Columbus DSM
 2G Turbo FWD Bolt &
Fastener Wizard
 
           

Description
 

 shaft Diameter x thread Size (mm) Length (mm) Thread Length (mm) Head Size (mm) Hardness
           
A/C Belt Tensioner          
     (1x) hex cap nut to hold pulley/bearing onto bracket 10 x 1.25        
     (1x) bolt + lock + 22mm washer 8 x 1.25 20 13 12 4
     (1x) bolt + lock + 22mm washer 8 x 1.25 25 18 12 4
           (longer bolt = slip bolt)          
              (both bolts are notched at end with slight taper)          
           
A/C Compressor attachment to Mounting Bracket          
    (4x) long bolts + lock + 18mm washer 8 x 1.25 100 20 12 7
           
A/C Compressor Mounting Bracket          
    (2x) long bolts + lock + 22mm washer (upper bolts) 10 x 1.25 60 22 14 7
    (2x) short bolts + lock + 22mm washer (lower bolts) 10 x 1.25 25 17 14 7
           
Alternator Mount Bracket to Water Pump          
    (1x) hex cap bolt 8 x 1.25 65 21 12 7
           
Balance Shaft Sprocket - Front Upper to balance shaft          
    (1x) hex cap nut + 24mm washer (2mm thick) 8 x 1.25 16 14 12 10
           
Balance Shaft - Rear Lower to Oil Pump Driven Gear          
    (1x) hex cap bolt 8 x 1.25 16 14 12 10
           
Battery Tray          
    (3x) short bolts 8 x 1.25 20 13 12 4
    (1x) longest bolt - closest to firewall and engine 8 x 1.25 25 18 12 7
 
Brake Fluid Reservoir
    1) the longer bolt passenger side 8 x 1.25 25 18 12 7
        (lock washer on first then 18mm reg. washer)
    2) the shorter bolt with lock washer 8 x 1.25 16 11 12 4
 
Camshaft Bearing Caps to Head
     6 bearing caps x 2 camshafts = 12 caps x 2 bolts = 24 bolts
    (24x) hex cap bolts 8 x 1.25 38 20 12 7
 
Cam Angle Sensor Plate to Camshaft Sprocket
    (4x) Phillips head screws + lock washer 5 x 0.80 10 7 + +
 
Camshaft Sprockets (Cam Gears) to Camshafts
    (2x) hex cap bolts  65 ft. lbs. 12 x 1.25 30 24 17 7
 
Clutch Accumulator
    (3x) bolts + lock + 18mm washer 8 x 1.25 20 13 12 4
           
Clutch Slave Cylinder
    (2x) bolts + lock + 14mm washer 8 x 1.25 55 19 12 4
           
Coolant Overflow Tank to frame          
     1) bolt with 16mm washer under air cleaner (not original bolt) 8 x 1.25 20 20 13 SS
    2) bolt with lock washer and 18mm reg. washer 8 x 1.25 16 9 12 4
           
Coolant Tube (big metal one next to front of block)          
    (connects water pump to thermostat housing)          
    (1x) hex cap bolt - this bolt attaches tube to the block 8 x 1.25 12 10 12 4
           
Downpipe (2.5" Buschur) to Catalytic Converter          
    Gasket          
    1-2) 2 bolts (red coated ones) + lock washers + nuts 10 x 1.50 30 30 17 8.8
           
Downpipe (2.5" Buschur) to EVO III O2 Housing          
    Gasket          
    1-2) 2 nuts and 2 washers  (the length is for the studs) 12 x 1.25 28 24 - -
       (that attach to the studs on the turbo O2 housing)
           
End Plate - Flywheel Side          
    (3x) hex cap bolts 6 x 1.00 14 14 10 7
    (2x) hex cap bolts 6 x 1.00 12 12 10 7
         
Emissions Bracket on back of Intake Manifold          
    (vacuum connectors to Throttle Body) 6 x 1.00 10 10 10 7
    (2x) hex cap bolts
 
Emissions Bracket on Firewall          
    (2x) bolts 6 x 1.00 30 22 10 4
        (lock washer on first then 18mm reg. washer)
           
Exhaust Manifold Heat Shield - Lower          
    (5x) hex cap bolts 8 x 1.25 12 12 12 ?
           
