hi...if you are thinking of removing bumper to change your headlight unit , here are some things you need to be aware of as it was a nightmare on a 2002 stilo...most of the torx screws were rusty and would not budge so resorted to molegrips and brute force with wd40 ....the nuts holding the headlight unit in place were very tight and i snapped x2 of the guide pins while undoing but , luckily still had enough to hold new unit on !! the torx screw attached to wing is very awkward and tight but if you place a screwdriver in the holes of the torx screwdriver it gives you extra leverage and loosens eventually. some might say to let garage sort it but k/flit wanted £250.00 ????? e bay came to rescue with new unit for £45.00. after giving up 10 times and then thinking about cost saving , i sorted my new unit and everthing now works ok ...just thought you ought to know...only attempted after reading guides and posts on this lifesaver of a forum ..thank u all guys and girls ..keep up the good work..........

yeah that happens, but, if you soak the bolts a week in advance (thats what i do top up every night) and then on the day tighten them first normally helps a bit, if they still wont budge use heat (soldering iron on the bolt to warm it) and then try again, if nothing leave another day and come back to it, and mine undid after that if it helps

I am in the same position as you Gordon, I removed my front bumper and both wings to get the headlight units out, mines an 02 as well and ever single nut and bolt was rusted. The torx screws are hopeless really. Once I get my new headlight units I think I'm going to take a trip to the dealers and order all new torx bolts for the bumper and new mounting kits for the headlight units, and paint them all in curust before the bumper goes on!

Out curiosity, what headlights did you buy on eBay? I was going to get mine from aceparts but they told me theirs don't fit mine for some reason? :s

You don't need to remove the wings to get the headlamps out, just the bumper.

Kurust only reacts with rusty ferrous metal, it will have no effect on new bolts.

Ahh ok, so could you recommend something that could perhaps inhibit rust appearing again in future?

And well I didn't just remove them to take the headlights out I suppose, I had no archliners on and the chassis was caked in muck, and I'm also planning a wire loom tuck

Paint? but if you use new original Torx screws, the paint could block the Torx sockets.

I replaced some of mine 3 or 4 years ago, the new ones haven't gone rusty yet. I just put a little grease on the threads to aid future removal.

copper grease on the threads and some stainless or titainum bolts, they don't have to be torx ones

A low strength threadlocker is good too. When it sets it excludes air and water preventing it corroding in place. It also means you don't have to tighten it too much as it won't vibrate loose.

Didn't mean to dislike, apologies!

I do like, and thank you

The threadlocker is good for fine pipe threads too or fitting delicate sensors.Eg 1/4 or 1/8 BSP. Use it rather than thread tape. Just screw in hand tight or a light nip if into a solid housing. Once set has sealed the thread and will not come loose.

just removed the front end on two 02 stilos and both were dead easy and not rusty.... could it depend on the environment they have been used in?

both were 100k or near enough on the clock

clock34 said:

just removed the front end on two 02 stilos and both were dead easy and not rusty.... could it depend on the environment they have been used in?

both were 100k or near enough on the clock

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It's possible, to be fair I bought my Stilo in Adrossan (right on the west coast of Scotland) and have no idea how long it lived there for, salty coastal air could affect it? Perhaps with my more inland location my new array of nuts, bolts and screws should last much longer

tbf, my blue car had lived in newcastle by the sea and in cumbria by the sea and although none snapped they were definatly harder to remove then my red stilo that live in oxford central, probably one of the most inland possitions. so it could be that? mabee also the amount they have been driven in winter.

I remove the front bumper for pretty much everything headlight related.

WD40 on the bolts and allow it to soak over night.
Replace all bolts with new and cooper grease the threads.

I can now remove the front bumper in less than 10 minutes, bumper off and both headlights out and on the floor in less than 20 minutes.

Here here Shadey.... Im a bumper off man through and through. With a quick check around radiator/hoses etc.

I have Lady hands. I dont need to remove the bumper.

just had mine mot`d failed on headlight an extra £130 on top of service ouch:bang:

cab said:

just had mine mot`d failed on headlight an extra £130 on top of service ouch:bang:

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I have delicate musicians fingers, **** needs to be removed to make things easier and prevent hand damage.

Ouch...what did they do to charge you an extra 130 quid?

hi ...fyi i bought new headlight from "traderpartsuk" on fleabay...cost £48.54 total...kwik flit wanted £250.00...dont forget to confirm foglight fitted or not !! torx bolts sorted after mammoth struggle and loads of wd40 but got her sorted in the end !!! love this forum...thank u all