Inside the COM2000 - a "How Not To"

Talk about the 406's electrical system, what wires do what, how to add extra functionality, etc.

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Inside the COM2000 - a "How Not To"

Post by steve_earwig » Tue Jun 30, 2009 10:37 pm

I'm not going to follow this on from my removal How To because I'm not sure anyone's ever going to follow this. It's a pig to take to pieces and I'm not even sure there's much point. Nonetheless:

How to take it to pieces the hard way:

First you have to remove the spring collar in the middle of the air bag feed spool.
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This seems to be an interlock for the spool (yep, it's about 2 meters of ribbon cable, I had it all out in a heap) so without it the thing can turn so, first up, push it and turn the spool CLOCKWISE and count the number of turns until it goes tight (I think it's about 3 and a bit but I could be wrong, I wasn't paying much attention). This is where the ribbon is fully wound up and gives you a reference for when you reassemble (that's if you don't give up and stamp on the thing.) Now you can carefully (that's the last time I'm going to use that word, just take it as read everything you do here has to be done that way) prise out the collar:
Image

Next, two screws:
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and a few clips, so lots of prizing with a blunt implement.

Now, hopefully, you have the top off:
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Two connectors and the circuit board is held in with a few clips. Now that's out the way you'll be able to see the wipers:
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and the tracks on the back of the board:
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The indicators are the two in the middle, the others are flash and dip/main beam.

Next, to remove the stalk you need to prize it top & bottom thus:
Image

In the bottom of the stalk is a little knob with a spring behind it, which is what holds the stalk in place while it's in action:
Image
Image

This bears on some sort of ramp inside:
Image

On the front is a little rocker:
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When the stick is turned, this little jobbie is pushed by the knob and tips one way or t'other and is pushed back on by lugs on the bottom of the spool:
Image
which in turn pushes the knob and returns the stick.


So, what's wrong with it? Buggered if I know!! I couldn't make it go from indicating right straight to left and I was sodding about for ages. Should the rocker be sitting at an angle? Should the ramp look like that? Has the little spring behind the knob collapsed? I don't know. The only thing I could think to do is stretch the spring, BM (before mangling) it was 20mm, AM 25mm, and it does feel much more positive. Trouble is, there's no way it's going back on my car!

I did try taking the stalk out without dismantling it, I thought this could even be done in situ, unfortunately the little wires are too short, they're hooked round a bit of plastic and I can't figure out how to release them from outside. I also tried dismantling the stick but removing the foglight stage rather requires the wires to be disconnected from the other end. Dammit, they thought of everything.

The other problem I had was iffy contacts, I tried spraying contact cleaner in while it was in the car but it doesn't look like any of it got on them, they still had grease all over them. One thing you could try is drilling a small hole in the top so you can spray down behind the circuit board:
Image
You never know...

Ah well, rather pointless but it was more interesting than watching the crap they put on telly here Image
Unskilled meddling sin©e 2007

2004 D9 2.0 HDi 110 Estate lhd VF38ERHZF81657352 - sold but being very well looked after.
1991 Yamaha TDM850 - fuel leaks galore!
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Re: Inside the COM2000 - a "How Not To"

Post by Welly » Wed Jul 01, 2009 7:30 am

Just how bloody complicated can you make your wiper and indicator stalks? ask Peugeot! :roll:

Looking at that lot it's no wonder they fail over time. A lazy spring would seem most likely to me or a worn track/guide where the stalk's been up and down so many times?
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Re: Inside the COM2000 - a "How Not To"

Post by DaiRees » Wed Jul 01, 2009 8:05 am

Well done Steve,

Now if you just take your new one apart you'll be able to see what they've changed..... :wink: :P
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Re: Inside the COM2000 - a "How Not To"

Post by steve_earwig » Wed Jul 01, 2009 8:28 am

Sorry to keep on about this, I do seem to have a bee in the bonnet about it but it really p!sses me off that these fail and cost so much to replace. Not to mention the arse-clenching fear of having the airbag go off in your face while you're changing it.

