100k maintenance decisions - need help!

[Gregory_tolson]

100,000 mile maintenance items. Have you:

1. Refreshed the DISA valve? The pin design is a flaw that needs to be addressed north of 100k miles. Mine was half way from falling out into the intake. I replaced it with the German Auto Solutions kit. Its pricey for the materials but worth it.
2. Changed Gear Oil and Transmission fluid?
3. Changed any suspension? Rear Springs are known to crack.
4. Changed Spark Plugs?
5. Resolved all oil leaks? Valve Cover gasket and Oil Filter housing gasket?
6. Changed Engine Mounts?

Definitely change CCV and very good job changing all the cooling items. Im dreading doing that one.

[fernando306]

100,000 mile maintenance items. Have you:

1. Refreshed the DISA valve? The pin design is a flaw that needs to be addressed north of 100k miles. Mine was half way from falling out into the intake. I replaced it with the German Auto Solutions kit. Its pricey for the materials but worth it.
2. Changed Gear Oil and Transmission fluid?
3. Changed any suspension? Rear Springs are known to crack.
4. Changed Spark Plugs?
5. Resolved all oil leaks? Valve Cover gasket and Oil Filter housing gasket?
6. Changed Engine Mounts?

Definitely change CCV and very good job changing all the cooling items. Im dreading doing that one.

Hey my friend,

1 - Fully rebuilt the DISA with the upgraded kit from X8R.
2 - Yes, both trans and diff.
3 - Changed all springs, struts and bump stops
4 - Brand new plugs
5 - Valve cover gasket changed, now I will do the Oil Filter housing.
6 - No. I haven't noticed the need for it, but might do it just for the heck of it (it's easy).

Will do the PCV.

My friends, how about the heater core hoses? There are two, one long and easy to replace, and one small that attaches to the back of the engine to the heater core. Looks like it is a nightmare to change. Are these known to fail? Overkill to replace those?

[Gregory_tolson]

100,000 mile maintenance items. Have you:

1. Refreshed the DISA valve? The pin design is a flaw that needs to be addressed north of 100k miles. Mine was half way from falling out into the intake. I replaced it with the German Auto Solutions kit. Its pricey for the materials but worth it.
2. Changed Gear Oil and Transmission fluid?
3. Changed any suspension? Rear Springs are known to crack.
4. Changed Spark Plugs?
5. Resolved all oil leaks? Valve Cover gasket and Oil Filter housing gasket?
6. Changed Engine Mounts?

Definitely change CCV and very good job changing all the cooling items. Im dreading doing that one.

Hey my friend,

1 - Fully rebuilt the DISA with the upgraded kit from X8R.
2 - Yes, both trans and diff.
3 - Changed all springs, struts and bump stops
4 - Brand new plugs
5 - Valve cover gasket changed, now I will do the Oil Filter housing.
6 - No. I haven't noticed the need for it, but might do it just for the heck of it (it's easy).

Will do the PCV.

My friends, how about the heater core hoses? There are two, one long and easy to replace, and one small that attaches to the back of the engine to the heater core. Looks like it is a nightmare to change. Are these known to fail? Overkill to replace those?

I think any rubber hoses have to be addressed. Did you change the plastic tube underneath the intake manifold? I would assume the heater core hoses would be ideal to change when intake manifold is removed. Whats unfortunate is RealOEM does not show the PN of the heater core hoses. These are those tubes underneath the intake manifold:

[fernando306]

Found on FCP Euro!
11537502525 and 11531705210.

Do these really tend to fail? It's getting expenssssssive...

[fernando306]

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[BumpyZ4]

IMG_9510.jpg

You have to loosen the engine mount and jack the engine to get the water pump out. German engineering at it's finest!!

[BumpyZ4]

Found on FCP Euro!
11537502525 and 11531705210.

Do these really tend to fail? It's getting expenssssssive...

I replaced mine at @96K because I had the intake off for the CCV and they were EXTREMELY brittle where the go into the engine block. I would definitely change them if you have the intake off.

[fernando306]

Got the pump out by undoing the motor mounts and jacking it up!
The water pump looks flawless lol. I wish it had the manufacturing date on it to know whether it is stock or has been replaced already.

[enuff_zed]

Got the pump out by undoing the motor mounts and jacking it up!
The water pump looks flawless lol. I wish it had the manufacturing date on it to know whether it is stock or has been replaced already.

Even though it may look flawless, a lot of times it's the bearing that starts to fail. Then the slightest movement allows water past the seal into the area in front of the bearing. If you look underneath you'll see a drain hole which is the tell tale for bearing failure.
So even if the impeller looks good, there's no knowing the state of the bearing.

[fernando306]

What is the part number of this pulley? Funny, I can't seem to find it on FCP Euro!

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[enuff_zed]

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[fernando306]

Indeed FCP Euro didn't have it. Had to order from ECS Tunning.
Okay, so here's what we're doing:

- Belts, tensioners and pulleys
- Cooling system overhaul, all new parts.
- CCV system (got the winter version)
- Oil filter bracket gasket and valve cover gasket
- Control Arm bushings
- Motor mounts
- Got the wheels refurbished and new Continental tires on them.

Just that.

[tug]

Brilliant work. Your zed will be in excellent working order for the long trip. Wouldnt it be funny (probably not!) if after all this fine work, 15 miles into the trip you get a flat tyre!

[DMike]

Indeed FCP Euro didn't have it. Had to order from ECS Tunning.
Okay, so here's what we're doing:

- Belts, tensioners and pulleys
- Cooling system overhaul, all new parts.
- CCV system (got the winter version)
- Oil filter bracket gasket and valve cover gasket
- Control Arm bushings
- Motor mounts
- Got the wheels refurbished and new Continental tires on them.

Just that.

If you are replacing the tensioner (M54 i presume?) too, then sourcing an old design oem spring tensioner may prove hard. That was superseded by a hydraulic tensioner, oem made by INA and, comparing them side by side, the old design is flimpy compared to the new one. INA has a nice retrofit kit for the conversion.

[fernando306]

My friends, what are the torq specs for these?

- Intake Manifold
- Throttle body
- Vanos unit (I'm replacing that gasket too)
- Valve cover
- The 6 oil filter bracket bolts
- Water pump
- Control arm bushings 31126783376

Lots of things to put together!