Saab 2000-06

Camshaft, Bearings & Lifters

Print

Bearing Replacement



2.0L & 2.3L Engines
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Ignition module cartridge
     
    Valve cover
     
    Crankcase ventilation hose
     

  4.  
  5. Position the crankshaft at Top Dead Center (TDC). The 0 mark on the flywheel should align with the timing mark on the bell housing end plate. The camshafts should be lined up with their respective timing marks.
    WARNING
    Use a proper holding tool to hold the camshafts from rotating. Always keep the camshafts in their correct basic setting. If the setting of the crankshaft or camshafts is altered at this stage the valves can be damaged.



    Oil pipes
     
    Center bolts securing the camshaft sprockets
     



    Timing chain tensioner
     
    Camshaft sprockets
     

  6.  
  7. Mark the bearing cap positions and relation to the front of the engine. The caps must be installed in their original location.
  8.  
  9. Loosen the camshaft bearing cap bolts 1 turn at a time to avoid uneven valve spring pressure on the camshafts. When all bolts are loose, remove the bearing caps and lift out the camshafts.
  10.  

To install:

  1. Place the camshafts in their proper positions and install the bearing caps in their original location.
  2.  
  3. When installing the bolts, tighten them 1 turn at a time to draw the camshaft down evenly against the valve springs. Torque the bearing cap bolts to 11 ft. lbs. (15 Nm).
    NOTE
    The black bolts have an oiling passage and must be installed on the spark plug side.

  4.  
  5. Install or connect the following:

    Camshaft sprockets. Exhaust cam is installed first. Hand-tighten the center bolts securing the camshaft sprockets.
     
    Timing chain tensioner with the piston under tension. Be sure the copper gasket is in good condition and that the sealing surface is clean and free from burrs. Torque the tensioner to 47 ft. lbs. (63 Nm).
     

  6.  
  7. Trigger the chain tensioner by pressing the pivoting chain guide against it. Thereafter, press the pivoting guide against the chain to give the chain its basic tension. Check that the chain tensioner maintains tension on the chain when the pressure on the chain guide is released and that the basic setting stop for the tensioner holds the chain guide tight against the chain. A limited amount of play will be present until the hydraulic pressure takes over once the engine is running.
  8.  
  9. Depress the pivoting guide to check that the tensioner is working. Rotate the crankshaft 2 complete turns clockwise, viewed from the transmission end. Be sure the crankshaft and camshaft timing marks still align properly.
  10.  
  11. Hold the camshafts in their proper position and torque the cam sprocket bolts to 49 ft. lbs. (67 Nm).
  12.  
  13. Install or connect the following:

    Oil pipes
     
    Valve cover and torque the bolts to 11 ft. lbs. (14 Nm)
     
    Crankcase ventilation hose
     
    Ignition module cartridge
     
    Negative battery cable
     

  14.  
  15. Start the engine, check for leaks and repair if necessary.
  16.  

2001-02
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Negative battery cableIgnition module cartridgeValve coverCrankcase ventilation hose

    Negative battery cable
     
    Ignition module cartridge
     
    Valve cover
     
    Crankcase ventilation hose
     

  4.  
  5. Position the crankshaft for TDC. The 0 mark on the flywheel should align with the timing mark on the bell housing end plate. The camshafts should be lined up with their respective timing marks.0
  6.  
  7. Remove or disconnect the following: Oil pipesCenter bolts securing the camshaft sprockets.

    Oil pipes
     
    Center bolts securing the camshaft sprockets.
     

  8.  


WARNING
Use a proper holding tool to hold the camshafts from rotating. Always keep the camshafts in their correct basic setting. If the setting of the crankshaft or camshafts is altered at this stage the valves can be damaged.



Timing chain tensioner
 
Camshaft sprockets
 

  1. Mark the bearing cap positions and relation to the front of the engine. The caps must be installed in their original location.
  2.  
  3. Loosen the camshaft bearing cap bolts 1 turn at a time to avoid uneven valve spring pressure on the camshafts. When all bolts are loose, remove the bearing caps and lift out the camshafts.
  4.  

