headlight bezel removal?

Morgonzo · Post by **Morgonzo** » Tue Apr 25, 2017 4:56 pm

So, i'm trying to remove the front upper quarter panels to check the seal for water intrusion AND, I cannot figure out how to remove the headlight bezel which the handy dandy manual say has to happen BEFORE you can take that panel off. It refers you to section 51 of the manual but section 51 does not help really. Any advice?

Also I think I found the source of my oil leak. Loose hose clamps on the short fat hose between the turbo and the manifold. We'll see if that does it.

Morgonzo · Post by **Morgonzo** » Tue Apr 25, 2017 5:20 pm

Also let me add that I did search and did not come across anything

. I don't have to take the whole headlight assembly out do i?

north54 · Post by **north54** » Tue Apr 25, 2017 5:46 pm

This might help you as it did for me.

http://www.mdocuk.co.uk/forums/viewtopic.php?t=12646

If it doesn't let me know and I can check my deli as we have the same rectangular 1990 and earlier headlights.

Good luck

Morgonzo · Post by **Morgonzo** » Tue Apr 25, 2017 6:48 pm

God golly miss molly, that'll do it! I had the three bezel screws but it didn't budge and didn't want to break anything (easy does it ) it is almost 30 y/o plastic.

Tanks for the help

Post by **Growlerbearnz** » Tue Apr 25, 2017 11:51 pm

When reinstalling the bezel, it's easiest to remove the 2 plastic lugs in the headlamp frame (the lower ones that the lowest 2 screws go into). They just unclip. Then screw them onto the bezel, and the whole thing just snaps back in, no need to fiddle around with long screws above the bumper. I suspect this is how they did it at the factory.

Morgonzo · Post by **Morgonzo** » Wed Apr 26, 2017 5:47 am

Thanks GB, I tried to ease one of those clips out but it seemed stubborn and I wanted use use Mind over Might...not my usual method but it was opposite day

. It's a good thing i didn't pull it all the way off as I still have to get some seam sealer (or the Yank equivalent ) and more wire brushes. I killed the last one trying to clean up that ugly mess under my drivers side carpet, which i've cut from the rest of the carpet to be able to take it out and clean the monitor the mess. I also bought the wrong size probe for the pyrometer D'oh! that one'll go into the IDI and we'll do a take two on the Deli. Not that any of that had to do with headlight bezel removal...I just wanted to tell you how much of a space cadet i am sometimes...

"Pig's in SPACE!!!!"

Morgonzo · Post by **Morgonzo** » Fri Apr 28, 2017 1:33 pm

So I bought the Seam sealer today! But these machine screws that hold the quarter panel on are a Bit#h!

I've hit them multiple times with the PB Blaster and knocked them with a hammer and chisel to try and break the bond. I'm running the risk of ruining the heads of the screws. I don't think any of my phillips bits are in clean enough shape to get these out without destruction. Why oh why couldn't they be 10mm hex nuts? t think i'm due for a trip to Disposable Tools R Us..(Harbour Freight). This is a good weekend to do it, nice warm weather and no rain forecasted.

Post by **Growlerbearnz** » Sat Apr 29, 2017 12:19 am

Morgonzo wrote:I tried to ease one of those clips out but it seemed stubborn

Probably a good call, I have vague memories of breaking one myself before I figured out the trick.

cosmo727 · Post by **cosmo727** » Sat Apr 29, 2017 2:59 am

A trick that I have learned for stubborn screws is to use a speed handle (preferably one with a flat circular knob on the end of the handle). Use valve grinding compound on the tip of the bit for extra grip and really lean into the screws.

Morgonzo · Post by **Morgonzo** » Sat Apr 29, 2017 6:32 am

Hey Cosmo, thanks for the tip. I think the grinding compound for extra grip is an interesting idea. The problem I have to overcome is that my right hand is still very weak after the injury. I can barley make a fist, not great for trying to produce a bunch of torque to budge stubborn screws. I'm trying Mystery Machine's trick of a phillips bit in a ring end wrench (or spanner..

) to get the front two out at the awkward angle their at. Well, I'm off to Horrible Freight, hopefully today's the day to finish this up!

Morgonzo · Post by **Morgonzo** » Sat Apr 29, 2017 12:26 pm

Done! and Mother nature has brought me a thunderstorm to test my handiwork

I took pics as I went and will post them when the wife gets back with her phone. Fingers crossed that we're High And Dry....so we can go On Through The Night. I've been listening to a lot of hearing impaired spotted cats lately

sk66 · Post by **sk66** » Wed May 03, 2017 2:29 pm

After 3 days driving cross country in the rain, I finally did the seam sealing today.

While removing the second panel screw that required drilling out I found the trick to removing them. Bang on the side of the head with a cold chisel a couple times and from a couple of directions... like you're trying to pop the screw head off. Once I figured that out I was able to get all of the remaining screws out with minimal effort.

Morgonzo · Post by **Morgonzo** » Fri May 05, 2017 6:47 am

Hey sk66, I defiantly had to aim my chisel at the screw heads (all of them..) and hit 'em real good several times. I went and bought a fresh screwdriver bit kit that came with a ratcheting handle from HF. The only one I could not get was that one right under the headlight. I used a 1/4" ring end with a short phillips bit duct taped in, and the wood chisel pushed under to apply force against the bit to keep it in the screw. It worked well and did not strip the screw head. I took pics but am having a hard time re-sizing them of course. I'm happy to say that after several days of rain and a trip to the self-wash, still no water that was not from out feet.