Well new inner wing supports are in and Zeatec tray on. Also replaced headlight washer pump and found the reason why my a/c gas leaks!
Ended up taking bumper off as I wanted to check out the pipes and other parts behind this, plus the pipes to the headlight washers. with the horns, washers and a/c filter behind the o/s wing there isn't a lot of room to work with the bumper on but just released at the back. It was only 6 torx bolts (2 missing), and I didn't have to disconnect fogs or pipes. Just rested on carpet in front of car. Good practice as I want to replace the plastic grill panel at some stage and probably respray bumper. And it looks like I'm going to need another new rad soon!! Bottom is pretty badly corroded and stone damaged with fins missing.
Should have taken a picture really!
Zeatec tray isn't actually wide enough for outer mounting holes and are in wrong place for bottom of supports and bottom corner holes of bumper. Holes don't line up with the mountings on the wing supports.
So now fitted with 3 front and 2 rear bolts only. Not overly happy with that as it's pretty heavy, so I'd rather have those two extra fixings. May have to modify the tray slightly to get it to fit properly. Anyone else considering a Zeatec tray might like to take note. I didn't need to remove the sump to gearbox bridge either .. plenty of clearance.
Actually it's only one rear bolt at the moment. One rivnut fixing had a snapped off bolt jammed in it, so gently ground the edge down and punched it out. But try as I might I can't get the new rivnut to compress properly and grip on the chassis rail. As soon as the weight of the tray goes on, it pops out of the hole. Two new rivnuts down I decided not to mess up any more and tie-wrapped it for now. So on the lookout for a rivnut tool for hire or cheap. I guess that they are M8 nuts at the back they have 10mm heads. Nothing on eper to help or the label on the new bolts. So if anyone has any ideas, let me know ..
Chris155 ... tried your diy tool but I can't seem to get bolt tight enough to "squidge" the rivnut fully and didn't want to snap another bolt off!
Fitting the new headlight washer pump was relatively easy as it just pushes in the seal. As my water tank was pretty full, it made a bit of a mess though. So I drained it off completely into a bowl and took it right out to give it a good clean up. My inner wing soundproofing was stuck to the bottom of the tank too! Must be where washer fluid and coolant spillages run underneath.
Also cleaned up the contacts on the horns as one is erratic .. not want you want at M40 J4 .. the notorious Handy Cross roundabout ... in the rush-hour sounds more like Rome!!!
And I found out why I don't seem to keep a/c gas in my system. There's a pipe running from the condensor to the filter unit in the o/s wing (part no 60653199). This has been rubbing on the chassis rail and has a neat cut right through the rubber pipe section
I'll add a piccy once I've got them off my camera.
So a reasonable days efforts ... what shall I do tomorrow?