To install:

  1. Place the camshafts in their proper positions and install the bearing caps in their original location and position.
  2.  
  3. When installing the bolts, tighten them 1 turn at a time to draw the camshaft down evenly against the valve springs. Torque the bearing cap bolts to 11 ft. lbs. (15 Nm).
  4.  


NOTE
The black bolts have an oiling passage and must be installed on the spark plug side.

  1. Install or connect the following: Camshaft sprockets. Exhaust cam is installed first. Hand-tighten the center bolts securing the camshaft sprocketsTiming chain tensioner with the piston under tension. Be sure the copper gasket is in good condition and that the sealing surface is clean and free from burrs. Torque the tensioner to 47 ft. lbs. (63 Nm).

    Camshaft sprockets. Exhaust cam is installed first. Hand-tighten the center bolts securing the camshaft sprockets
     
    Timing chain tensioner with the piston under tension. Be sure the copper gasket is in good condition and that the sealing surface is clean and free from burrs. Torque the tensioner to 47 ft. lbs. (63 Nm).
     

  2.  
  3. Trigger the chain tensioner by pressing the pivoting chain guide against it. Thereafter, press the pivoting guide against the chain to give the chain its basic tension. Check that the chain tensioner maintains tension on the chain when the pressure on the chain guide is released and that the basic setting stop for the tensioner holds the chain guide tight against the chain. A limited amount of play will be present until the hydraulic pressure takes over once the engine is running.
  4.  
  5. Depress the pivoting guide to check that the tensioner is working. Rotate the crankshaft 2 complete turns clockwise, viewed from the transmission end. Be sure the crankshaft and camshaft timing marks still align properly.
  6.  
  7. Hold the camshafts in their proper position and torque the cam sprocket bolts to 49 ft. lbs. (67 Nm). Oil pipesValve cover and torque the bolts to 11 ft. lbs. (14 Nm)Crankcase ventilation hoseIgnition module cartridgeNegative battery cable

    Oil pipes
     
    Valve cover and torque the bolts to 11 ft. lbs. (14 Nm)
     
    Crankcase ventilation hose
     
    Ignition module cartridge
     
    Negative battery cable
     

  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

2003-04
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  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 or disconnect the following:
  10.  
  11. Cover over the ignition coils
  12.  
  13. Ignition coil bolts, lift up each ignition coil and move aside, starting with the ignition coil for cylinder No. 1
  14.  
  15. Crankcase ventilation hose from the camshaft cover
  16.  
  17. Cable duct from the cylinder head and camshaft cover and move it carefully aside
  18.  
  19. Ground lead from the camshaft cover
  20.  
  21. Heat shield over the turbocharger
  22.  
  23. Camshaft cover
  24.  
  25. Right-hand wheel
  26.  
  27. Right fender liner
  28.  
  29. Relieve the pressure on the belt tensioner and remove the belt. Use 83 96 095 belt circuit relieving tool. Mark the belt's direction of rotation.
  30.  
  31. Lower the car and zero the engine by turning the crankshaft in the direction of rotation of the engine until the marking on the crankshaft pulley is aligned with the marking on the timing cover. The cam lobes on cylinder No. 1 intake and exhaust camshafts should be pointing up and in.
  32.  
  33. Remove the exhaust camshaft and intake camshaft bearing shells No. 2 and No. 7. Position the 83 96 046 kit, adjustment tool, camshaft 175 HP and 83 96 079 adjustment tool, camshaft by pressing down the tool by hand onto the camshafts without tightening the bolts.
  34.  
  35. If the adjustment tool does not fit the cam lobes undo the camshaft gear bolts slightly, gripping the camshaft with a spanner on the flats. Tighten the adjustment tool bolts to 7 ft. lbs. (10 Nm).
  36.  
  37. Check that the markings on the crankshaft pulley and the timing cover are in agreement. Tighten the camshaft gear a first step, gripping the camshaft with a wrench on the flats. Tightening torque is 22 ft. lbs. (30 Nm).
  38.  
  39. Remove the adjustment tools and fit the bearing caps. Torque to 6 ft. lbs. (8 Nm). Tighten the camshaft gear to its final torque. Grip the camshaft with a wrench on its flats. Tighten to 63 ft. lbs. (85 Nm), plus an additional 30 degrees.
  40.  
  41. Rotate the crankshaft 2 turns in the direction of engine rotation until the mark on the crankshaft pulley agrees with the mark on the timing cover. Remove the bearing caps and fit 83 96 046 kit, adjustment tool (175 HP engines) and 83 96 079 adjustment tool (B207, 200 HP) again to check the camshaft setting. Remove the adjustment tool and refit the bearing caps. Torque to 6 ft. lbs. (8 Nm).
  42.  

