Hmmm…what else can I take out of the car?

airbag crash sensor[4]airbag sensor[4]Okay.  So.  I stripped out the dash…removed a bunch of stuff yesterday.  I only had a couple hours to do things today (because I slept-in…hehe).  So, I just kind of wondered out with coffee in hand to see what I could get rid of.  The first thing was to remove the rest of the crash sensors from the airbag system.  With the computer and the airbag gone…these sensors sure weren’t gonna do any good. I removed the interior sensor yesterday, but the body sensors were still on the car.  There are three:

  1. One in the front of each front wheel well.
  2. One right next to the hood latch.

airbag sensor connector[4]

airbag connector[4]

As before, all the airbag connectors are two piece, with an orange connector that has to come off first, and a blue connector that is held on by the orange.  However, since I remove the computer and airbag yesterday I didn’t need to be all that careful about it….there’s nothing to trigger.  Each of the wheel well sensors has a long cable that runs all the way back to the engine compartment through a grommet up under the fender.  First I disconnected the orange/blue connectors.  Both of these are pretty hard to get to.  On the drivers side it is underneath the relay mounting bar.  I didn’t really want to remove, I got a big flat bladed screw driver and jamed it into the connector and twisted.  Ta-da!  Both connectors came off in one twist.  Similarly, on the passenger side it is located underneath the fuse box.  Again with the screw driver.

airbag sensor cable[4]

airbag sensor passage[4]

Once the connectors are loose and the sensors are unbolted, it is a simple matter to pull the grommet out of the hole, and pull the connectors on through.  At a little over one pound each…its quite a good amount of weight.  It doesn’t seem like all that much, but that is the way most of the weight comes off the car 5-10 lbs at a time.

I also removed the stock tie downs.  I didn’t take pictures of these, but they are 3/16” steel welded plates and bent steel rod with 3 large bolts.  I think they weighed about 3 lbs each.  Again…just a few pounds, but its another 6 lbs gone.  I’m keeping a running tally of weight removed in another post Weight Removed.
power steering actuator[4]

While I was in the engine compartment I removed the cruise control actuator.  This is the large vacuum cylinder, with cable headed back to the firewall.  The cable has a small clip that attaches to the master cylinder.  The harder part is getting the grommet out of the firewall.  There are four tabs on the plastic plug…two on top and two on bottom.  It seems like it takes 5 hands to push the tabs down and force the plug through the hole.  Plus, its work right around the most crowded part of the firewall with the pedals and steering column and wireing harness to get in the way.  Anyway, about 15 minutes of swearing and out popped through.  Another couple pounds.
a-post trim

At this point, I just started looking at the car for more things to remove.  There’s not much left under the “dash”.  The bits in the engine compartment need parts to replace the existing ones (SP inductions for the stock airbox…for example).  Anyway, I figured the A-post and overhead trim has to come off someday, and the door panels, too…why not today? The trim bits were simple.  The toughest bit was the rear view mirror.  There is a small spring-clip that holds the mirror on, and two screws that hold the spring clip.  then all the trim bits are just held in with spring posts.  If you plan on saving the trim, then take them off from the top down (head piece first).  There a a couple of plastic tabs that angle downwards.    If you pull from the bottom up these will get broken off.

On to the door panels.  I didn’t really take enough pictures here, but its all pretty simple.  There is a single screw in the door latch….then it slides out.  Then the Door handle has three screwsspeaker coverspeaker.  The panel itself is only held in by friction clips.  Simply slide a flat bladed screw driver under the edge and slide it around the perimeter until you find the first clip.  Pry it and it pops right out.  Repeat around the sides and bottom.  Then the whole panel is hanging from the window ledge.  Lift it away.  Under the door panel was a plastic sheet.  This is held on by this tar like goo.  It must be just about the stickiest stuff on earth.  Oh my gosh!  First the speaker cover and speaker needed to be removed.  The cover was held in by more clips.  Same trick…off.  4 horribly rusted screws held the speaker.  Now that plastic….

I used a razor knife to cut the plastic close to the door latch.  Then I began the process of pulling the plastic loose from the tar without getting too much of it on me.  Once the plastic was off…the tar….hmmm….I tried to use a putty knife to scrape it off.  Didn’t really work very well.  it mostly just spread the stuff around.  Some would come up…then it would “restick” and roll under the knife.  Okee dokee.  So, I got out a can of mineral spirits and begin to rub.  It dissolved pretty well.  Well that was good, anyway.  But, it was clearly going to take a number of rags and a good bit of mineral spirits to get it all off.  After an hour or so I had most of it off.  No reason to get too carried away…the metal bits are all coming off eventually before the cage goes in.

stick goo all gone

The finished door.  I got started on the drivers door, but we had a party to go to…so, I only got the handle and panel removed.  I still have the tar left to remove on that side.  The door bits weighed another 6 lbs each.  The glass, window mechanism, and inner steel panel should weigh another 40-50 lbs or so.  The cage that will go back weighs about 20-25 lbs.  So, it will be a net gain of about 25 lbs per door.

All told for the day it was another 25 lbs removed from the car.

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