Anyway, I've been wondering about this:
Image

This is the source of the rattle I mentioned in the other thread, it fell out while I was taking it to piece the first time, I put it to one side for further consideration and forgot about it. Since then I've been wondering if it has anything to with this:
Image
which is the clip on the circuit board right next to the indicator stalk contacts. All the rest are the usual flat piece of plastic with a triangular bit on the side but this one looks like it doesn't do very much and I thought it was just there to line the board up. If this tiny bit of plastic was meant to be holding the circuit board, maybe its absence is enough to let the board move up a few thou and hence the bad contacts :?:

The other thing I've noticed is there's no way you could get the stalk out in situ, as well as the wire the cover is shaped so it covers half the base. Gah!

What we really need is for a mug to do the spring stretchy thing, reassemble and see if it clears the r/h-l/h floppy stick thing. The fear is the airbag contacts to the circuit board are two tiny little springs and I'd worry they'd create trouble. Then again, most of the SRS is in place to stop it accidentally firing, so hopefully you'd only get the airbag fault light up if there was a problem. What also would be interesting is to see what that spring looks like on one that's failed completely. Hell, if you've not got the time and/or patience to take it apart send it to me (I'll even pay the postage) and I'll do it!! Yep, it's bothering me that much :oops:
Unskilled meddling sin©e 2007

2004 D9 2.0 HDi 110 Estate lhd VF38ERHZF81657352 - sold but being very well looked after.
1991 Yamaha TDM850 - fuel leaks galore!
2008 Toyota Recall4 2.0 VVTI ATM LHD JTMBH31V90D007261 - flimsy piece of crap.
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Re: Inside the COM2000 - a "How Not To"

Post by steve_earwig » Wed Jul 01, 2009 8:31 am

DaiRees wrote:Now if you just take your new one apart you'll be able to see what they've changed..... :wink: :P
As if! Hopefully they changed everything...
Unskilled meddling sin©e 2007

2004 D9 2.0 HDi 110 Estate lhd VF38ERHZF81657352 - sold but being very well looked after.
1991 Yamaha TDM850 - fuel leaks galore!
2008 Toyota Recall4 2.0 VVTI ATM LHD JTMBH31V90D007261 - flimsy piece of crap.
1953 Matchless G3LS - It's alive!!

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Re: Inside the COM2000 - a "How Not To"

Post by Welly » Wed Jul 01, 2009 9:03 am

You might earn youself a nice little service-exchange business there steve!

Someone on here'll design you a web page and punters from all over can send you their units for 'repair' :cheesy:

This time next year you'll be a millionaire 8) just remember your friends on here that's all :wink:
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2005 Volvo S40 T5 German Diesel botherer with new tyre grippage
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Re: Inside the COM2000 - a "How Not To"

Post by steve_earwig » Wed Jul 01, 2009 1:26 pm

Sounds like a plan :cheesy: I just need a victim, sorry, volunteer to try it out on...

The question is, how many different varieties are there? There's this DAV(ros), Semen's and Dolphin, which I presume will be more-or-less the same for each manufacturer, also the early ones still go wrong but apparently you can just change the switch. Off for a squint in Service Pox...
Unskilled meddling sin©e 2007

2004 D9 2.0 HDi 110 Estate lhd VF38ERHZF81657352 - sold but being very well looked after.
1991 Yamaha TDM850 - fuel leaks galore!
2008 Toyota Recall4 2.0 VVTI ATM LHD JTMBH31V90D007261 - flimsy piece of crap.
1953 Matchless G3LS - It's alive!!

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Re: Inside the COM2000 - a "How Not To"

Post by steve_earwig » Wed Jul 01, 2009 10:02 pm

Back from Pervert's Socks and what did I find? If your car is multiplex and you don't have a rear wiper or ESP (does anyone?) then you have a Valeo. If you have either of these then you have a Delphi, or more probably this DAV (and I found a post where Jasper, I think it was, said they went broke because of this). This is saloon, estate and coupe (rear wash/wipe? Err, ok) Looking through the posts by people with D9 indicator issues what else do I find?

Dai Rees - my main car is a Pug 406 Executive Estate
Bangernom1cs - a nice shiny 2002 executive estate
Parcelman - doesn't say
Eoin - ive a 90 saloon - not multiplex.
Jasper - Don't say either
djp30djp - The car is a 2000(X) 110 Exec Estate
Captain Sparkle - another one who doesn't know...
Mark H - same
Pug 1 - I have a T reg 406 estate

See a pattern forming?
Last edited by steve_earwig on Wed Jul 01, 2009 10:14 pm, edited 1 time in total.
Unskilled meddling sin©e 2007

2004 D9 2.0 HDi 110 Estate lhd VF38ERHZF81657352 - sold but being very well looked after.
1991 Yamaha TDM850 - fuel leaks galore!
2008 Toyota Recall4 2.0 VVTI ATM LHD JTMBH31V90D007261 - flimsy piece of crap.
1953 Matchless G3LS - It's alive!!