Exhaust Manifold Heat Shield - Upper          
    (3x) hex cap bolts 8 x 1.25 12 12 12 ?
           
Exhaust Manifold to Head          
    (7x) nuts (small) lengths are for the studs  20 ft. lbs. 8 x 1.25 28 20 12 ?
          28mm is how far stud sticks out from block          
         (5x) 18mm washers          
         (1x) 22mm washer 1/16" thick  ???          
         (1x) 22mm washer 1/8" thick   ???          
    (2x) nuts (large) with 20mm washers  21 ft. lbs. 10 x 1.25 28 22 14 ?
           
Flywheel          
    (7x) bolts 12 x 1.25 21 13 17 11
           
Flywheel Lower Cover Plate          
   1 - 3) 3 bolts, all the same with lock washers 6 x 1.00 12 8 10 7
   4) bigger, longer bolt with lock washer 8 x 1.25 18 13 12 7
           
Flywheel Upper Cover Plate          
   (2x) hex cap bolts 6 x 1.00 10 9 10 7
           
Front Case to Block (or belt side end plate) 8 x 1.25 ? ? ? ?
     17 ft. lbs.          
           
Fuel Pressure Regulator          
    (2x) bolts + lock washers 6 x 1.00 12 8 10 7
           
Fuel Rail feed line attachment          
    (2x) bolts + lock washers and Phillips head on hex top 6 x 1.00 16 12 10 +
           
Fuel Rail to Head          
     (3x) round black plastic spacers 10mm thick 22 dia.          
     (3x) hex cap bolts + lock washers 8 x 1.25 65 20 12 4
          8.7 ft. lbs.  (104.4 in/lbs.)          
           
Fuse Box L-bracket          
   Qty: 4 - lock washer on first then 13mm reg. washer 6 x 1.00 16 12 10 4
        (bolt has a notch on end)          
           
Head Bolts          
   (10x) 12-point bolts = 22mm washers (2mm thick) 11 x 1.25 98 29 12 none
           
Hood (attachment to hinge)          
   (4x) bolts + lock + 18mm washer 8 x 1.25 18 11 12 4
          (all bolts and washers painted to match exterior of car)          
           
Intake Manifold to Head          
   (7x) bolts + lock  14 ft. lbs. 8 x 1.25 28 19 12 7
   (2x) nuts + lock to go on studs  26 ft. lbs. 10 x 1.25 29 22 14 ?
          (2nd stud is 30mm not 29mm)          
   (1x) bolt + lock  26 ft. lbs. 10 x 1.25 30 22 14 7
   (The thicker bolt and 1 larger nut goes on motor lift bracket)          
           
Intake Manifold Support Bracket          
   (3x) hex cap bolts  22 ft. lbs. 10 x 1.25 16 14 14 4
           
Motor Mount - Front - Bracket on Tranny          
    1-2) bolts with lock washers 12 x 1.25 30 23 17 7
           
Motor Mount - Passenger          
   1) long bolt through bushing (with cap nut on other end) 12 x 1.25 95 24 17 7
   2-5) 4 cap nuts to hold motor mount to bracket on tranny 12 x 1.25        
           
Motor Mount - Passenger - Bracket on Tranny          
    1-2) bolts with lock washers 12 x 1.25 30 23 17 7
           
Motor Mount - Rear          
   1) long bolt through bushing (with lock washer & nut) 10 x 1.25 90 29 14 7
       (pointed at end for 6mm with no threads at end)          
   2 - 4) 3 bolts attaching mount to frame 10 x 1.25 25 22 14 7
           (tapered ends starting at 5mm, lock washer)          
           
Motor Mount - Rear - Bracket on Tranny          
    1-3) 3 bolts with lock washers 12 x 1.25 30 23 17 7
           
Oil Dipstick to block unknown        
      10 ft. lbs.          
           
