need help,2004 Coupe headlight removal, air box removal

[k1coupe]

I am stuck and can not find a way to tale headlights out, anyone know how, photos are nice too.
On left side seem if I could take air box out, then I could access the headlight easy, is it possible
to remove air box without taking front bumper cover off?

 

[Twinspark]

Iirc its best to do it through the wheel wells and removing the front wheels.

 

[k1coupe]

I have removed the wheel and liner, but can not get to left headlight because air box is on the way.

 

[FIFTY]

Personally I would take the bumper off it is quite easy and you can tidy up any rust you might find back there. This should help

https://www.sportsmaserati.com/index.php?threads/how-to-front-bumper-removal.20397/

Beware getting the headlights back in is really fiddly. You will need to make sure the bumper brackets in the wheel arch are as slack as possible when refitting the lights (this could even be the reason why you are struggling to take them out if you have not touched the bumper brackets)

N.B. do not over tighten the headlight bolt that goes into the bottom of the light housing or you will snap the mount off

 

[k1coupe]

Thank you for the link, it certainly help. It seem you got the headlights out before taking the bumper off.
This thing was sitting lose on top of air box, it's the one you mentioned "snap the mount off", maybe
after I take the light out I could re build the mount.

 

[FIFTY]

Ah it is quite a common problem I believe. If that is indeed from the headlight housing then it can be plastiwelded back on. A plastiwelder only costs about £50

Also the very top mount on the airbox tends to sheer and there are flex bush mounts from the airbox to the subframe which tend to seize then sheer also. Ultimate solution is new airbox and flex mounts or throw it in the bin and put a K&N onto the end of the intake instead

 

[TimR]

Its a bit chicken & egg..!
The headlights can come out with the wing/bumper in place, yes. As this is how you refit them too..Once they are in, you can no longer reach the wing fixings so these must be in place first...! But you might get them in without bolting them up, rotate them to allow access to the wing fixings, then rotate them back for fastening...!
The airbox is a pig. It really doesnt come out without removing the bumper, although I have done it ! Now I have new paint, there's no way Id try it again TBH !
Get a plastic welder and fix the clip..( fifty beat me 2 it !)

 

[k1coupe]

This thing is not coming out!!!!

 

[k1coupe]

Ah it is quite a common problem I believe. If that is indeed from the headlight housing then it can be plastiwelded back on. A plastiwelder only costs about £50

As for plastiwelding the 3rd mount of headlight, I only took the 2 remaining mounting bolts and before it the light was solid in its place, so I think 2 out of 3 is sufficient to hold it securely in place

 

[FIFTY]

Looks like you are very close.

You need to pitch it forwards and upwards very carefully (at your own risk obviously)

Have you put some slack on the bumper to wing bracket? This will reduce the amount the headlight is being pinched in place

 

[k1coupe]

Its a bit chicken & egg..!
The headlights can come out with the wing/bumper in place, yes. As this is how you refit them too..Once they are in, you can no longer reach the wing fixings so these must be in place first...! But you might get them in without bolting them up, rotate them to allow access to the wing fixings, then rotate them back for fastening...!

Get a plastic welder and fix the clip..( fifty beat me 2 it !)

As for plastiwelding the 3rd mount of headlight, I only took the 2 remaining mounting bolts and before it the light was solid in its place, so I think 2 out of 3 is sufficient to hold it securely in place
Thank you for the hint about putting the headlight back, for now I am stuck taking it out, and unbolting the one thru foglight access was real torture.

 

[TimR]

The airbox is not very happy or clever accident of assembly line manufacturing imo...
I did this to mine. Everything is life is easier with the airbox delete...!

 

[k1coupe]

Wish, I knew this before, my paper(Maserati) filter is due to arrive soon and I be using air box, if I get the light out for a good lens polish( worst case I polish them hooked to the car)

 

[k1coupe]

It's out

 

[2b1ask1]

The airbox is not very happy or clever accident of assembly line manufacturing imo...
I did this to mine. Everything is life is easier with the airbox delete...!

^^^^ This ^^^^ & sounds awesome too!

 

[Scaf]

It's out
View attachment 77862


View attachment 77863

Congratulations- sound like a pig of a job

 

[StickyPlastics]

Its even harder to paint the inside of the lamps if you need to. The receipe is gas mark 4 for 30 mins. tutto è possibile

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[philw696]

It's amazing that so many of her indoors appliances like the dishwasher, hairdryer and the oven can be used in the Automotive World too

 

[FIFTY]

Its even harder to paint the inside of the lamps if you need to. The receipe is gas mark 4 for 30 mins. tutto è possibile

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I had the understanding that it is not possible to "bake" the adhesive open but rather you need to cut/break the lens free with a Stanley knife - hence why I have not fancied doing it

 

[StickyPlastics]

Its worked on every lamp I've ever tried. Apart from I failed on a front fog lamp as forgot about it. Other tip is make sure not on fan as an old e39 headlamp I put in melted the lense because the constant blow of heat. Now I just get oven to temp then turn it off.

I would say prizing without heating your going to break the lense. Maybe possible without heat, never tried.

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