To install:

  1. Raise the car, relieve the belt tensioner and fit the belt in the marked direction of rotation. Fit the right fender liner. Install the front wheels.
  2.  
  3. Lower the car and fit the camshaft cover with new seals. Take care not to disturb the position of the seals when fitting. Torque cover bolts to 8 ft. lbs. (10 Nm).
  4.  
  5. Install or connect the following: Heat shield over turbocharger (make sure clip under heat shield snaps onto holder)Ground cable to camshaft coverCable duct on camshaft coverCrankcase ventilation hose to the camshaft coverIgnition coils (start with coil for cylinder No. 4); torque to 6 ft. lbs. (8 Nm)Cover over the ignition coilsBolts for bracket to camshaft cover; fit fuel pipes in snap fastenersFilter elementCover on air cleaner casingMAF sensor connectorSAI hoseTurbocharger inlet hose to the air cleanerUpper engine cover

    Heat shield over turbocharger (make sure clip under heat shield snaps onto holder)
     
    Ground cable to camshaft cover
     
    Cable duct on camshaft cover
     
    Crankcase ventilation hose to the camshaft cover
     
    Ignition coils (start with coil for cylinder No. 4); torque to 6 ft. lbs. (8 Nm)
     
    Cover over the ignition coils
     
    Bolts for bracket to camshaft cover; fit fuel pipes in snap fasteners
     
    Filter element
     
    Cover on air cleaner casing
     
    MAF sensor connector
     
    SAI hose
     
    Turbocharger inlet hose to the air cleaner
     
    Upper engine cover
     

  6.  

Removal & Installation



3.0L Engine

WARNING
To avoid damage to the valves, DO NOT rotate the camshafts. The crankshaft may only be turned between 0 TDC and 60° BTDC when the camshafts are locked in position with the appropriate locking tool.

  1. Drain the cooling system.
  2.  
  3. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  4.  
  5. Remove or disconnect the following: Negative battery cableFront exhaust pipe from the exhaust manifoldsBracket for the check valvesLower center air deflectorTop engine coversCruise control cable and throttle cableThrottle control rod from the bracketBracket mounting bolt and set the bracket with cables attached to the sideClamps on the air intake pipes at the intake manifold and the mass air flow meterAir intake pipes. Raise them slightlyVacuum hoses and electrical connections and label them for identificationPipes with resonator attachedIntake plenum boltsIdle Air Control (IAC) valve connectorFuel pressure regulator hoseWiring harness from under the throttle bodyThrottle position indicatorIgnition coilTCS connectorsIntake plenum and plug the intake runnersFuel injectorCPS sensor connectorsFuel line connectionsCenter intake manifold and fuel rails and set them asideSpark plug wiresIgnition coil. Bend the ignition coil aside and disconnect the ignition coil bracketLifting eyeHeat shield over the exhaust manifoldResonator bracket and secondary air injection pipe from the exhaust manifoldPower steering reservoirTorque arm engine mount connectionTorque armPower steering line clamp from the torque arm engine mountEngine mountHose from the coolant expansion tankUpper alternator air intakePower steering pump pulleyWater pump pulleySix outer crankshaft pulley bolts

