Technical Fiat 500 rounded nut on bumper alignment bolt

[aliclubb]

Hi everyone! I recently attempted to remove the bumper on my Fiat 500 1.2 Lounge RHD (2012) in order to replace the near side DRL housing. Unfortunately, even after copious amounts of WD-40, I was unable to undo the bumper alignment bolt on the passenger side. I used the correct spanner size for the nut and the correct T30 bit for the bolt but I have ended up slightly rounding off the nut.

Has anyone got any ideas about how I might go about removing the nut? I would try some of those rounded nut removal sockets but unfortunately I don't think I could get them installed onto the nut due to the annoying angle involved. I did wonder if removing the wheel and then the wheel arch liner could help but sadly that's something I am not equipped for and I'm also not confident in removing a wheel.

Any ideas would be greatly appreciated, as right now it's looking like it will now be a garage job...

 

[bugsymike]

Hi everyone! I recently attempted to remove the bumper on my Fiat 500 1.2 Lounge RHD (2012) in order to replace the near side DRL housing. Unfortunately, even after copious amounts of WD-40, I was unable to undo the bumper alignment bolt on the passenger side. I used the correct spanner size for the nut and the correct T30 bit for the bolt but I have ended up slightly rounding off the nut.

Has anyone got any ideas about how I might go about removing the nut? I would try some of those rounded nut removal sockets but unfortunately I don't think I could get them installed onto the nut due to the annoying angle involved. I did wonder if removing the wheel and then the wheel arch liner could help but sadly that's something I am not equipped for and I'm also not confident in removing a wheel.

Any ideas would be greatly appreciated, as right now it's looking like it will now be a garage job...

Without being there it is not always possible to see the problem, some times a small angle grinder can be used and as you say the rounded nut removal tools often work if you can get at it. I know with those tools you can sometimes fit a spanner to them.
Is it possible to come at it from underneath to get to the DRL.
My other thought with all due respect is if as you say you are not confident to remove the wheel safely, it maybe that you may have to "bite the bullet" and take it to a garage, it is possible they can reach in and do it in an easier way much quicker from previous experience or have a better tool for the job.

 

[aliclubb]

Without being there it is not always possible to see the problem, some times a small angle grinder can be used and as you say the rounded nut removal tools often work if you can get at it. I know with those tools you can sometimes fit a spanner to them.
Is it possible to come at it from underneath to get to the DRL.
My other thought with all due respect is if as you say you are not confident to remove the wheel safely, it maybe that you may have to "bite the bullet" and take it to a garage, it is possible they can reach in and do it in an easier way much quicker from previous experience or have a better tool for the job.

Thanks for the reply bugsymike! I totally agree that this is one of those "got to be there" situations. Not sure about accessing the car from underneath, ideally need the bumper off anyway to replace the front badge (hands too big to just remove the four top bolts, gently pull the bumper away and reach inside) as well as check for the fog light wiring connector as I'm looking to retrofit fog lights if I'm lucky enough to have that present.

My only hesitation with removing the wheel is purely down to the fact that I've never done that before in my life, let alone jacked up a car. I've watched videos online from various people but I still get nervous about things like that. It's probably something where if I do it, I'll wonder what all the fuss was about... I'm quite new to car repairs in general but I do electronics repairs in my spare time so I'd like to think (hopefully not arrogantly so!) that I could learn this stuff over time with it being somewhat of a distant cousin, so to speak.

It's already booked in at the garage for Wednesday next week as I'd much rather it be done well than risk making the car worse. They were already going to do brake fluid, brake discs and brake pads anyway so they have agreed to also fit the DRL part that I've sourced.

 

[bugsymike]

Thanks for the reply bugsymike! I totally agree that this is one of those "got to be there" situations. Not sure about accessing the car from underneath, ideally need the bumper off anyway to replace the front badge (hands too big to just remove the four top bolts, gently pull the bumper away and reach inside) as well as check for the fog light wiring connector as I'm looking to retrofit fog lights if I'm lucky enough to have that present.

My only hesitation with removing the wheel is purely down to the fact that I've never done that before in my life, let alone jacked up a car. I've watched videos online from various people but I still get nervous about things like that. It's probably something where if I do it, I'll wonder what all the fuss was about... I'm quite new to car repairs in general but I do electronics repairs in my spare time so I'd like to think (hopefully not arrogantly so!) that I could learn this stuff over time with it being somewhat of a distant cousin, so to speak.

It's already booked in at the garage for Wednesday next week as I'd much rather it be done well than risk making the car worse. They were already going to do brake fluid, brake discs and brake pads anyway so they have agreed to also fit the DRL part that I've sourced.

Probably for the best, if you are unsure jacking a car up, people have been crushed . I agree once you have done it a couple of times you will wonder what all the fuss was about, but the first time, it is best if someone more familiar with it is there to guide you.

 

[The Panda Nut]

Thanks for the reply bugsymike! I totally agree that this is one of those "got to be there" situations. Not sure about accessing the car from underneath, ideally need the bumper off anyway to replace the front badge (hands too big to just remove the four top bolts, gently pull the bumper away and reach inside) as well as check for the fog light wiring connector as I'm looking to retrofit fog lights if I'm lucky enough to have that present.

My only hesitation with removing the wheel is purely down to the fact that I've never done that before in my life, let alone jacked up a car. I've watched videos online from various people but I still get nervous about things like that. It's probably something where if I do it, I'll wonder what all the fuss was about... I'm quite new to car repairs in general but I do electronics repairs in my spare time so I'd like to think (hopefully not arrogantly so!) that I could learn this stuff over time with it being somewhat of a distant cousin, so to speak.

It's already booked in at the garage for Wednesday next week as I'd much rather it be done well than risk making the car worse. They were already going to do brake fluid, brake discs and brake pads anyway so they have agreed to also fit the DRL part that I've sourced.

