geetee
January 17th, 2009, 05:02 PM
The front fog lights on the UK 2001 onwards model are quite prone to corrosion inside. This is due to dampness getting inside the lamp housing.
These light units are not cheap from Mazda. :confused:
The materials for this repair will cost you about $30 at the most, and the whole job should take no more than 2 or 3 hours to do both lights.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp13.jpg
1. Remove 3 screws that hold up the corner of the splash guard on each side. You should be able to simply bend the splash guard down then, rather than completely removing it.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp2.jpg
2. This reveals the fog lamp fixing. Remove the 13mm nut.
The cable for the lamp is fixed inside the bumper. Its hard to reach, but you should be able to just pull it free. If it breaks the peg, then you can always cable tie it back when you replace the light. Unplug the light unit.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp3.jpg
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp4.jpg
3. Remove as much as you can from the light unit, remove the outer casing screws on the back, and the bulb and cable.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp6.jpg
4. Pop the light in a pre-heated oven at about 150c (or 300f) for about 5 minutes. Keep checking it, but its not plastic so theres no real danger of a catastrophic melting incident!!! :rolleyes:
When it comes out you should be able to prise the glass off quite easily. If its not very easy then pop it back in the oven for a wee while longer.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp5.jpg
5. Remove the beam deflector from the reflector, then give the reflector a good rub down with 600 grit paper. Finish it off with 800 grit.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp7.jpg
6. The products I've used. The paint doesn't need a primer.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp8.jpg
7. Six or 7 decent coats should do it. Leave to dry, preferably overnight.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp9.jpg
8. Using the liquid metal stuff, fill the previously cleaned out glass recess, but don't overfill it. You don't want it all overflowing back into the lens when we clamp it up. Also make sure you replace the beam deflector!!!
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp10.jpg
9. Drop the spotlessly clean glass back in, making sure the small indent in the glass matches the foglight housing. This makes sure you get the correct beam pattern. Clamp it nice and tight, wiping off any overflowing glue.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp11.jpg
This stuff bonds fairly instantly, but I left it for an hour before putting the lamp back together.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp.jpg
The finish is pretty good, and you'd only notice the difference to a standard lamp if you knew it had been done. If your that fussy, you could do both lamps like this. I only did one, and you can't notice the difference. I also cleaned up all the fixings, as they were quite rusty.
Re-fitting is a reversal of the removal procedure. :D
These light units are not cheap from Mazda. :confused:
The materials for this repair will cost you about $30 at the most, and the whole job should take no more than 2 or 3 hours to do both lights.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp13.jpg
1. Remove 3 screws that hold up the corner of the splash guard on each side. You should be able to simply bend the splash guard down then, rather than completely removing it.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp2.jpg
2. This reveals the fog lamp fixing. Remove the 13mm nut.
The cable for the lamp is fixed inside the bumper. Its hard to reach, but you should be able to just pull it free. If it breaks the peg, then you can always cable tie it back when you replace the light. Unplug the light unit.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp3.jpg
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp4.jpg
3. Remove as much as you can from the light unit, remove the outer casing screws on the back, and the bulb and cable.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp6.jpg
4. Pop the light in a pre-heated oven at about 150c (or 300f) for about 5 minutes. Keep checking it, but its not plastic so theres no real danger of a catastrophic melting incident!!! :rolleyes:
When it comes out you should be able to prise the glass off quite easily. If its not very easy then pop it back in the oven for a wee while longer.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp5.jpg
5. Remove the beam deflector from the reflector, then give the reflector a good rub down with 600 grit paper. Finish it off with 800 grit.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp7.jpg
6. The products I've used. The paint doesn't need a primer.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp8.jpg
7. Six or 7 decent coats should do it. Leave to dry, preferably overnight.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp9.jpg
8. Using the liquid metal stuff, fill the previously cleaned out glass recess, but don't overfill it. You don't want it all overflowing back into the lens when we clamp it up. Also make sure you replace the beam deflector!!!
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp10.jpg
9. Drop the spotlessly clean glass back in, making sure the small indent in the glass matches the foglight housing. This makes sure you get the correct beam pattern. Clamp it nice and tight, wiping off any overflowing glue.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp11.jpg
This stuff bonds fairly instantly, but I left it for an hour before putting the lamp back together.
http://img.photobucket.com/albums/v487/nellyeff/Fog%20light%20how%20to/Fogrestocomp.jpg
The finish is pretty good, and you'd only notice the difference to a standard lamp if you knew it had been done. If your that fussy, you could do both lamps like this. I only did one, and you can't notice the difference. I also cleaned up all the fixings, as they were quite rusty.
Re-fitting is a reversal of the removal procedure. :D