    Negative battery cable
     
    Front exhaust pipe from the exhaust manifolds
     
    Bracket for the check valves
     
    Lower center air deflector
     
    Top engine covers
     
    Cruise control cable and throttle cable
     
    Throttle control rod from the bracket
     
    Bracket mounting bolt and set the bracket with cables attached to the side
     
    Clamps on the air intake pipes at the intake manifold and the mass air flow meter
     
    Air intake pipes. Raise them slightly
     
    Vacuum hoses and electrical connections and label them for identification
     
    Pipes with resonator attached
     
    Intake plenum bolts
     
    Idle Air Control (IAC) valve connector
     
    Fuel pressure regulator hose
     
    Wiring harness from under the throttle body
     
    Throttle position indicator
     
    Ignition coil
     
    TCS connectors
     
    Intake plenum and plug the intake runners
     
    Fuel injector
     
    CPS sensor connectors
     
    Fuel line connections
     
    Center intake manifold and fuel rails and set them aside
     
    Spark plug wires
     
    Ignition coil. Bend the ignition coil aside and disconnect the ignition coil bracket
     
    Lifting eye
     
    Heat shield over the exhaust manifold
     
    Resonator bracket and secondary air injection pipe from the exhaust manifold
     
    Power steering reservoir
     
    Torque arm engine mount connection
     
    Torque arm
     
    Power steering line clamp from the torque arm engine mount
     
    Engine mount
     
    Hose from the coolant expansion tank
     
    Upper alternator air intake
     
    Power steering pump pulley
     
    Water pump pulley
     
    Six outer crankshaft pulley bolts
     

  6.  


NOTE
When removing the crankshaft pulley, remove the 6 outer bolts only, DO NOT remove the center bolt.



Drive belt and tensioner
 
Power steering pump
 
Timing cover
 
Crankshaft pulley
 
Timing belt, tensioner, and camshaft sprockets. Refer to the Timing Belt Unit Repair Section.
 

  1. Rotate the crankshaft back to 60° Before Top Dead Center (BTDC), to prevent damage to the valves.
  2.  
  3. Remove or disconnect the following: Valve cover. Be sure the O-rings stay in position and do not fall into the engineBearing caps. Note the position markings on the bearing caps and loosen the bearing cap bolts in stages of 1/2 to 1 turn at a time

    Valve cover. Be sure the O-rings stay in position and do not fall into the engine
     
    Bearing caps. Note the position markings on the bearing caps and loosen the bearing cap bolts in stages of 1/2 to 1 turn at a time12
     

  4.  


NOTE
The bearing caps located where valve tappets are compressed should be removed last.



Camshafts
 

To install:

  1. Be sure the crankshaft is still positioned at 60° BTDC.
  2.  
  3. Be sure all gasket contact surfaces are clean.
  4.  


NOTE
The camshaft bearing caps are marked L1-l8 for the Front or Left bank and R1-r8 for the Rear or Right bank and the camshaft bearing seats in each head are numbered 1-8.

  1. Thoroughly lubricate the camshafts and install the camshafts with new front camshaft gaskets. Be sure the locating pins are properly positioned. Install the bearing caps in their proper location and position. Tighten the bearing cap bolts in sequence 1/2 to 1 turn at a time, to a torque of 72 inch lbs. (8 Nm).12
  2.  
  3. Install or connect the following: Timing covers

    Timing covers
     

  4.  
  5. Check to be sure that the camshaft locating pins are in the proper position. Check the locating pins, if they are hollow, replace them with solid pins.
  6.  


NOTE
The locating pins of both camshafts 1 & 2 should be point towards the inboard bolts of the camshaft bearing caps. The locating pin for the intake camshaft No, 3 should be pointing downwards, in line with the inboard bolt of the bearing caps. The locating pin for the exhaust No. 4 camshaft should be pointing upwards, in line with the edge of the camshaft sensor.



Camshaft sprockets
 
Tensioner and timing belt. Refer to the Timing Belt Unit Repair Section.
 
