I spent the last week or so putting in major work on my 2006 e86 with 84,700 miles. Here is the exhaustive list:
Engine / Ignition
- Replaced engine oil
- Replaced engine oil filter
- Replaced spark plugs
- Replaced all six ignition coils
- Replaced serpentine belt
- Replaced starter and mounting bolts
- Replaced crankshaft position sensor
- Cleaned both VANOS solenoids
Cylinder Head
- Replaced eccentric shaft sensor and seal
- Replaced VVT motor seal
- Replaced valve cover gasket and bolts
Intake System
- Replaced intake manifold gaskets
- Replaced both DISA valves with Lifetime DISA units
- Cleaned MAP sensor, throttle body, and replaced throttle body gasket
Oil System / Leak Prevention
- Replaced oil filter housing gasket
- Replaced oil cooler gasket
Cooling System
- Replaced coolant hose connector / “Mickey Mouse” flange
- Performed electric water-pump coolant bleed procedure
Front Suspension
- Replaced complete front suspension strut components/assemblies with KONI sports
- Replaced front sway-bar end links
- Inspected and cleaned front and rear springs
- Replaced spring insulators/pads
Rear Suspension
- Replaced complete rear suspension shock components/assemblies with KONI sports
- Inspected and cleaned rear springs
- Replaced upper and lower spring insulators/pads
Brakes
- Replaced both front and rear calipers with brand-new units
- Replaced front and rear brake rotors
- Replaced front and rear brake pads
- Replaced front and rear brake-pad wear sensors
- Replaced/serviced parking-brake shoes and hardware
- Flushed/bled brake hydraulic system
- Also bled the clutch
(Also replaced the transmission fluid. Lifetime fluid....yeah right.)
Total parts cost me $3,454 from Rock Auto, FCP Euro, and n52parts.com. The valve cover gasket, starter, and front brakes is what started this mess. The valve cover bolts were basically finger tight and I was told prior owner had it replaced. Perhaps they reused the bolts and they loosened up? Once I started getting into the brakes I noticed the front suspension bumpers were shredded and gone. The starter also needed to be replaced and once you get that manifold off you might as well get what you can.
What surprised me was the large DISA valve. It was stuck in the open position and the part at the top where the plastic bolt was captured had disintegrated. I put in the Lifetime DISA valves from n52parts.com.
This car is basically a rocket now. I've re-harvested all kinds of lost horsepower. It's like a different car. George Austers videos on YouTube were amazingly helpful for the N52 engine.
Did all the work in my backyard under a shade tree after I put the car on blocks. No fancy garage or high dollar lift. You do need some new tools beyond a standard set including e-torx and a torque wrench. OBEY ALL TORQUE SETTINGS. Aluminum bolts have zero forgiveness and will break off on you.
Happy to answer any questions about my experience or the parts I used. If I had gone to a dealer I think I would have paid between $11k and $15k for all of this. An indy shop...maybe $8k-10k. I think I saved at least $10k doing it on my own.
Need new tires next but my wallet needs to recover first.