Removing the heating air intake panel

If you have a need to remove the Air Intake Panel, in order to access the wiper mechanism etc, then be aware that the plastic panel can age, go brittle, and be liable to break, especially at the outer ends at the narrowest section.

The Workshop Manual does not tell you that there is a clip on the back, at each end of the panel, that goes through the little rubber shroud and clips under the windscreen glass. If it hasn't been disturbed for several years, these clips could be stuck, and too much leverage to remove the panel could cause the latter to break (as mine did!). I found that when refitting the new panel, the easiest way was to open the bonnet and lay the panel roughly in position. Then locate one clip under the screen edge about 50mm from the screen corner, and slide the panel outwards until it's corner was correctly aligned. Fitting the other ends requires a little flexing of the panel, so make sure that this tends to happen in the central section rather than at the end.

Also it is worth mentioning that to initially remove the panel, you need to remove the 6 small round caps that cover the fixing screws. These can become stuck with age, and whilst there are small indentations in the side of the holes to allow a small screwdriver to prise the caps out, if they are stuck as firmly as some of mine were, then there is a good chance you will end up damaging the panel itself. The caps only cost £1.44 +VAT for a new set, so it is probably far better to replace them than struggle. Use something like a corkscrew to pierce through the centre of the cap enough to get a good grip on the cap, and simply pull! Result - no damage to the panel itself.

If you have to buy a new panel, (costing £25.92 +VAT Feb 2002), then the seal that runs along the windscreen glass comes with it, as does the other that seals off the 'underbonnet' bay.