Part 1: Battery Removal

Time: 6 Minutes   Difficulty: 3/10

Step 1: Locate the battery's negative terminal.


Step 2: Loosen the nut that secures the terminal using a 10mm socket or 10mm wrench.


Step 3: Once the nut is loose, lift the terminal off the pole and place it aside.


Step 4: Lift the red cover off the positive terminal


Step 5: Loosen the nut that secures the terminal using a 10mm socket or 10mm wrench.


Step 6: Lift off the terminal and place it aside.


Step 7: Loosen the two nuts that secure the battery holder using a 10mm deep socket.


Step 8: Pull the hook back so that it disconnects from the battery holder.


Step 9: Unhook the other side and lift out the battery tie down.


Step 10: Make sure everything is out of the way and carefully lift out the battery.


Step 11: If the plastic battery tray is dirty, remove and clean it.

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Part 2: Air Box Removal

Time: 12 Minutes   Difficulty: 3/10

Step 1: Disconnect the mass air flow sensor connector and place the wires out of the way.


Step 2: Loosen the two bolts that secure the air box using a 12mm socket.


Step 3: Un-clip the coolant lines from the air box cover.


Step 4: Loosen the clamp that secures the intake boot to the turbo inlet using a flat head screw driver.


Step 5: Pull back and lift up the intake boot.


Step 6: Push the air box towards the motor so that the rubber piece on the air box is free.


Step 7: Lift up on the air box and carefully remove it.

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Part 3: Intercooler Removal

Time: 10 Minutes   Difficulty: 3/10

Step 1: Disconnect the three air hoses from the intercooler.


Step 2: Separate the by pass valve from the intercooler by removing the two bolts using a 12mm socket.


Step 3: Remove the two bolts that secure the intercooler to the brackets using a 12mm socket.


Step 4: Loosen the clamp that secures the intercooler tube to the turbo using a 10mm socket.


Step 5: Loosen the clamp that secures the intercooler to the throttle body using a flat head screw driver.


Step 6: Lift up on the back of the intercooler and remove it.

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Part 4: Lifting Car

Time: 8 Minutes   Difficulty: 4/10

Step 1: Park the car on level ground. Be sure there is enough room to safely work.

Step 2: Make sure the e-brake is engaged and that the car is in gear.

Step 3: Locate the correct jacking point according to what area of the car you are going to be working on.

Step 4: Lift the car enough so that the wheel is off the ground or so that there is enough room under the car to work.

Step 5: Place stand(s) if needed. If you aren't going to use stands, place a safety stand near the jack in case the jack fails.

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Part 5: Coolant Draining

Time: 10 Minutes   Difficulty: 3/10

Step 1: Locate the drain plug on the radiator. Place a bucket under the drain to catch the coolant.

Step 2: Turn the drain plug counter-clock wise to loosen it. Remove the drain plug.

Step 3: Once the coolant is draining, you can open the radiator cap to speed up the draining process.

Step 4: Once all of the coolant is drained, install the drain plug. Be sure not to over tighten it.

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Part 6: Lowering Car

Time: 8 Minutes   Difficulty: 4/10

Step 1: Make sure there is nothing under your car (bolts, tools, friends, etc.)

Step 2: If the car is supported on jack stands, lift the jack until there is no load on the stand. Remove the stand(s).

Step 3: If the car is supported by the jack, remove the safety stand.

Step 4: Once again make sure that it is safe to lower the car.

Step 5: Lower the car and remove the jack.

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Part 7: Coolant Filler Tank Removal

Time: 7 Minutes   Difficulty: 5/10

Step 1: Remove the 2 bolts that secure the top of the tank to the intake manifold using a 12mm socket.


Step 2: Remove the nut that secures the bottom of the tank using a 12mm socket.


Step 3: Pull back the two clamps that secure the two hoses that go from the tank to the radiator.


Step 4: Disconnect the coolant lines.


Step 5: Disconnect the coolant line that goes from the filler tank to the turbo.


Step 6: Disconnect the two air vaccum lines that go to the turbo inlet and place them out of the way.


Step 7: Disconnect the coolant line that is on the bottom of the filler tank.


Step 8: Remove the coolant filler tank.


Step 9: Disconnect the clamp and remove the coolant line that went from the bottom of the filler tank to the block.

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Part 8: Alternator Cover Removal

Time: 5 Minutes   Difficulty: 3/10

Step 1: Remove the bolt that secures the alternator cover using a 10mm socket.


Step 2: Remove the nut that secures the alternator cover using a 10mm socket.


Step 3: Remove the two clips that secure the throttle body cable to the alternator cover using pliers or something to pinch the clips together.


Step 4: Lift up on the alternator cover and slide it off the stud.

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Part 9: Disconnecting Throttle Cables

Time: 13 Minutes   Difficulty: 4/10

Step 1: Loosen the nut on each cable that is closer to the front of the car using a 12mm wrench.


Step 2: Spin that nuts that are closest to the throttle body


Step 3: Pull the cables back so that the non-threaded part can slide up.


Step 4: Lift the cables up and place them aside.


