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Originally Posted by tckma
What I want to know is how to get those f&*@ clips off the underbody cover without breaking them -- they're about $2 bucks each from the cheapest parts place I can find... I break at least one of the nine every time I change the oil. Grr.
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Yep, Dzus fasteners aren't cheap. If you notice the next time you're under the car, you should see 2 very slightly raised straight lines molded into the head of the clip (on the Honda OEM clips, at least). Look carefully; they're hard to see. If you put your flat-blade screwdriver parallel to those lines, and pry gently between the inner head and the outer ring, a bit at a time from each end, they'll pop off enough where you can just pull them out with your hand, without breaking. However, I don't think they'll last forever, even taking them off the right way.
To insert them, stage the clip so that it's just short of starting to engage the outer lock and push it outward (ie; put the inner stud in about halfway. Then squeeze the outer jacket if needed, and put it into the hole until the outer ring seats against the surface of what you're fastening. Finally, push the inner stud in until it seats.
One thing I do is to try and position those line markers all generally facing the same way. That might be a bit anal for some, but it sure makes it easier for me to take them off the next time. I *will* say that when they put them on at the factory, those line markers are in all different directions - so it sometimes makes it hard to get the screwdriver in at the correct angle to pry on the clip. Another reason I line them up when I reinsert them.
Mine seem a little bit weaker, after having been on / off three times - and I haven't broken one yet, btw. They're all over the car, too. Had to remove a bunch when I put my hitch on a couple months ago.
One other thing on those undercover clips - on my '06, they're in at least 2 (if not 3) different sizes. Make sure you match them up - if you try to jam a larger clip into one of the smaller holes, it's a real pain to get it in - then you realize you put the wrong clip in, and say "to h#ll with it - I'm not taking that out again"

Larger clips are toward the back of the undercover, I think - can't remember offhand.
You want to know something ? I've had half the clips off my front undercover for a good three months now because I cracked mine, ordered a new one, then decided to wait for my next service to replace it. You could potentially leave some of the clips off the engine undercover in strategic places, and make it easier on yourself. You should still have the two 10mm bolts holding the front part to the frame crossmember - as long as you don't run over anything really big, they should hold the undercover in place.
The downside is that you'd have a slightly dirtier undercarriage - to me, it's nice working on a nice clean engine - the undercovers help a lot with that. I doubt that you'd take much of an aero hit, to be honest - mine hasn't changed, and I don't hear any extra noise, etc.