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Re: Inside the COM2000 - a "How Not To"

Post by Doggy » Wed Jul 01, 2009 10:07 pm

When I was looking for my car, I drove a 2002 exec estate with a dodgy com2000 and a 2001 gtx estate, which had the old-style cruise stalk so I assume non-com2000, but it indicated left spontaneously twice in 10 miles....

Mine so far is OK
2002 HDi 2.2 Exec Estate, (2008-12)
2003 HDi 2.2 6-speed Exec Estate (2012-19)
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Re: Inside the COM2000 - a "How Not To"

Post by Welly » Thu Jul 02, 2009 8:03 am

steve_earwig wrote:See a pattern forming?
If I said that the problem affects 'Estates' do I win a lolly? :mrgreen:
Cars in my care:

2005 Volvo S40 T5 German Diesel botherer with new tyre grippage
2010 Citroen C4 1.6 HDi turbo de' explosions, bizarre gearbox model
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Re: Inside the COM2000 - a "How Not To"

Post by Captain Jack » Thu Jul 02, 2009 8:08 am

Didn't soops replace hers 3 times on her saloon taxi? (I think it was a saloon anyway)
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2003 - 2008: 1998 Peugeot 406 2.1 TD 110bhp LX Saloon
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Re: Inside the COM2000 - a "How Not To"

Post by steve_earwig » Thu Jul 02, 2009 1:49 pm

It seems to me the COM2000 made by DAV are more likely to go faulty but then I don't know if Valeo have always been making them all along or just since DAV went belly-up. Did DAV make the pre-multiplex ones and, if so, which? I know they go faulty too but is it for the same reason? Did they use the same design, just fitted in a bigger box? Who put the bop in the bop shoo bop shoo bop? Find out in the next thrilling installment of Oh My God, My Knob Fell Off!!
Unskilled meddling sin©e 2007

2004 D9 2.0 HDi 110 Estate lhd VF38ERHZF81657352 - sold but being very well looked after.
1991 Yamaha TDM850 - fuel leaks galore!
2008 Toyota Recall4 2.0 VVTI ATM LHD JTMBH31V90D007261 - flimsy piece of crap.
1953 Matchless G3LS - It's alive!!

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Re: Inside the COM2000 - a "How Not To"

Post by steve_earwig » Fri Jul 03, 2009 7:45 am

Captain Jack wrote:Didn't soops replace hers 3 times on her saloon taxi? (I think it was a saloon anyway)
Shame all her posts disappeared... Ah, but did it have a rear screen wiper?
Unskilled meddling sin©e 2007

2004 D9 2.0 HDi 110 Estate lhd VF38ERHZF81657352 - sold but being very well looked after.
1991 Yamaha TDM850 - fuel leaks galore!
2008 Toyota Recall4 2.0 VVTI ATM LHD JTMBH31V90D007261 - flimsy piece of crap.
1953 Matchless G3LS - It's alive!!

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Re: Inside the COM2000 - a "How Not To"

Post by Nicodemus » Thu Jul 16, 2009 9:58 am

I didn't think saloons had a rear wash wipe?

Mine has prob's with the flippy indicator, usual stuff - from right flips back to left when straightening steering... Sometimes sticks in left even though stalk appears to have re-centered.

Oh, as below, it's a 52 plate hdi(90) lx saloon.

IIRC we had the same prob on a 02/52 plate 306.

Nick
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Re: Inside the COM2000 - a "How Not To"

Post by jasper5 » Thu Jul 16, 2009 12:11 pm

Mine is a saloon, 51 reg without rear wash/wipe.

Don't know what make it is.

The fault with mine is that you indicate right, then after turning right the indicator flashes left until you manually stop it, also the indicator stalk is very weak in its operation.

I must admit, I can't be bothered fixing mine, the car is used mostly on motorways, my wife drives M65/M61 every day to and from work.

These things can be repaired, BBA-Reman offer a "send it in and we'll recon it" service, unfortunately they want £100.

I wouldn't mind having a go at fixing one where it can be scrapped if the repair is not successful.

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