Crankcase ventilation housing
 

  1. Be sure the valve cover O-rings are still in position and clean. Lubricate the O-rings with soapy water, apply (81-52-381) sealer at the corners of the large end bearing caps. Valve coverTiming coverCrankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)Water pump pulleyPower steering pump pulleyDrive belt tensioner, and drive beltUpper alternator air intakeTorque arm engine mountPower steering line clampTorque arm and bolt the connection to the torque arm engine mountUpper hose to the coolant expansion tankPower steering reservoirLifting eyeSecondary air injection pipe to the exhaust manifoldExhaust manifold heat shieldResonator bracketIgnition coil bracketIgnition coilSpark plugs and torque them to 19 ft. lbs. (25 Nm)Spark plug wiresCenter intake manifold with fuel railCenter intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)Fuel linesCKP sensorFuel injector connectorsIntake plenum into position and connect the TCS throttle body and torque to 15 ft. lbs. (20 Nm)Throttle position indicator connectorIgnition coil connectorTCS connectorWiring harnessFuel pressure regulator hoseIAC valve connectorLabeled electrical and vacuum connections on the intake manifoldAir intake pipes, with resonator attachedVacuum hoses and electrical connection to air intakeAir intake pipes to the mass airflow meter and intake manifoldThrottle control bracket with cablesThrottle control rodThrottle cable and cruise control cable. Adjust the kick-down cable and the throttle cableUpper engine coversLower center air deflectorBracket for the check valvesFront exhaust pipe to the exhaust manifoldNegative battery cable

    Valve cover
     
    Timing cover
     
    Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Water pump pulley
     
    Power steering pump pulley
     
    Drive belt tensioner, and drive belt
     
    Upper alternator air intake
     
    Torque arm engine mount
     
    Power steering line clamp
     
    Torque arm and bolt the connection to the torque arm engine mount
     
    Upper hose to the coolant expansion tank
     
    Power steering reservoir
     
    Lifting eye
     
    Secondary air injection pipe to the exhaust manifold
     
    Exhaust manifold heat shield
     
    Resonator bracket
     
    Ignition coil bracket
     
    Ignition coil
     
    Spark plugs and torque them to 19 ft. lbs. (25 Nm)
     
    Spark plug wires
     
    Center intake manifold with fuel rail
     
    Center intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    CKP sensor
     
    Fuel injector connectors
     
    Intake plenum into position and connect the TCS throttle body and torque to 15 ft. lbs. (20 Nm)
     
    Throttle position indicator connector
     
    Ignition coil connector
     
    TCS connector
     
    Wiring harness
     
    Fuel pressure regulator hose
     
    IAC valve connector
     
    Labeled electrical and vacuum connections on the intake manifold
     
    Air intake pipes, with resonator attached
     
    Vacuum hoses and electrical connection to air intake
     
    Air intake pipes to the mass airflow meter and intake manifold
     
    Throttle control bracket with cables
     
    Throttle control rod
     
    Throttle cable and cruise control cable. Adjust the kick-down cable and the throttle cable
     
    Upper engine covers
     
    Lower center air deflector
     
    Bracket for the check valves
     
    Front exhaust pipe to the exhaust manifold
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  


WARNING
To avoid damage to the valves, DO NOT rotate the camshafts. The crankshaft may only be turned between 0 TDC and 60° BTDC when the camshafts are locked in position with the appropriate locking tool.

