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Re: the plastic clips at the top of the boiler are broke.
Hi It is very ahrd to replace any of the clips on the terminals, but you can use heat shrink tubing and form an insulator on the ends. Remember its heat SHRINK, so make the covers a little longer before you shrink.
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Here is a quick guide to taking apart your rio and re-gluing the scroll wheel.
This is the most common part to break on the rio carbon but is reasonably easy to fix.
How to disassemble a Rio Carbon:
First take off the front plate (you may want to warm it up, not fry it, with a hairdryer to make the removal easier.
Then you will see near the bottom there are two holes
which if you get a very small screwdriver then you can unclip 2 of the
clips holding the back plate on.
Then pry your screwdriver between the back of your rio
and the rubber and lever the back off slightly (you may want to get a
cocktail stick/match stick etc. to keep this open) then on each side
you should see two more metal clips holding the back plate on. Lever
each of these clips and the back plate should pop off - don't force it
or you might break the plastic.
Then you will be able to see at the top left your scroll wheel (or where it should be!)
How to attach the scroll wheel:
The scroll wheel was originally attached on by two connections which you should b able to see - these were the weakest joints on your player and kind of lets rio down because the rest of the player is great in my opinion even though it does break a lot.
basically all you have to do is glue these back on...
Place a little epoxy glue on the points of contact (you can use super glue or a hard plastic adhesive but often they are too brittle so if you drop it again it will almost definitely break)
The leads terminate in a plastic shroud which is held on to the distributor cap by a barbed clip. This must be carefully levered away from the cap socket by a small amount to get the lead off. The trouble is the plastic becomes brittle with age and heat, and is prone to breaking when you try this. The clip can be seen in this photo (some ignition leads come down at the top instead of the side as here)
No idea to be honest never seen a monte carlo but when i get this i just break it off with a screwdriver then stick it back on with contact adhesive as plastic goes brittle with age so i dont bother i just break things with a screwdriver as have you ever slashed a finger or hand on a plastic clip thingy .sorry my hands are more important than a car especially a 1985 one
you have to p?sh the little clip thing on the side of the connector for it to come off and as they get older they become more brittle ,because i value my hands i have become ruthless with these connectors and if they will not push in i push a screwdriver down the side where the push in bit is and break the plastic apart ,then change the sensor or whatever and when i refit i just put a bit of contact adhesive on the connector to hold it on ,Yes i know its a right cowboy job but i have had one two many deep cuts from bits of plastic and now i just dont care as to me my hands are my living and the car is plastic bits and as such they are expendable .
If it is the small wiring harness that runs across the timing cover then it simply un clips (these are prone to breaking of the clips as the heat makes the plastic brittle).
I have used cable ties to re secure the wiring , as long as it clears all moving parts it will work.
Order the replacement boiler, (be sure to empty all of the hot water from the boiler first using the hot water function on the right side of your Solis) take your time and open the machine up, the top comes off. There are 3 mounting screws that hold the boiler in place, remove them, be sure to take hold of the boiler before removing the last mounting screw. Remove and replace the wires and 2 water hoses (w/clips). The orange wires the connect to a unique plastic harness are clipped into the harness. Look closely and you'll see a little window in the plastic harness at the end of each orange wire. Use a tooth pick or a pointed device and push the metal clips thru these windows, this unlocks the wires for removal from the boiler.
Here's the step by step procedure from the beginning.
Carefully remove the black one inch wide plastic molding strip that runs along the interior side of the tail light. This can be pried off carefully without breaking the plastic clips that hold it in place.
Using a 10mm socket, remove the two bolts that you see which secure the tail light housing.
The tail light housing is also held in place with three or four plastic clips which can be broken rather easily if you don't do this next step carefully. Begin prying the plastic tail light using a plastic putty knife or screwdriver. The top clip comes out pretty easily and so does the bottom one.
On a cold winter day, the middle clip is the one that can break rather easily so gently rock the tail light or wait for warm weather when the plastic isn't brittle.
Once the tail light "bucket" is removed it's a simple matter to replace the bulbs.