Refresh Tasks

Project Repair

Intake Remove and clean cabin filter and enclosure

Intake Remove and clean engine vanity covers

Intake Remove and clean airbox

Intake Disconnect brake booster

Intake Remove bulkhead walls at back of engine bay

Intake Disconnect intake boots and MAF

Intake Remove DISA (check for resistance when removing)

Intake Inspect DISA flapper

Intake Remove throttle body

Intake Remove ICV

Intake Detach injector harness

Intake Release pressure and detach fuel rail

Intake Remove air distributor

Intake Blow out area around intake

Intake Disconnect SAP solenoid hose, vacuum canister

Intake Remove oil dipstick tube and cover opening

Intake Remove intake manifold, clean mating surface and block ports with cloths

Intake Clean manifold and air distributor

Intake Clean ICV and throttle body with throttle cleaner

Fuel System Replace fuel pump

General Jack car

General Remove gravel pan

Cooling Remove fan shroud

Cooling Remove fan

Cooling Drain coolant at radiator

Cooling Drain coolant at block and replace plug 25Nm (18 ft-lbs)

Cooling Remove cooling parts: (if not new)

1. Expansion tank
2. Radiator upper and lower hoses
3. Disconnect temp sensor
4. Remove radiator

Cooling Remove belts and pulleys

Cooling Remove thermostat

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Cooling Remove water pump

Steering Drain power steering fluid at pump

General Drain oil - replace plug & washer - 25Nm (18 ft-lbs)

Fuel System Replace fuel filter

Electrical Replace plugs - 30 Nm (22ft-lb)

Electrical Replace coils

Electrical Label then replace pre-cat O2 sensors - 37Nm (50 ft-lbs)

Electrical Remove alternator

Electrical Remove starter motor

OFHG Remove and clean oil filter housing

Cooling Remove hard lines - VERY DELICATE, MAKE SURE NO PIECES GET INTO
ENGINE

Engine Clean block

Engine Clean timing chain cover

Cooling Install thermostat

1. 3 Identical Bolts 9.9 Nm (7.3 Ft Pounds)
2. Housing bolt right M8X30 24 Nm (17.7 ft-lbs)

Cooling Install water pump - 10Nm (7.4 ft-lbs, 89 in-lbs)

Electrical Repair harness

1. Boots on connectors
2. Fix wire loom

Electrical Harness connections:

1. Exhaust VANOS Solenoid
2. Exhaust camshaft position sensor
3. Thermostat heater - attach with zip tie
4. Intake camshaft position sensor

Intake Remove and replace CCV

Intake Replace air distributor o-rings

Intake Replace o-rings on dipstick

Intake Clean dipstick tube (bottom)

Intake Attach CVV drain line to dipstick

Cooling Replace hard lines - 10Nm

OFHG Re-install oil filter housing with new gasket - 6 bolts - 22Nm (16 ft-lbs)

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OFHG Replace oil filter and cap - 25Nm (18 ft-lbs)

OFHG Attach oil temp sensor - 8.5Nm (6.26 ft-lbs)

OFHG Install VANOS oil feed line - replace washers - 19mm 32 Nm (24 ft-lbs)

OFHG Attach oil pressure sensor - 8.5Nm (6.26 ft-lbs)

Electrical Attach Alternator to housing

1. M8 - 22Nm (16 ft-lbs)
2. M10 bolts: 33Nm (24 ft-lbs)

Electrical Install electrical leads to alternator terminals

1. Terminal B+ M10 / M20 - 5 Nm, all / others - M6 - 7 Nm
2. Terminal B+ S38 / B38 - 8 Nm, all / others - M8 - 13 Nm

Intake Replace crankshaft position sensor - 6.78Nm (60 in-lbs)

Electrical Install starter motor - M10x65 - 42Nm - (31 ft-lbs)

Electrical Attach start electrical leads

1. Starter - Main power line and alternator line to starter - M8 (13 nm)
2. Starter - Electrical leads - M5 (5 nm), M6 (7 nm)