Oil Pan to Block          
    16x hex cap bolts (no threads at end until 3mm) 6 x 1.00 13 13 10 7
    3x hex cap bolts  (go on belt end of block) 6 x 1.00 7 6 10 7
           
Oil Pickup          
    gasket          
    (2x) bolts + lock washers  14 ft. lbs. 8 x 1.25 20 16 12 7
           
Oil Pump Sprocket to Oil Pump Drive Gear          
  (usually called the lower/rear balance shaft sprocket)          
    (1x) hex cap nut 10 x 1.25     14  
           
Plastic fender well, passenger side,  transmission cover          
   1 - 2) 2 bolts, both the same, slight taper with notch 8 x 1.25 20 12 12 4
        (lock washer on first, then 22mm washer)          
           
Plastic fender well, passenger side, intercooler cover          
  (uncertain as to the original bolt length and hardness)          
  (replace these with SS bolts with similar length)          
   1 - 2) 2 bolts with 25mm (or 1") washer 6 x 1.00 16 15 10 SS
   3 - 7) black plastic Phillips head snaps          
 
Plastic fender well, driver side, belt-side engine cover          
  (replace these with SS bolts with similar length)          
   1 - 3) 3 bolts, all the same, slight taper with notch 8 x 1.25 20 12 12 4
        (lock washer on first, then 22mm washer)          
           
Plastic fender well, driver side, the big piece          
   1-4) coarse screws, hex cap with Phillips 6 x 1.75 20 19 10 ???
        (pointed - last 5 mm,  threads down to point)          
          (these are the longer screws that go at the fender edge          
           starting at rear of well & go forward to stop at 9 o'clock)          
        (13mm washer)          
   5-8) cap bolts with integrated washer 17mm 6 x 1.00 10 10 10 4
   9-13) black plastic "snaps" with Phillips head plastic screws 6 x 1.00 16 16    
       (rounded at end for 2mm)          
           
Power Steering Pump to Mounting Bracket          
   1) passenger side long adj. bolt in back (lock+18mm wash.) 8 x 1.25 45 20 12 7
   2) passenger side - lower front short bolt 8 x 1.25 22 14 12 -
   3) driver side - top short adj. bolt 8 x 1.25 22 14 12 -
   4) driver side - bottom short bolt 8 x 1.25 22 14 12 -
        (bolts 2 - 4 have lock washers + 16mm reg. washers and          
         Phillips on hex head)          
           
Radiator          
   2 metal brackets with large grommets to hold radiator          
    - each bracket has 2 bolts          
    - 4 bolts with lock washer on first then 18mm reg. washer 8 x 1.25 20 13 12 4
           
Rod to Crank (x4)          
   1 - 2) studs + hex cap nuts 8 x 1.00   26    
     - stud sticks out 35mm          
      - threads start 4mm away from end          
           
Shift Cable Bracket          
   1-2) 2 bolts 8 x 1.25 25 20 12 7
      (lock washer on first, then 22mm stepped washer,          
        stepped part is 14mm dia. 2mm tall - appears to have a          
        rubber edge to it)          
     (washer on other side of cable before bracket 22mm)          
           
Shift Cable Cotter Pins          
   Qty: 2  - 34mm long about 1mm thick          
           
Speed Sensor
    1) on Transmission on top next to rear motor mount 6 x 1.00 25 18 10 4
        (lock washer on first then 22mm reg. washer)
           
Starter          
    1) Lower bolt 10 x 1.25 65 22 14 8
    2) Upper, shorter bolt with wire holder 10 x 1.25 60 22 14 7
           
Thermostat Housing to Block          
    (3x) hex cap bolts 8 x 1.25 25 19 12 7
    (1x) hex cap bolts (bottom right one) 8 x 1.25 50 20 12 7
       (you will need to remove the thermostat elbow to get          
        the bottom right bolt out)          
           