I have a dremmel with cutting discs that are about 2cm diameter. Using part worn discs allows cutting in confined spaces. Often you dont need to cut entirely through to weaken things enough to break free.

 

[John202020]

If that's the one where the wing meets the bumper near the headlight the the nut was originally welded to the wing, I accidentally snapped one of ours right out the wing edge, at least it was out and actually didn't cause an issue being missing, the wing fixing clips held the bumper without issue, given your experience leave it to a garage as removing the six small screws can also be a real pain, ?

 

[Jockstrap]

Good advice above.

The garage could insert rivnuts on both sides. This would help in your bumper removal for the fog lights and your badge.
Also the fog light wiring connector is likely to be hung up so ask the garage to check and possibly make accessable from the wheel arch?

 

[puntodeltathema]

As your garage will be taking the wheel off to do brakes etc then you don't actually need to remove the bumper to get to the left-hand DRL. Removing the wheel arch liner gives you enough access. Not so on the right hand side where the washer bottle is in the way...and the bumper does have to come off for that one.

 

[aliclubb]

I have a dremmel with cutting discs that are about 2cm diameter. Using part worn discs allows cutting in confined spaces. Often you dont need to cut entirely through to weaken things enough to break free.

Thanks for the suggestion The Panda Nut! I don't own a dremel so just going to leave this one to the garage. They're an independent that specialise in Fiat and Alfa Romeo who I've used before, so I'm sure they'll have had this happen at least once before.

 

[aliclubb]

If that's the one where the wing meets the bumper near the headlight the the nut was originally welded to the wing, I accidentally snapped one of ours right out the wing edge, at least it was out and actually didn't cause an issue being missing, the wing fixing clips held the bumper without issue, given your experience leave it to a garage as removing the six small screws can also be a real pain, ?

Yes it is. If it was welded on, it isn't anymore. It suddenly gave way before I even started down the line of using a spanner on the nut itself...

 

[aliclubb]

Good advice above.

The garage could insert rivnuts on both sides. This would help in your bumper removal for the fog lights and your badge.
Also the fog light wiring connector is likely to be hung up so ask the garage to check and possibly make accessable from the wheel arch?

Smashing idea, I'll ask them to do that! I'll probably get them to fit the badge whilst the vehicle is there as it's a sub-two minute job with the bumper off. I'm crossing my fingers that the car has the fog light connector, apparently it's somewhat common/almost guaranteed?

 

[aliclubb]

As your garage will be taking the wheel off to do brakes etc then you don't actually need to remove the bumper to get to the left-hand DRL. Removing the wheel arch liner gives you enough access. Not so on the right hand side where the washer bottle is in the way...and the bumper does have to come off for that one.

Tis the driver side that needs replacing so washer bottle is in the way sadly.

 

[Jockstrap]

Let us know how you get on.

Not my neck of the woods, but should be helpful for others nearer you.

 

[aliclubb]

Let us know how you get on.

Not my neck of the woods, but should be helpful for others nearer you.

Have had to reschedule the works for 11th of March. Will report back here after then!

 

[aliclubb]

An update for anyone who was/is interested. The car has been to the garage and they have done a number of pieces of work on it:

• Whoever had the bumper off previously had done an absolutely dreadful bodge job, the mechanic at the garage had to grind off/cut both of the bolts in order to remove the bumper. He has replaced them with proper a proper nut and bolt setup on each side.
• They fitted my second-hand driver-side (I used the wrong terminology earlier in my post, I should have said off-side, sorry about that, I don't drive!) DRL unit for me.
• They Tiger sealed the passenger side DRL unit back into place as it had partially come away from the bumper.
• Chucked on my reclaimed front badge whilst the bumper was off (no charge as it's a 30 second job with the bumper off).
• Brake fluid replaced.
• Brake discs replaced.
• Brake pads replaced.
• Cam belt and water pump replaced - There was no record of the belt having been done in the last 5 years so I asked them to do it because why tempt fate? This also seems to have fixed the rough idle and jerkiness at very low speeds. Oh and for anyone wondering, yes, they did do the phonic wheel relearn procedure after changing the cam belt!
• Diagnosed that I could very well have a faulty thermostat as the heating inside does not run red hot when on max. They thought it could be air bubbles but I said the heating has never been red hot, but has been more than adequate.

Total for all of this, parts and labour + VAT, came to ~£780 which I felt was somewhat decent, though I'm no expert in good pricing as before May last year, we had never owned any vehicles and the 500 was only purchased late January this year. This was at The Fiat and Alfa Romeo Specialists in Bury St. Edmunds and from the experiences I have had with them, I would definitely recommend them. They also did a full service on the 500 earlier in the year which was ~£260 and included a full inspection, standard fluid changes, filters and spark plugs.

Thanks again to everyone who took the time to reply to this thread, even though it ended up being a garage job, at least for someone with my current skillset and experience.

 

[spleenharvester]

lol I knew exactly which bolt this was going to be, mine are shot on both sides. I had to replace the left side wing after an accident and could not find a single one that didn't still have that rounded off bolt still attached to it. I ended up dremelling both of mine off and it's been perfectly fine without them as long as the clips are intact.

As for the thermostat - you might just have an airlock, I had to fix an absolutely god awful one on mine today that was so bad it would only blow out cold air even when the coolant got hot enough for the radiator fan to kick in, it seemed like the entire heater core was airlocked. After a lot of bleeding it now runs very hot within a few minutes as long as the fan speed is on low. These cars are very prone to coolant leaks so there's any number of ways it could have gotten in. (But if it's the original thermostat then do consider replacing it with the metal version - the original thermostat has a plastic flange which is notorious for suddenly catastrophically failing and dumping your coolant out at speed).