  1. Drain the cooling system.
  2.  
  3. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  4.  
  5. Remove or disconnect the following: Negative battery cableFront exhaust pipe from the exhaust manifoldsBracket for the check valvesLower center air deflectorTop engine coversCruise control cable and throttle cableThrottle control rod from the bracketBracket mounting bolt and set the bracket with cables attached to the sideClamps on the air intake pipes at the intake manifold and the mass air flow meterAir intake pipes. Raise them slightlyVacuum hoses and electrical connections and label them for identificationPipes with resonator attachedIntake plenum boltsIdle Air Control (IAC) valve connectorFuel pressure regulator hoseWiring harness from under the throttle bodyThrottle position indicatorIgnition coilTCS connectorsIntake plenum and plug the intake runnersFuel injectorCPS sensor connectorsFuel line connectionsCenter intake manifold and fuel rails and set them asideSpark plug wiresIgnition coil. Bend the ignition coil aside and disconnect the ignition coil bracketLifting eyeHeat shield over the exhaust manifoldResonator bracket and secondary air injection pipe from the exhaust manifoldPower steering reservoirTorque arm engine mount connectionTorque armPower steering line clamp from the torque arm engine mountEngine mountHose from the coolant expansion tankUpper alternator air intakePower steering pump pulleyWater pump pulleySix outer crankshaft pulley bolts

    Negative battery cable
     
    Front exhaust pipe from the exhaust manifolds
     
    Bracket for the check valves
     
    Lower center air deflector
     
    Top engine covers
     
    Cruise control cable and throttle cable
     
    Throttle control rod from the bracket
     
    Bracket mounting bolt and set the bracket with cables attached to the side
     
    Clamps on the air intake pipes at the intake manifold and the mass air flow meter
     
    Air intake pipes. Raise them slightly
     
    Vacuum hoses and electrical connections and label them for identification
     
    Pipes with resonator attached
     
    Intake plenum bolts
     
    Idle Air Control (IAC) valve connector
     
    Fuel pressure regulator hose
     
    Wiring harness from under the throttle body
     
    Throttle position indicator
     
    Ignition coil
     
    TCS connectors
     
    Intake plenum and plug the intake runners
     
    Fuel injector
     
    CPS sensor connectors
     
    Fuel line connections
     
    Center intake manifold and fuel rails and set them aside
     
    Spark plug wires
     
    Ignition coil. Bend the ignition coil aside and disconnect the ignition coil bracket
     
    Lifting eye
     
    Heat shield over the exhaust manifold
     
    Resonator bracket and secondary air injection pipe from the exhaust manifold
     
    Power steering reservoir
     
    Torque arm engine mount connection
     
    Torque arm
     
    Power steering line clamp from the torque arm engine mount
     
    Engine mount
     
    Hose from the coolant expansion tank
     
    Upper alternator air intake
     
    Power steering pump pulley
     
    Water pump pulley
     
    Six outer crankshaft pulley bolts
     

  6.  


NOTE
When removing the crankshaft pulley, remove the 6 outer bolts only, DO NOT remove the center bolt.



Drive belt and tensioner
 
Power steering pump
 
Timing cover
 
Crankshaft pulley
 
Timing belt, tensioner, and camshaft sprockets.
 

  1. Rotate the crankshaft back to 60° Before Top Dead Center (BTDC), to prevent damage to the valves.
  2.  
  3. Remove or disconnect the following: Valve cover. Be sure the O-rings stay in position and do not fall into the engineBearing caps. Note the position markings on the bearing caps and loosen the bearing cap bolts in stages of 1/2 to 1 turn at a time

    Valve cover. Be sure the O-rings stay in position and do not fall into the engine
     
    Bearing caps. Note the position markings on the bearing caps and loosen the bearing cap bolts in stages of 1/2 to 1 turn at a time12
     

  4.  


NOTE
The bearing caps located where valve tappets are compressed should be removed last.



Camshafts
 

To install:

  1. Be sure the crankshaft is still positioned at 60° BTDC.
  2.  
  3. Be sure all gasket contact surfaces are clean.
  4.  


NOTE
The camshaft bearing caps are marked L1-l8 for the Front or Left bank and R1-r8 for the Rear or Right bank and the camshaft bearing seats in each head are numbered 1-8.