Electrical Harness connections

1. Knock sensors (including zip tie to hard line)
2. Crankshaft position sensor
3. Oil temp sensor
4. Oil pressure sensor
5. Alternator

Oil Pan Gasket Suspend engine

Oil Pan Gasket Disconnect headlight level sensor from passenger control arm

Oil Pan Gasket Detach engine mounts at bottom

Steering Remove steering pressure line

Oil Pan Gasket Detach steering coupler

Oil Pan Gasket Detach front control arm bushings (FCABs)

Oil Pan Gasket Detach and drop front end

Oil Pan Gasket Detach transmission mounts

Oil Pan Gasket Disconnect transmission cooler line support and clean

Oil Pan Gasket Lift engine

Oil Pan Gasket Disconnect oil level sensor

Oil Pan Gasket Remove and clean oil pan

Oil Pan Gasket Replace oil pan gasket and reinstall

1. RTV on joints (rear main seal and front)
2. 8.8 -16Nm (106 in-lbs)
3. 10.9 - 14Nm (10.3 ft-lbs)

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Oil Pan Gasket Re-connect steering coupler - 22Nm (16 ft-lbs)

Oil Pan Gasket Lower engine

Oil Pan Gasket Re-connect transmission cooler line support

Oil Pan Gasket Torque sway bar mounts - 22Nm (16 ft-lbs)

Oil Pan Gasket Re-install

1. Rack bolts - 42Nm (32 ft-lbs)
2. Front subframe to frame rail (10.9 grade) - 109Nm (81 ft-lbs)
3. Engine mounts - 45Nm (33 ft-lbs)
4. Transmission mounts - 21Nm (15.5 ft-lbs, 186 in-lbs)
5. FCABs - 60Nm (44 ft-lbs)

Oil Pan Gasket Replace front control arm brackets - 60Nm (44 ft-lbs)

Oil Pan Gasket Re-attach headlight level sensors 8Nm (72 in-lbs)

Oil Pan Gasket Harness connection:

1. oil level sensor

Oil Pan Gasket Fill oil 7l - put a cup in the filter housing - 25Nm (18 ft-lbs)

Steering Attach power steering pump - 22Nm (16 ft-lbs)

Steering Attach steering fluid reservoir - 22Nm (16 ft-lbs)

Steering Replace steering pressure line

1. Rack - M14 Banjo 35Nm (26 ft-lbs)
2. Pump - replace o-ring - 40Nm (30 ft-lb) - 17mm crows foot
3. Support to rack - 10Nm (89 in-lbs)

Steering Install new reservoir

1. Reservoir to pump - 2 hose clamps
2. Reservoir to radiator return line - 1 hose clamp
3. Rack to radiator return line - M16 Banjo 40Nm (30 ft-lbs)

Steering Fill steering fluid reservoir

Steering Bleed steering rack

Maintenance Flush Differential

1. Remove differential fill screw (stop if it doesn’t come out!)
2. Remove differential drain screw and drain completely
3. Replace drain screw - 52 ft lbs - 70nm
4. Fill using hand pump until level is just at bottom of fill hole
5. Replace fill screw - 52 ft lbs - 70nm

Intake Install O2Pilot mod on intake

Intake Connect coolant hard lines to hoses

Intake Fit intake manifold to head with new gasket - REMOVE 6 TOWELS

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Intake Replace vacuum hoses:

1. SAP to solenoid
2. Solenoid to non-return valve
3. Non-return valve to manifold port
4. Vacuum container to manifold port
5. Fuel pump regulator to upper boot F-connector

Intake Route fuel line through clips

Intake Attach intake manifold - TORQUE BOTTOM NUT

1. M7 Nuts - 15 Nm (11 ft-lbs)
2. Nut below throttle opening - M8 - 22 Nm (16 ft-lbs)
86139
10 4 2 5 7

Engine Replace o-rings on injectors

Engine Install fuel injector clips

Intake Attach fuel rail clips

Intake Connect fuel rail to fuel supply line and attach fuel rail - 10Nm (7 ft-lbs)

