Removing the front fascia and the radiator

[johnomac]

Have remved the headlights, surrounds, and all the bolts behind the grey bit but then i discovered its attatched to the black bit! Any tips on removing it completely would be greatly appreciated.
Also not sure on how to get to the radiator?
Thanks,
John

[bozzzydmc]

Are you trying to take the radiator out or remove the facia, if its the later then see this:-

Otherwise sorry your are doing a lot more than you have too.

To remove the front facia

(Text by Rich H)

You have to remove the bonnet to get at the screws along the top
edge.
You don't need to remove the headlights, they make absolutely no
difference.
There is a single screw attaching the centre of the fascia located
behind the DMC grill.

You will need to remove the front spoiler. Starting at passenger end:

1. One screw attached to the support arm, should come out OK with a
little easing oil.
2. Two studs attaching spoiler to front wing: nuts will probably shear
off
3. Two studs attaching to bumper and brackets, leave the brackets
attached to the bodywork. Remove the nuts from the studs, They will
probably shear off too
4. Five nuts on studs from bottom of mesh panel.
5. Remove two bolts either side of the mesh.
6. Remove five bolts across the top of the mesh.
7. Remove mesh.
8. Two studs attaching to bumper and brackets, as 3 above but we're now
on the drivers side. Guess what?...The nuts will probably shear off.
9. Two studs attaching spoiler to front wing. Absolute git to get at as
they are behind the washer bottle cover: nuts will probably shear off
10. One screw attached to the support arm, should come out OK with a
little easing oil.
11. Withdraw spoiler
12. Stick you head under the passenger corner of the fascia and look up,
about level with the corner of the fibreglass tub, you should see a stud
poking inwards from the fascia, there -may- be a nut attached to it -
remove it.
13. Do the same on the drivers side, only this time you'll have to go by
feel as you can't see it. Pray the nut is missing.....*Skip 14 if it is*
14. Remove washer bottle to get at offending nut (sorry)
15. Prise out the sides of the fascia, roughly at the bottom of the
black 'bumpery' bit to release the studs from the front wings, be
careful not to scratch the steel.
16. Lift the fascia from the bottom edge up and out in a hinging motion
about the top edge.
17. Recover from the ordeal.
18. Drill out all the broken studs on the spoiler and replace with bog
standard nut/washer/bolts instead.
19. When reassembling, if you had to remove the awkward nuts from the
side of the fascia, don't bother replacing them - unless you really
fancy torturing yourself to do it.
20. Use liberal quantities of copper grease!!


Radiator Removal


It can be done without removing the condenser. Or any drastic surgery.

In short:

Disconnect top and bottom coolant hoses.

1. Remove rad lower mounting brackets (and horns attached)
2. Remove two 45 degree supporting frame brackets
3. Use big tie wraps to hang the condenser (and rad) from two
conveniently placed strips of metal at the front of the bodywork.
4. Remove fans/cowl from rad (6 bolts) it's a squeeze but it can be
done.
5. Unbolt rad from condenser(which is hanging on tie wraps)
6. Place antifreeze soaked clothing in washing machine.


Rich Hutchinson
DOC 365 VIN 1274

[steve.s]

hi

couple of tips/comments

washer bottle cover is a sod to remove. Rivnuts just spin.

i had to drill out most, with a drill flexi extension (as there is no working room)
the larger brackets also, mine just spun round.

my bonnet brackets disintegrated, so new from dmc. mark the nut positions so it goes back into the same position.

get plenty of large bubble wrap (garden centre?) to protect that bonnet (and two people) (three helps to re-install).

pjgrady have a replacement rock screen if yours is too bad.

good luck

ps while off, i had to repair all light wiring (mouse had them for dinner).
and i repainted the black coating with black tetroseal...worked a treat.

[johnomac]

HAHAHA i have some work to do, looks even more difficult after a few beers, thanks lads, ill let you know how it goes (probably crap).

[johnomac]

Oh and its ok bozzzy, i already soaked my clothes in antifreeze when i exploded the coolant resevoir- theres none left!

[dmckelv12]

Looks like a five minute job!!! I've got this all to come yet too!!!!

[johnomac]

5 minutes, try 5 days!!

[dmckelv12]

Looking forward to it already!!!!

[johnomac]

well i managed to get the spoiler off today, but wont be able to get back to her until wednesday- work