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cookymunster

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  1. HAZARD SWITCH / INDICATOR RELAY CLICKING ALL THE TIME I have basically managed to fix the annoying constant or intermittent clicking from the Hazard Switch / Indicator Relay. Yes the problem lies with a worn out contact in the Indicator Stalk or Indicator Leaver which I took apart, cleaned and soldered a very small nipple back onto the contact that had worn off. Without this little nipple making contact I guess the stalk was not turning the relay off properly. The following is how I did it and what tools I used. TOOLS: 1. 24mm Socket with 1/2 inch Wrench 2. Hex Screw Head Set 3. Flat Head Screwdriver 4. Phillips Head Screwdriver 5. Solder and Soldering Iron 6. Fine Emery Cloth 7. Wire Brush 1. Take off steering column Covers. One Hex screw and two Phillips head screws underneath. Then prize apart the 2 covers to remove. 2. Un-clip the airbag wire harness. It should be to the left of the column and holds the wires that rotate around the rear of the steering wheel. This is instead of disconnecting the battery. Be sure to reconnect on re-assemly!! 3. REMOVE STEERING WHEEL: - Insert key into ignition, and turn to the "on", but not "over" position (this will keep the wheel from locking). - Turn the wheel 90 degrees to one side. You will feel/see a small hole in the back. - Insert a small flathead screwdriver into the hole. Make sure the screwdriver is angled such that the handle is against the steering column, and the flathead is as high up within the hole as possible. Make sure to push the screwdriver in as far as you can. - Pull up on the handle. What you are trying to do is push down on a small spring within the steering wheel that holds the airbag locking latch secured. - You may have to try a couple times, but you will eventually see, hear, and feel the airbag catch release from the spring. - Turn the wheel in the opposite direction 180 degrees until you can see/feel the second hole. - Repeat the screwdriver procedure. - The airbag and horn should now be released from the steering wheel. However, Horn & Airbag still attached to their wiring harnesses. I managed to leave these connected and balance the airbag while undoing the steering wheel nut. Then the whole ting comes off together with wiring intact. Otherwise make sure to unplug the harnesses from the airbag and horn before you pull it out too far from the wheel. Be sure to reconnect on re-assemly!!. - Use the 24mm Socket to undo the Lupo Steering Wheel Nut and Steering Wheel will come free. 4. Un-clip the indicator wiring harnesses from left and right sides of the steering column. 5. Undo the 3 screws to free the indicator stalk from the windscreen wiper stalk and pul free. 6. Take the stalk to your cleaning area where you can arrange the bits we are going to dismantle. Don't worry as below should be pictures I've done to help you through dismantling and reassembly. 7. Undo the one screw on stalk case. Gently unclip the 3 little clips around the case. The case is still held together because of a copper terminal running through both halves of the case. You need to push the protruding copper prong back through its hole with a pair of pliers, being careful not to bend it. The case will prize apart now. 8. Basically we need to clean all terminals of grime and rub them clean with the emery cloth. 9. The main thing on mine was to re-solder a nipple onto the terminal / brush on the Stalk as shown in the picture below. P.S. These pictures are from my server so they may not be around for ever. I wish Club Lupo could host them!!!
  2. cookymunster

    Indicator/Hazard Clicking Noise

    HAZARD SWITCH / INDICATOR RELAY CLICKING ALL THE TIME I have basically managed to fix the annoying constant or intermittent clicking from the Hazard Switch / Indicator Relay. Yes the problem lies with a worn out contact in the Indicator Stalk or Indicator Leaver which I took apart, cleaned and soldered a very small nipple back onto the contact that had worn off. Without this little nipple making contact I guess the stalk was not turning the relay off properly. The following is how I did it and what tools I used. TOOLS: 1. 24mm Socket with 1/2 inch Wrench 2. Hex Screw Head Set 3. Flat Head Screwdriver 4. Phillips Head Screwdriver 5. Solder and Soldering Iron 6. Fine Emery Cloth 7. Wire Brush 1. Take off steering column Covers. One Hex screw and two Phillips head screws underneath. Then prize apart the 2 covers to remove. 2. Un-clip the airbag wire harness. It should be to the left of the column and holds the wires that rotate around the rear of the steering wheel. This is instead of disconnecting the battery. Be sure to reconnect on re-assemly!! 3. REMOVE STEERING WHEEL: - Insert key into ignition, and turn to the "on", but not "over" position (this will keep the wheel from locking). - Turn the wheel 90 degrees to one side. You will feel/see a small hole in the back. - Insert a small flathead screwdriver into the hole. Make sure the screwdriver is angled such that the handle is against the steering column, and the flathead is as high up within the hole as possible. Make sure to push the screwdriver in as far as you can. - Pull up on the handle. What you are trying to do is push down on a small spring within the steering wheel that holds the airbag locking latch secured. - You may have to try a couple times, but you will eventually see, hear, and feel the airbag catch release from the spring. - Turn the wheel in the opposite direction 180 degrees until you can see/feel the second hole. - Repeat the screwdriver procedure. - The airbag and horn should now be released from the steering wheel. However, Horn & Airbag still attached to their wiring harnesses. I managed to leave these connected and balance the airbag while undoing the steering wheel nut. Then the whole ting comes off together with wiring intact. Otherwise make sure to unplug the harnesses from the airbag and horn before you pull it out too far from the wheel. Be sure to reconnect on re-assemly!!. - Use the 24mm Socket to undo the Lupo Steering Wheel Nut and Steering Wheel will come free. 4. Un-clip the indicator wiring harnesses from left and right sides of the steering column. 5. Undo the 3 screws to free the indicator stalk from the windscreen wiper stalk and pul free. 6. Take the stalk to your cleaning area where you can arrange the bits we are going to dismantle. Don't worry as below should be pictures I've done to help you through dismantling and reassembly. 7. Undo the one screw on stalk case. Gently unclip the 3 little clips around the case. The case is still held together because of a copper terminal running through both halves of the case. You need to push the protruding copper prong back through its hole with a pair of pliers, being careful not to bend it. The case will prize apart now. 8. Basically we need to clean all terminals of grime and rub them clean with the emery cloth. 9. The main thing on mine was to re-solder a nipple onto the terminal / brush on the Stalk as shown in the picture below. P.S. These pictures are from my server so they may not be around for ever. I wish Club Lupo could host them!!!
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