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Ampaul

How to: Remove front bumper & replace air con conditioner

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I wasn't sure if this would be of any help but then thought why not, although an easy job was still a bit daunting for a novice like me, and if I can do it so can any of you (and hopefully save some cash by not paying to get this done) :thumbsup_still:

Firstly I ordered a new conditioner on Ebay from coolpartsuk for £48 plus £6 postage and comes with a 2 year warranty. I got the 2 O-rings from Edinburgh OPC as advised in Duffys 'Buying from an OPC' thread, very helpful and no postage added!! The O-ring sizes are 10.6 x 2mm and cost about £8 for both.

Firstly you need to turn the front wheels fully in one direction for easier access. Then pull out the side indicators from the wheel arch end (they just pop out easily). Behind these there are 2 philips screws. One you can see easily (red arrow in photo), the other is pointing up from the inside of the bumper (green arrow). To get to this one you'll need to pull away the wheel arch lining, it has 2 plugs that just pull out with some pliers (lubricate them first).

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Next you need to take of the plastic trim from around the boot release, these are held in with just 4 plugs that just need turning with a screwdriver so the groove is sideways as you look at it....note I have one missing. Once removed the trim just pulls off.

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This then reveals 2 philips screws to be undone

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Now its time to get under the car. There are 9 (9!!!) torx screws here that can be done with a socket set so no need to jack the car up.

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At first I thought there were just seven but the bloody thing wouldn't budge, had another look and found 2 more 'hidden ones'....the arrow to the left shows their position.

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This photo of the inside of the removed bumper shows their position better.....

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Once all have been removed the bumper will pull off with a bit of persuasion revealing this. (note the friends S2000 garage queen in the background, sobbing as it never gets to come out and play!)

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You can see here some of the old leaves

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Now you need to remove the black rubber covers that are over the condensers. They are held in with just 5 torx screws (can see 3 here)

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Here you can see all the cr*p around the busted condenser, I find it amazing that when the previous owner had the drivers side replaced they didn't clean out the other side.

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Next I put some penetrating spray on the allen bolts then set about cleaning drivers side condenser while it worked it's magic (condensers just wiggle out once the 2 bolts have been undone).

I then unscrewed the 2 allen bolts (green arrows) before undoing the 2 bolts that hold condenser inplace (red arrows)

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Knackered condenser

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Dirty radiator!

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Cleaned the radiator up and fitted new condenser with new O-rings :)

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Then its just a case of putting it all back together (cleaning bits as I go). I had help with getting the bumper back in place, otherwise it'd be easier to remove the headlights.

Just need a regas now!!!!

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Very good "How To" someone was on here the other week trying to find out why he had two screws left over from a bumper removal he did, well I was in the same place as him once when I did it and it turned out to be one of the screws on each side shown in the 6th photo down, I couldn’t explain where they were so didn’t reply to that particular thread, wish this section was up and running then that picture as they say Paints a thousand words, so easy to miss the second screw as it is so close to the other one.

Well done again Ampaul.

Guvs.

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When I took my bumper off the 987 model there were two clips kind of under the headlamp that were a royal pain to remove... in fact one of them was rusted through so I bought some new ones when refitting are these not on a 986 ?

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Well done and thanks for sharing!

Do you need to extract the remaining gas (if any) first otherwise I think the harmful gas will be released into the atmosphere?

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When I took my bumper off the 987 model there were two clips kind of under the headlamp that were a royal pain to remove... in fact one of them was rusted through so I bought some new ones when refitting are these not on a 986 ?

No they aren't.

You just need a small hooked tool and give them a pull to the centre and they slide off as easily.

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