Step 5: Pop off the metal clip that is on the cruise control cable.


Step 6: Lift up on the rollers and maneuver the cable out from the channel.


Step 7: Lift up on the rollers and maneuver the cable out from the channel.


Repeat Steps 6 and 7 to remove the main throttle cable.

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Part 10: Placing Power Steering Pump Aside

Time: 13 Minutes   Difficulty: 4/10

Step 1: Disconnect the power steering pump connector.


Step 2: Remove the three bolts that secure the power steering lines to the brackets using a 10mm socket.


Step 3: Loosen the bolt that secures the alternator to the bracket using a 12 mm socket.


Step 4: Loosen the bolt that holds the tension bolt in place using a 12mm socket.


Step 5: Turn the bolt that lowers the alternator in a clockwise direction.


Step 6: Push down on the alternator so that the belt is loose.


Step 7: Lift the belt off the alternator pully and then move it off the other pullys and remove the belt.


Step 8: Remove the bolt that was secures the alternator to the power steering pump bracket.


Step 9: Remove the three bolts that secure the power steering pump to the block using a 12mm socket.


Step 10: Place the power steering pump aside, just above the abs pump. Keep the lines on the power steering pump connected.

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Part 11: Intake Manifold Removal

Time: 30 Minutes   Difficulty: 8/10

Step 1: Locate the three connectors that are located by the power steering pump.


Step 2: Disconnect the oil pressure switch connector.


Step 3: Disconnect the crankshaft position sensor connector.


Step 4: Disconnect the coolant temperature sensor connector.


Step 5: Disconnect the two coolant hoses from the throttle body.


Step 6: Disconnect the brake booster hose.


Step 7: Disconnect the vacuum line from the turbo inlet.


Step 8: Disconnect the two connectors on the driver side that connect the engine harness to the front harness.


Step 9: Remove the bolt that secures the connector bracket using a 10mm socket.


Step 10: Disconnect the engine harness connector on the passenger side.


Step 11: Disconnect the knock sensor connector.


Step 12: Disconnect the camshaft position sensor connector.


Step 13: On the driver side head, pull back the clip that secures the ignition coil wires.


Step 14: On the driver passenger head, un-do the clip that secures the ignition coil wires.


Step 15: Disconnect the four ignition coil connectors.


Step 16: Disconnect the three fuel lines using a phillips head screw driver and pliers.


Step 17: Remove the eight bolts that secure the intake manifold to the heads.


Step 18: Make sure everything is disconnected and carefully remove the intake manifold. There are a lot of things that the engine harness may get caught on.

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Part 12: Grimmspeed Phenolic Spacer Install

Time: 5 Minutes   Difficulty: 2/10

Step 1: Place the tgv gaskets onto both heads.


Step 2: Place the phenolic spacers on top of the gasket.


Step 3: Place another gasket on top of the phenolic spacers.

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Part 13: Intake Manifold Install

Time: 30 Minutes   Difficulty: 8/10

Step 1: Install the intake manifold carefully, it is very easy for it to get caught on things.


Step 2: If the power steering pump was not removed it will be easier to connect the camshaft position sensor connector, knock sensor connector, and crankshaft position sensor connector before while maneuvering the intake manifold into place.


Step 3: Make sure there is a good seal between the intake manifold, phenolic spacers, and heads and that the phenolic spacers and gaskets are aligned correctly.


Step 4: Install the 8 bolts and washers that secure the intake manifold to the heads using a 13mm socket. Tighten the bolts to 18.1 foot pounds of torque using a torque wrench.


Step 5: Connect the three fuel lines. Secure the clip on the evaporation line and tighten the two clamps that secure the fuel feed and return lines using a phillips head screw driver.


Step 6: Connect the four ignition coil connectors.


Step 7: On the drivers side head, connect the clip that secures the ignition coil harness.


Step 8: Connect the oil pressure switch connector.


Step 9: Connect the coolant temperature sensor connector.


Step 10: Connect the connectors on the passenger side that connect the engine harness to the bulkhead harness.

Step 11: Tighten the bolt that secures the engine harness to front harness connector bracket using a 10mm socket.

Step 12: Connect the two connectors on the driver side that connect the engine harness to the front harness.

Step 13: Connect the vacuum line from the turbo inlet.


Step 14: Connect the brake booster hose.


Step 15: Connect the two coolant hoses to the throttle body.


Step 16: Connect the vaccum hose to the pcv valve.


Step 17: If you didn't remove the power steering pump connect the power steering pump connector.


Step 18: If you didn't connect the camshaft position sensor connector, knock sensor connector, and crankshaft position sensor connector in step 4, connect them now.

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Part 14: Power Steering Pump Install

Time: 13 Minutes   Difficulty: 4/10

Step 1: Disconnect the power steering pump connector.


Step 2: Remove the three bolts that secure the power steering lines to the brackets using a 10mm socket.


Step 3: Loosen the bolt that secures the alternator to the bracket using a 12 mm socket.


Step 4: Loosen the bolt that holds the tension bolt in place using a 12mm socket.