Intake Connect injector electrical bus

Intake Connect fuel tank breather line from EGR to canister

Intake Connect CCV oil drain line from dipstick tube

Intake Re-install throttle body to intake with new seal - 10Nm (7 ft-lbs)

Intake Re-attach harness electrical box - 10Nm (7 ft-lbs)

Intake Replace dipstick - REMOVE RAG! - 22Nm (16 ft-lbs)

Intake Re-install Idle Control Valve (ICV) - 10Nm (7 ft-lbs)

Intake Connect fuel filter vent line to f-connector

Intake Install upper and lower intake boot and MAF

Intake Reinstall DISA - 10Nm (7 ft-lbs)

Intake Harness connections:

1. Intake camshaft position sensor
2. SAP solenoid
3. EGR valve
4. MAF
5. DISA
6. ICV
7. Throttle body
8. Intake air temp sensor
9. Intake VANOS solenoid

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Electrical Connections checklist - CONFIRM

1. Intake camshaft position sensor
2. ICV
3. Throttle
4. Oil temp and pressure sensors
5. Alternator
6. EGR
7. Knock sensors
8. MAF
9. DISA
10. IAC
11. Throttle body Crankshaft position sensor
12. Oil level sensor
13. Vacuum solenoid
14. Injectors
15. Intake temp sensor
16. Intake VANOS solenoid

Body Attach brake booster bulkhead panel - connect hose bracket

Intake Re-attach brake booster vacuum line

General Reconnect battery

Pulleys Install new drive belt tensioner - 24Nm (18 ft-lbs)

Pulleys Install new drive belt tensioner pulley - 45Nm (33 ft-lbs)

Pulleys Install new idler pulley - 45Nm (35 ft-lbs)

Pulleys Install power steering pump pulley - 22Nm (16 ft-lbs)

Pulleys Install water pump pulley - 10Nm (7.4 ft-lbs, 89 in-lbs)

Pulleys Install new serpentine belt

Pulleys Clean and re-install AC belt tensioner

1. Tensioner M10-55 - 24Nm (18 ft-lbs)
2. Pulley - 45Nm (33 ft-lbs)

Pulleys Install new A/C belt

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Cooling Install level sensor bottom of expansion tank

Cooling Install expansion tank mounting plate to radiator - remember transmission

cooler piece

Cooling Install expansion tank - remember to secure at base and plate

Cooling Attach radiator

Attach transmission cooling block

Cooling Connect radiator and coolant lines

1. Upper radiator
2. Lower radiator
3. ET return line

Cooling Install fan

Cooling Connections
1. Expansion tank level sensor
2. Fan
3. Coolant temp sensor
4. AUC

Cooling Fill coolant - 8.4l

Cooling Bleed cooling system

General Check coolant level

General Check oil level

General Check brake fluid

Diagnostics Start car and run codes

Diagnostics Check A/C

Diagnostics Test fuel pressure

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Body Attach alternator air ducts

Electrical Connect washer heater temp sensor

Electrical Connect temp sensor

Body Install fender liners

Engine Reinstall engine vanity covers

Fuel Attach fuel filter cover

Intake Reinstall airbox and route harness/power cables

Intake Reinstall fan cowl

Body Re-attach all rubber seals on engine compartments

Intake Install cabin air filter and housing - attach harness

Body Attach reinforcement plate - 59Nm (44 ft-lbs) + 90° + 30°

Body Attach gravel pan

General Drop car

Transmission Drain transmission fluid - REMOVE FILL SCREW FIRST!!!

Transmission Unbolt 22 screws

Transmission Replace drain plug 35Nm (26 ft-lbs)

Transmission Clean pan

Transmission Replace transmission filter 5Nm

Transmission Replace pan gasket and attach 6Nm (4 ft-lbs)

8 4 2 6 10
10 14
13 11
9 5 1 3 7

Transmission Refill transmission fluid

Transmission Fill plug 30Nm (23 ft-lbs)

Body Fix radio reception