9-3 1999

Valve Covers

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Removal & Installation



2.0L Engine
  1. Before servicing the vehicle, refer to the precautions.
  2.  
  3. Remove the engine cover and disconnect the crankcase ventilation hose from the valve cover.
  4.  
  5. Remove the turbo delivery pipe (2 bolts under the wiring harness).
  6.  
  7. Remove the front wiring harness channel and cut the securing points on the rear section of the wiring harness.
  8.  
  9. Remove the wiring harness channel from the cylinder head and disconnect the fuel lines from the camshaft cover.
  10.  
  11. Remove the fastener for the fuel lines on the engine mounting.
  12.  
  13. Remove the camshaft cover.

    Click image to see an enlarged view

    Fig. Apply sealing compound 87 81 841 to the sealing surface as shown (3) and install a new gasket (2) to camshaft cover (4)

  14.  

To install:

  1. Installation is the reverse of removal.
  2.  
  3. Clean any gasket remains from the sealing surfaces on the camshaft cover.
  4.  
  5. Install a new gasket to the camshaft cover.
  6.  
  7. Apply sealing compound 87 81 841 to the sealing surface, see illustration.
  8.  
  9. Position the cover on the cylinder head and tighten the bolts to 72 inch lbs. (8 Nm).
  10.  

2.3L Engine
  1. Before servicing the vehicle, refer to the precautions.
  2.  
  3. Remove the upper engine cover.
  4.  
  5. Unplug the MAF sensor connector. Detach the SAI hose. Undo the turbocharger inlet hose and remove the filter casing cover. Remove the filter element.
  6.  
  7. Detach the fuel pipes from their snap fasteners and remove the bracket bolts from the camshaft cover.
  8.  
  9. Remove the cover over the ignition coils.
  10.  
  11. Remove the ignition coil bolts, lift up each ignition coil and move aside, starting with the ignition coil for cylinder #1.
  12.  
  13. Remove the crankcase ventilation hose from the camshaft cover.
  14.  
  15. Remove the cable duct from the cylinder head and camshaft cover and move it carefully aside.
  16.  
  17. Remove the ground lead from the camshaft cover.
  18.  
  19. Remove the heat shield over the turbocharger.
  20.  
  21. Remove the valve cover.
  22.  

To install:

  1. Install the camshaft cover with new seals. Take care not to disturb the position of the seals when installing. Torque cover bolts to 8 ft. lbs. (10 Nm).
  2.  
  3. Install the heat shield over turbocharger (make sure clip under heat shield snaps onto holder).
  4.  
  5. Install the ground cable to camshaft cover.
  6.  
  7. Install the cable duct on camshaft cover.
  8.  
  9. Install the crankcase ventilation hose to the camshaft cover.
  10.  
  11. Install the ignition coils (start with coil for cylinder No. 4); torque to 6 ft. lbs. (8 Nm).
  12.  
  13. Install the cover over the ignition coils.
  14.  
  15. Install the bolts for bracket to camshaft cover; install fuel pipes in snap fasteners.
  16.  
  17. Install the filter element.
  18.  
  19. Install the cover on air cleaner casing.
  20.  
  21. Install the MAF sensor connector.
  22.  
  23. Install the SAI hose.
  24.  
  25. Install the turbocharger inlet hose to the air cleaner.
  26.  
  27. Install the upper engine cover.
  28.  

 
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