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Modification Details

450 Front Panel Removal

Difficulty

Credit

Evilution

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For

Old Style 600cc For2
Old Style 700cc For2

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At first there was very few reasons to remove the front panels, to change the headlight bulb or replace a damaged section. Now however, front panel removal is becoming more common place as people install oil radiators, better horns, lights etc.

Despite it seeming like a nightmare task it is relatively easy as long as you have a bit of space, an extra pair of hands comes in handy too. The front grill is held on by 7 clips, on the Mk1 to Mk5 there were 4 clips on the top and 3 along the bottom.

From Mk6 onwards there were 3 on the top and 4 along the bottom (circled in red below).

Looking in between the panels will make the clips obvious, you can unclip them one by one with a screwdriver or insert a lolly stick into each one and slide the grill out.

The clips are quite robust but have been known to snap if unclipped in cold weather.

With the grill removed you can see the clips in place.

On the inside of the fog light is a T25 Torx screw that need to be removed on each side (circled).

Open the doors and remove the five Torx 25 screws from both sides.
The top screw is plastic, you will have to pull out the insert too.

The plastic triangles in front of the mirrors will now pull away, Remove the Torx
screw hidden underneath with a Torx25 bit.

Unscrew the aerial, remove the plastic triangle and undo the screw underneath.

Pull the bottom of the wheel arch and the whole side should move to one side.
Try to keep it clear from the tridion as you remove it to save scratching the paint.

Reach down behind the panel and undo the fog light connections.

Remove the side indicators (found here) and push the connector through the hole.

With a person on each side, flex the arches out and take the panel off.

Changing the panels

Using a screwdriver, carefully lever off the yellow clips circled below.

A better tool to remove these clips is circlip pliers.

Simply place the jaws of the pliers into the hole either side of the clip, squeeze and pull.

Undo the 2 Torx 25 bolts that hold the lower splitter on.

Push the plastic pin from the centre of the inserts at each end, the rivet will then pull out.

Same again with the lower uprights.
The splitter will now come off allowing you to pull the separate panels apart.

Refitting the front panel is the reverse of above.

Job done.

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