I am having a problem removing the radiator shrowd. I have removed all the pins and screws that are mentioned in step 7 of Callway's instructions. However it still feels like there is something holding it in place and I don't wan't to force it.

In section 7 of the Callaway instructions it mentions as the final step "Pull gently on the front fascia and remove (2) screws holding the sides of the radiator shrowd".

I could not find the screws they were talking about so maybe I have missed them.

I took a picture below of the screws and pins I did remove for anyone in the know to say I missed some. You will notice there is one pin by it's lonseome (center of picture) that was from the side of the shrowd there is a second one but the other fell down and is still ratteling around.



The side wings of the shrowd are below a metal support and I am wondering if need to force it on top of the metal support that it is underneath before I pull the shrowd up. You can see the metal support it has the silver clip on the end of it. I have a picture of the side wing and the metal support that it is underneath.

 

Have you been looking from under the car? It's been a while, but I seem to remember having the same problem and found them under there, looking up from the bottom. I had the front jacked up and it made it much easier.

 

Yes I have been underneath with a light looking here there and everywhere but I can't see anyting I missed.

 

I really like my honker but there instructions were not the best IMO. I had to bend the hell out of the shroud to get it out, over the metal tab. I thought it would break but it didn't. Others have had the same problem. An extra pair of hads will help, it's a bitch to get back in too. I don't want to say for sure but I think you have everything out that you need to.

 

I have a sneeking feeling as well. I tried bending those wings over top of the metal tab as well but I stopped for fear of breaking it as well. So I am clear you bent the plastic wings over top of the metal tab on both sides before you could pull it out?

 

Why can't you cut the shroud in the car? Slide a piece of aluminum, plexiglas, or anything to protect from cutting into the condenser.

 

You probably could cut it in place if you were very limber and had great dexterity but I would rather have more freedom to do it out of the car. I just got off the phone with Callaway and spoke to one of their tech's and there are two things that he enlightened me on.

1) The instructions for step 7 are incorrect and there are only 5 screws where the instructions say 7 screws as I was concerned the fact it was not coming out had to do to the fact it was still attahced somewhere.

2) The shroud is a B*tch to get out as you need to force the side wing over the metal bracket on each side. The tip he gave me was to slide the shrowd as far over to one side before trying to pull the wing on top of the metal bracket, he said it will give you about another 3/8" of play.

I'll give her a shot tonight with with my new found knowledge, and he said yes it is just as fun putting it back in.

 

Yep, you just have to force it out. After a couple of hours of tring to find some other way to get it out I just got mad and yanked it out. It is a very clean looking install when it's all said and done! To bad we are not closer I'd be glad to help you out, good luck!

 

Thanks for the offer, I'll be closer to PA in August when I am down at Carlisle. I'll try channeling some of that anger tonight when I get home from work to try and get her out.

 

Maybe I'll see you there, I only live about 30min away.

One other thing, when you drill the holes in the frame that holds the air cleaner you don't need to drill the hole way through it. Don't think it tells you that in the instruction either. Not that you can see when it all together but still wish I wouldn't have.
Kane

 

Well thanks for all the info I got a good anger on, grunted, groand and did a lot of cursing but I finally got that &%$!@ shroud out. Holes are drilled and it's all marked to cut the hole out tomorrow night after work.

I hope reinstalling it is not any harder than removing it.

 

No, not any harder. Mine kept getting hung up on the temp senser when I was putting it back in.

 

I noticed the temp sensor is held in place by a little clip that is easily removed. I am tempted to remove it and reinstall after the shroud is back in. I am just afraid my big meat paws may have difficulty getting down there to reinstall the sensor and press the clip back in.

 

Don't you just LOVE how instructions make things sound so easy?

I haven't seen the instructions for the Callaway intake, but I'm sure they read something like this: 'Remove screws securing radiator shroud and lift shroud clear of engine compartment'. Reminds me of the nightmare I had with my exhaust install (posted in another thread)... instructions said words to the effect of 'Remove nuts securing H-pipe to to downpipes and slide collars back'. Ha! How easy that sounds!

Cheers,
Ian.

 

Well they would not want to scare you off by being too truthful of effort. In all honesty like most things I think once you do it for the first time and learn all the tricks and gotchya's the next one would be much easier.

The instructions could be a little more detailed with pictuers but rarely are instructions from any vendor picture perfect. I must say when I called Callaway yesterday for advice they put me in touch with an installer right away who was very friendly and helpful.

 

I am watchning your progress with some interest, as I have a Honker waiting to be instaled. I want to run it at the strip first to get a baseline before I put it on. Please keep us informed what you think of it after you finish and what performance you feel you gained. Good luck. Larry

 

I thought about removing the temp senser too, but if I remember right I could hardly reach the darn thing, so I just worked around it.

 

Well for those that are following my gripping saga. I cut the shrowd and rivited the bottom assembly into place (thanks NMK for the pointer on not needing to drill all the way through).

I actually found putting the shroud back in easier than the removal even manouvering those pesky side wings underneath the metal tab at the bottom of each side.

I messed up and lost one of the push pins that goes on the side wings half way up the shrowd (there is one of these on each side) and the two push pins that affix the shrowd to the bumper I found were very loose when I put them back in and were not as snug as when I removed them. I attibute that to the fact that the type of push pin they are is a pin within in a pin kind of like a wall anchor and a screw where the screw when you screw it in expands the wall anchor. I did not know that at the time so I just reifed on the pin and pulled it out without removing the center piece first. I'll have to head to the dealer and see if I can purchase the pins separeately. Hopefully they don't say they only sell them with the shrowd .

After putting the shrowd back in (less the couple of pins) I then tackled inserting the MAF assembly in the Honker. Well I must say it was a battle. That is one mighty tight rubber gasket on the honker and even right now it is not in properly. I got so pooped trying to put it in snugly I gave up. I was thinking it was cold today outside and the plastic and rubber was cold so I brought the assembly inside to warm up and the MAF assembly make it difficult to get some good leverage on to push it it. I will try it again tomorrow. I know that putting a little lubircant on the assembly would assist but I don't want to risk putting any sort of comtaminangt so close to the MAF sensor to possibley corrupt it.

We will see what happens tomorrow we are close and within site of the finish line. Provided I properly oriented the template and cut the shrowd properly and the honker lines up with the TB, God please let it line up

 

You can get all kinds of push pins at lowes, there are .50 for a bag of two. That's what I did, I'm sure it's cheaper than the dealer.

You could try soapy water to help get the honker and MAF together. Mine was a tight fit too.

 

No Lowes in my area but we have a Home Depot I'll try them for the push pins. I finally did get the MAF assembly in. After bringing it into the house and letting it warmm up over top of one of the furnace floor vents it went right in.