Throttle Body Elbow to Throttle Body          
    gasket
    1-2) 2 long bolts with lock washers - front upper & lower 8 x 1.25 75 19 12 7
    3-4) 2 nuts with lock washers - rear upper and lower 8 x 1.25        
           
Throttle Cable Bracket on back of Intake Manifold          
    1-2) 2 bolts, with notch on end 6 x 1.00 16 11 10 4
       lock washer on first then 13mm reg. washer          
      (ground strap is connected under bolt closest to          
      the driver side then attached to firewall)          
           
Timing Belt Cover - Lower          
    (6x) hex cap bolts 6 x 1.00 18 17 10 7
    (1x) hex cap bolt - longest one (#8 on diagram) 6 x 1.00 28 18 10 7
    (2x) bolt + lock + 18mm washer (#7 & #10 on diagram) 6 x 1.00 25 17 10 7
           
Timing Belt Cover - Middle          
    (3x) hex cap bolts 6 x 1.00 18 17 10 7
    (1x) hex cap bolt - bracket on rear to hold electrical plugs 6 x 1.00 28 17 10 7
           
Timing Belt Cover - Upper          
    (2x) hex cap bolts 6 x 1.00 16 16 10 7
    (1x) hex cap bolt - longest one (#2 on diagram) 6 x 1.00 45 19 10 7
           
Transmission to Block bolts          
  (Not counting the Starter Bolts)          
  Head is on Passenger side          
    1) Closest to Firewall (with wire holder) 10 x 1.25 40 22 14 7
    2) Slightly pointed (threads go down to the point) 10 x 1.25 43 27 14 7
    3) Same as bolt #1 10 x 1.25 40 22 14 7
    4) The long bolt (down low in front) 10 x 1.25 60 22 14 7
  Head is on Driver's side          
    1) On bottom of engine next to driver-side differential 8 x 1.25 60 20 12 10
         (lock washer on first then 18mm reg. washer)  
           
Turbo Oil Drain Line to Oil Pan          
   (2x) bolts + lock + 18mm washer 6 x 1.00 25 18 10 7
           
Turbo Oil Supply Line to Head          
   (1x) banjo bolt + (2x) 16mm copper washers 10 x 1.25 20 12 17 none
           
Turbo to Exhaust Manifold (Big16G turbo)          
   (3x) hex cap bolts + (2x each) 20mm washers 10 x 1.25 80 22 14 11
       (bolts are tapered at end for last 2mm w/o threads)
          20-22 ft. lbs. + 60 to 70 degrees more
   (1x) hex cap nut + 20mm washer to go on stud 10 x 1.25
          20-22 ft. lbs. + 60 to 70 degrees more
 
Valve Cover to Head          
    Inner bolts          
       (6x) bolts + lock washers 6 x 1.00 22 18 10 7
         - plus 2-wire holder attached to one bolt          
    Outer bolts          
       (8x) bolts + lock washers 6 x 1.00 25 17 10 7
           
Water Pump          
    1x hex cap bolt 8 x 1.25 25 21 12 4
    1x hex cap bolt 8 x 1.25 14 12 12 4
    2x hex cap bolts 8 x 1.25 22 20 12 4
           
Water Pump Pulleys to Water Pump          
    larger pulley is on outside, both pulleys cupped inward          
    large pulley = 140mm dia. (5.5")          
    small pulley = 95mm dia. (3.75")          
    (4x) bolts + lock washers 6 x 1.00 14 10 10 7
           
Wheel Nut 22 x 1.50     32  
  Cotter Pin 48mm long          
           
Wiring Harness to Intake Manifold (plastic holder)          
    2 thin metal U-shaped clips to hold electrical plugs on          
    2 bolts with lock washers and 13mm reg. washers 6 x 1.00 16 11 10 4
         (bolts are tapered 3mm at end plus notched)          
           
Y-Plate          
    1 - 4) 4 bolts with lock washers, see image 10 x 1.25 22 16 14 10
    5) The long bolt, see image 10 x 1.25 74 26 14 10
        (lock washer on first, then 22mm reg. washer)          
           

         
           
           
 

This page last updated on 6/17/2003.