  1. Thoroughly lubricate the camshafts and install the camshafts with new front camshaft gaskets. Be sure the locating pins are properly positioned. Install the bearing caps in their proper location and position. Tighten the bearing cap bolts in sequence 1/2 to 1 turn at a time, to a torque of 72 inch lbs. (8 Nm).12
  2.  
  3. Install or connect the following: Timing covers

    Timing covers
     

  4.  
  5. Check to be sure that the camshaft locating pins are in the proper position. Check the locating pins, if they are hollow, replace them with solid pins.
  6.  


NOTE
The locating pins of both camshafts 1 & 2 should be point towards the inboard bolts of the camshaft bearing caps. The locating pin for the intake camshaft No, 3 should be pointing downwards, in line with the inboard bolt of the bearing caps. The locating pin for the exhaust No. 4 camshaft should be pointing upwards, in line with the edge of the camshaft sensor.



Camshaft sprockets
 
Tensioner and timing belt.
 
Crankcase ventilation housing
 

  1. Be sure the valve cover O-rings are still in position and clean. Lubricate the O-rings with soapy water, apply (81-52-381) sealer at the corners of the large end bearing caps. Valve coverTiming coverCrankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)Water pump pulleyPower steering pump pulleyDrive belt tensioner, and drive beltUpper alternator air intakeTorque arm engine mountPower steering line clampTorque arm and bolt the connection to the torque arm engine mountUpper hose to the coolant expansion tankPower steering reservoirLifting eyeSecondary air injection pipe to the exhaust manifoldExhaust manifold heat shieldResonator bracketIgnition coil bracketIgnition coilSpark plugs and torque them to 19 ft. lbs. (25 Nm)Spark plug wiresCenter intake manifold with fuel railCenter intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)Fuel linesCKP sensorFuel injector connectorsIntake plenum into position and connect the TCS throttle body and torque to 15 ft. lbs. (20 Nm)Throttle position indicator connectorIgnition coil connectorTCS connectorWiring harnessFuel pressure regulator hoseIAC valve connectorLabeled electrical and vacuum connections on the intake manifoldAir intake pipes, with resonator attachedVacuum hoses and electrical connection to air intakeAir intake pipes to the mass airflow meter and intake manifoldThrottle control bracket with cablesThrottle control rodThrottle cable and cruise control cable. Adjust the kick-down cable and the throttle cableUpper engine coversLower center air deflectorBracket for the check valvesFront exhaust pipe to the exhaust manifoldNegative battery cable

    Valve cover
     
    Timing cover
     
    Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Water pump pulley
     
    Power steering pump pulley
     
    Drive belt tensioner, and drive belt
     
    Upper alternator air intake
     
    Torque arm engine mount
     
    Power steering line clamp
     
    Torque arm and bolt the connection to the torque arm engine mount
     
    Upper hose to the coolant expansion tank
     
    Power steering reservoir
     
    Lifting eye
     
    Secondary air injection pipe to the exhaust manifold
     
    Exhaust manifold heat shield
     
    Resonator bracket
     
    Ignition coil bracket
     
    Ignition coil
     
    Spark plugs and torque them to 19 ft. lbs. (25 Nm)
     
    Spark plug wires
     
    Center intake manifold with fuel rail
     
    Center intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    CKP sensor
     
    Fuel injector connectors
     
    Intake plenum into position and connect the TCS throttle body and torque to 15 ft. lbs. (20 Nm)
     
    Throttle position indicator connector
     
    Ignition coil connector
     
    TCS connector
     
    Wiring harness
     
    Fuel pressure regulator hose
     
    IAC valve connector
     
    Labeled electrical and vacuum connections on the intake manifold
     
    Air intake pipes, with resonator attached
     
    Vacuum hoses and electrical connection to air intake
     
    Air intake pipes to the mass airflow meter and intake manifold
     
    Throttle control bracket with cables
     
    Throttle control rod
     
    Throttle cable and cruise control cable. Adjust the kick-down cable and the throttle cable
     
    Upper engine covers
     
    Lower center air deflector
     
    Bracket for the check valves
     
    Front exhaust pipe to the exhaust manifold
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system.
  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

