Post-Purchase Inspection / Service Checklist

Service Items

• Engine Oil & Filter Change
• Transmission Oil Change
  • Clean drain plug (including in the valley using a pick).
• Transfer Case Oil Change
  • Clean drain plug.
• Differential Oil Change
  • Clean drain plug.
• Brake Fluid Flush
• Clutch Fluid Flush
• Power Steering Fluid Flush
• Coolant Flush
• Fuel Sender Antiseize
  • Disconnect the rubber line from the fuel sending unit under the car first, then from the fuel sender (counter-torquing the flex pipe to avoid bending and creasing it). Apply liberal antiseize to both ends of this hose and reconnect.
• Exhaust Antiseize
  • Exhaust hardware notoriously seizes with heat cycles. Apply copper-based antiseize to all hardware that is not already seized.
• Skirt / Bumper Antiseize
  • The flanged bolts that retain the bumpers and skirts often rust very badly and will break. If your vehicle hasn’t fallen victim to this yet, remove the bolts and apply anti-seize to them. This includes the two nuts on each skirt (one at either end).
• Window Regulator Track Grease
  • Apply liberally, helps to avoid breaking the poorly designed window regulators.
• Spark Plugs
  • Clean and regap or replace if electrode degraded.
• Spark Plug Wires
  • Do not use wires without a boot on the valve cover side (such as some series of MSD wires).
• Fuel Filter Change
  • If last change unknown, change.
• Shifter Bushings
  • Inspect and replace if floppy.
• Timing Service (Basic – 60k Miles)
  • Timing Belt (OEM, Contitech, Gates)
  • Water Pump (OEM, Aisin, Hitachi)
  • Timing Belt Tensioner (OEM, Washer Mod)
  • Timing Belt Tensioner Pulley (OEM, Koyo)
  • Timing Belt Tensioner Pulley Bolt (OEM – Grade 8)
  • Timing Belt Idler Pulley (OEM, Koyo)
• Timing Service (Extended – 120k Miles)
  • Cam Seals (OEM, FelPro)
  • Valve Stem Seals (OEM, FelPro)
  • Oil Pump (Many Discontinued, Measure Clearance, Can Adapt NA to TT by Swapping Spring)
• Handbrake Cable Tension
  • Should be fully engaged after 3 clicks, tighten by removing arm rest and tightening nuts on cables.
• 99 Lifters OR Cleaned Stock Lifters
  • Stock lifters can be cleaned with diesel fuel.
• Capacitor Service (Especially 91-93) – We Perform These As a Service
  • ECU (Engine Controller)
  • TCU (Transmission Controller, Automatic Vehicles)
  • Digital Climate Screen (If Equipped)
  • ECS Controller (If Equipped)
  • Gauge Cluster

Repair of Common Failures

• Power Antenna
  • Stripped teeth from mast.
• Dash Defroster Vents
  • Cracked from expanding foam inside dash, remove vents, remove 1/8″ of foam around opening under vinyl (likely with rotary tool), install new vents.

Visual Inspection Items

• Oil Pan Sump
  • No dent on sump, should be concave dome.
• Oil Leaks
  • Observe any oil leaks in the engine bay or under the car and make note of likely locations.
• Wash Test
  • Pressure wash the vehicle and engine bay taking care to angle the water fan to clean behind panel crevices (skirts, door caps, etc) – the amount of dirt this flushes will tell you how likely you will be to uncover hidden rust.
  • Pressure wash off any oil leaks, this will allow you to observe their origin after a short drive as it will not have pooled.
• Inside Gas Tank (Rust / Degraded Ethanol)
  • Open camera app on phone, go to video mode, turn on flash, lower into gas tank with fuel sender out and spin the camera around. Provides good inspection capability.
• Fuel Sender Pipe
  • Ensure no previous poor repair or crease in pipe.
• Bumper L-Shaped Bracketry
  • The bracketry between the front bumper and fenders and the rear bumper and quarter panels notoriously rust. Remove, strip and paint if necessary (POR-15 helps).
• License Plate Bracketry
  • The bracketry that supports the rear license plate commonly rusts. Remove, strip and paint if necessary (POR-15 helps).
• Lower Fenders
  • Beneath the side skirts often rusts the fenders. Inspect, strip and paint if necessary (POR-15 helps).
• Rocker Panels (Rust)
  • If the bracketry between the rear bumper and the rocker panels was allowed to rust, rust may have started on the quarters. Deal with this quickly before it requires a weld-in repair.
• Brake Pads / Rotors
  • Inspect brake pad life and for any grooves in the rotors. Replace if necessary.
• Turbo Shafts
  • Inspect for play in the shafts of the turbos when wiggled gently between your thumb and your finger. Additionally, inspect for any fin damage. Rebuild if necessary.
• Intake Piping
  • Inspect for the presence of any oil in the bubble pipe (right after the MAF), and the Y pipe. Presence may indicate turbo wear or PCV valve failure.
• Rear View Mirror (Fogginess / Delamination)
  • Heat causes the factory mirror to delaminate. Replace if necessary.

Tool Assisted Inspection Items

• Throttle Position Sensor
  • Inspect with multimeter to ensure idle sensor and throttle position sensor (both part of the unit) are functional and calibrated.
• Idle Air Control
  • Remove and inspect for excessive tip play and caked carbon. Clean with throttle body cleaner if necessary. Inspect all 4 coil resistances with multimeter, replace or rebuild if necessary.
• Mass Airflow / IAT / Barometric
  • Ensure intake air temperature, barometric pressure and airflow readings are sensible (scantool helps a lot).
• Alternator Voltage
  • Measure output voltage of alternator and ensure above 13 volts.
• Fuel Pump Voltage
  • Measure voltage at fuel pump to ensure it is in spec.
• Fuel Pump Flow
  • Optionally measure fuel pump flow to ensure replacement is not necessary.
• Boost / Vacuum Leak Test
  • Ensure intake holds a regulated 15psi of air pressure with no leaks. Replace pipes, clamps and seals where necessary.
• Starter Voltage
  • Measure voltage at the starter solenoid when the key is turned to start (disconnected from solenoid) to ensure the ignition switch is not adding too much resistance to the circuit.
• Starter Ground Resistance
  • Measure the resistance from the starter body to the negative battery clamp to ensure grounds are in good condition.

Mod Installation (OEM+)

• Sensor Upgrades
  • Fuel Pressure
  • Manifold Pressure (MAP)
  • Oil Pressure
  • Wideband O2
  • CANBUS Converter to Monitor with Android / OBD2
• Headlight Upgrade (HID or Reputable LED)
• Turn Signal Upgrade w/Flasher (If LED Turn Signals)
• Reverse Light Upgrade (LED)
• Fog Light Upgrade (LED)
• Vacuum Reduction
  • Connect Fuel Pressure Regulator Directly to Plenum
  • Additional Vacuum Reduction at Owner Discretion
• Stereo Upgrade
• Battery Relocation
  • The front washer bottle can be removed as well, and the front sprayers can be fed from the rear tank with the implementation of two solenoids.