in each direction as the groove engages with the opening in the "A" post, spreading the sealer, to ensure that it forms a continuous seal between the gaiter and the body metalwork. Wipe off any excess sealer to restore a good cosmetic appearance.
10. At the passenger side front footwell, remove the dash liner/armature for access.
11. Cut and discard the ratchet strap retaining the harness to the blown aspirator and disconnect from the aspirator.
12. Displace the heater duct outlet.
13. Carefully un-clip the passenger door aperture flange finisher from the area of the "A" post fuse box trim pad.
14. Remove the screw which secures the fuse box trim pad and remove the trim pad.
15. Remove the passenger side front floor carpet.
16. Remove the screws which secure the fuse box to the body.
17. Release the fuse box from its front retaining clip, allowing the fuse box to be moved aside as required for further access.
18. Disconnect the Blue and Yellow connectors, FE 41 and FE 42 of the Engine Control Module (ECM), remove the 4 securing screws and remove the ECM.
19. Release connector assembly LB/RB 09 (White, 12 way) from its clip on the LH sill.




20. Remove the lower foam block (Item 3, Fig.3) from the "A" post cavity. Inspect/check the foam block, by squeezing it. If the block is dry, refit it. If the block is wet, replace it by a new block.
21. Displace and remove the "A" post upper foam pad, (Item 1, Fig. 3) to give access to the upper foam block (Item 2, Fig. 3). Similarly inspect/check the upper foam block. If dry, refit the block. If wet, replace the block by a new one. Refit the upper foam pad.
22. Extract the LH side harness grommet from the "A" post. Use the cleaning solvent to remove all traces of grease from the groove of the grommet and from the aperture in the "A" post into which it fits.




23. Allow the cleaning solvent to evaporate, then apply a bead of Mastic sealer to the full circumference of the groove of the grommet. See Fig.4.
24. Refit the grommet into the "A1, post. Twist the grommet in each direction as the flange engages with the opening in the "A" post, spreading the sealer to ensure that it forms a continuous seal between the gaiter and the body metalwork. Wipe off any excess sealer.
25. Disconnect the mating portions of the LB/RB 09 connector assembly, previously released from its mounting clip.
26. Treat both mating faces with spray grease, allow 15 seconds for the solvent to evaporate, then reconnect.
27. Apply spray grease to the rear faces of both connectors.




28. Raise the connector assembly and secure it with a ratchet strap (Part No. C 46294), to the side harness in a position as high as the harness leads will permit. See item 1, Fig. 5 Cut off the protruding tail of the ratchet strap.
29. Re-engage the fuse box to the retaining clip at the forward end, refit and tighten the screws which secure the fuse box.

NOTE:
Refit the spacer washer before refitting the upper screw.