Step 5: Turn the bolt that lowers the alternator in a clockwise direction.


Step 6: Push down on the alternator so that the belt is loose.


Step 7: Lift the belt off the alternator pully and then move it off the other pullys and remove the belt.


Step 8: Remove the three bolts that secure the power steering pump to the block using a 10 mm socket.


Step 9: Remove the bolt that was loosened to allow the alternator to be lowered.


Step 10: Place the power steering pump aside, just above the abs pump. Keep the lines on the power steering pump connected.

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Part 15: Connecting Throttle Cables

Time: 13 Minutes   Difficulty: 4/10

Step 1: Loosen the nut on each cable that is closer to the front of the car using a 12mm wrench.


Step 2: Spin that nuts that are closest to the throttle body


Step 3: Pull the cables back so that the non-threaded part can slide up.


Step 4: Lift the cables up and place them aside.


Step 5: Pop off the metal clip that is on the cruise control cable.


Step 6: Lift up on the rollers and maneuver the cable out from the channel.


Step 7: Lift up on the rollers and maneuver the cable out from the channel.


Repeat Steps 6 and 7 to remove the main throttle cable.

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Part 16: Alternator Cover Install

Time: 5 Minutes   Difficulty: 3/10

Step 1: Install the alternator cover.

Step 2: Install the nut and bolt that secures the cover using a 10mm socket.

Step 3: Install the two clips that secure the throttle cables to the alternator cover.

Step 1: Remove the bolts that secures the alternator cover using a 10mm socket.


Step 2: Remove the nut that secures the alternator cover using a 10mm socket.


Step 3: Remove the two clips that secure the throttle body cable to the alternator cover.


Step 4: Lift up on the alternator cover and slide it off the stud.

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Part 17: Coolant Filler Tank Install

Time: 5 Minutes   Difficulty: 5/10

Step 1: Connect the lower coolant line to the coolant pipe that goes to the block and secure it with a clamp.


Step 2: Connect the coolant line to the bottom of the tank and clamp the hose to secure it.


Step 3: Install the 2 bolts that secure the top of the coolant tank to the intake manifold using a 12mm socket.


Step 4: Install the nut that secures the bottom of the tank using a 12mm socket.


Step 5: Connect the two air vaccum lines that go to the turbo inlet.


Step 6: Connect the coolant line that goes from the filler tank to the turbo and install the clamp to secure it.


Step 7: Connect the two coolant lines that go to the radiator and install the clamps to secure the hoses.

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Part 18: Air Box Install

Time: 12 Minutes   Difficulty: 3/10

Step 1: Install the air box lower case.

Step 2: Secure the air box lower case to the body by securing the two bolts using a 12mm socket. Tighten the bolts to 24.6 foot pounds of torque using your torque wrench.

Step 3: Install the air box upper cover to the air box lower case by aligning correctly.

Step 4: Secure the air box upper cover to the lower case by securing the two clamps.

Step 5: Secure the intake boot to the turbo inlet by tightening the clamp using a flat head screw driver.

Step 6: Connect the mass air flow sensor connector.

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Part 19: Intercooler Install

Time: 15 Minutes   Difficulty: 5/10

Step 1: Install the top mount intercooler. Be sure that the two throttle body clamps and the intercooler turbo pipe clamps are already on the hoses.


Step 2: Tighten the clamp that secures the intercooler air duct to the turbo using a 10mm socket.


Step 3: Tighten the clamp that secures the intercooler to the throttle body by tightening the clamps using a 8mm socket or a flat head screw driver.


Step 4: Secure the intercooler to the brackets by tightening the two bolts using a 12mm socket. Tighten the bolts to 11.7 foot pounds of torque using a torque wrench.


Step 5: Place a new gasket between the bypass valve and intercooler. Secure the by pass valve to the intercooler by tightening the two bolts using a 12mm socket. Tighten the bolts to 11.7 foot pounds of torque using a torque wrench.


Step 6: Connect the three air hoses to the intercooler.

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Part 20: Battery Install

Time: 6 Minutes   Difficulty: 3/10

Step 1: Install the plastic battery tray.


Step 2: Make sure everything is out of the way and lower the battery onto the tray.


Step 3: Place the battery tie down into position.


Step 4: Hook both rods under the battery.


Step 5: Evenly tighten the two nuts that secure the battery holder using a 10mm deep socket.


Step 6: Place the positive connector onto the terminal.


Step 7: Tighten the nut that secures the connector using a 10mm socket or 10mm wrench.


Step 8: Place the red cover over the positive terminal


Step 9: Place the negative connector onto the negative terminal.


Step 10: Tighten the nut that secures the connector using a 10mm socket or 10mm wrench.

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Part 21: Coolant Filling

Time: 10 Minutes   Difficulty: 2/10

Step 1: Remove the coolant filler tanks cap.


Step 2: Fill the coolant reservoir tank until full.


Step 3: Install the coolant filler tanks cap and clean up any coolant that spilled.


cars with manual transmissions take 8.1 quarts of coolant.
cars with automatic transmissions take 7.3 quarts of coolant.

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