9-5 Models
3.0L Engine

WARNING
To avoid damage to the valves, DO NOT rotate the camshafts. The crankshaft may only be turned between 0 Top Dead Center (TDC) and 60° Before Top Dead Center (BTDC) when the camshafts are locked in position with the appropriate locking tool.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Lower spoiler sections and install wedges between the oil sump and the subframe and the gearbox and subframe
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Water pump and power steering pump pulley bolts
     
    Tension from the V belt
     
    Water pump and power steering pump pulleys
     
    Belt tensioner
     
    Alternator air intake
     
    Timing cover
     
    Crankshaft pulley
     
    Throttle cable
     
    Upper intake manifold vacuum hoses
     
    Pressure sensor connector
     
    Water hoses from the throttle body
     
    Turbocharger pressure hose
     
    Charge air bypass pipe
     
    Vent valve hose from the throttle body
     
    Ignition discharge module
     
    Fuel injector connectors
     
    Fuel lines
     
    Upper and middle intake manifolds
     
    Lower intake manifold and make certain that the markings on the camshaft sprockets and the timing cover are aligned
     
    Tensioning pulley and adjuster rollers
     
    Lower adjuster roller after marking the rotation of the belt
     
    Bracket and tensioning roller and upper adjuster roller. Rotate the crankshaft to 60 degrees BTDC.
     
    Camshaft sprockets
     
    Water pump
     
    Inner timing cover
     
    Camshaft cover
     
    Camshafts
     
    Tappets with special Tool 83-91-401
     

  8.  

To install:

  1. Install or connect the following:

    Valve tappets and rotate the crankshaft to 60 degrees BTDC
     
    Camshafts into position and fit the stuffing boxes and bearing caps
     

  2.  
  3. The locating pin on the camshafts should point toward the inside bolts for the camshaft bearing caps.
  4.  
  5. The locating pin for the intake camshaft should be in line (downward) with the inside bolts for the bearing caps.
  6.  
  7. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head. Torque the bolts, in stages, to 6 ft. lbs. (8 Nm).
    NOTE
    The bearings caps marked L1-L8 are for the cylinder head for 1-3-5 cylinders and the caps marked R1-R8 are for cylinders 2-4-6. The camshaft bearing seats in each cylinder head are numbered 1-8.



    Camshaft cover and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Ignition discharge module
     
    Inner timing cover
     
    Camshaft sprockets properly in relation to the locating pins and torque the bolts to 37 ft. lbs. (50 Nm) plus 60 degrees.
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Bracket with the tensioning roller and the upper adjusting roller
     
    Tool KM-800-1 on camshafts no. 1-2 sprockets and Tool KM-800-2 on no. 3-4 camshaft sprockets
     

  8.  
  9. Rotate the crankshaft just before the O degree make and install Tool KM-800-10. Rotate the crankshaft in the direction of the engine until the arm is lying against the water pump flane. Remove the tool.
    NOTE
    Make sure that the markings on the camshaft belt and correspond with the markings on the camshaft sprocket and the crankshaft.



    Camshaft belt according to the markings on the belt
     
    Loosely install the lower tensioning pulley and make certain that the washer is in place. Adjust the tensioning pulley by hand so that the belt does not jump.
     

  10.  
  11. Install a Crankshaft locking tool. Install Tool 83-93-985 with a cut piece from an old timing belt, to measure belt tension.
  12.  
  13. Snug the center bolts of the adjusting rollers. Turn the lower adjusting roller counterclockwise, until a belt tension of 275-300 Nm is reached. Tighten adjusting roller center bolts to 30 ft. lbs. (40 Nm).
    NOTE
    This adjustment of the timing belt is just preparation and should not be used as a final check.

  14.  
  15. Adjust the tensioner pulley until the marks are aligned. Tighten the tensioner pulley to 15 ft. lbs. (20 Nm).
  16.  
  17. Remove camshaft locking tool from camshaft sprockets 1 & 2. Adjust the upper adjusting roller until sprocket No. 2 moves 1-2mm clockwise. Tighten the upper adjusting roller to 30 ft. lbs. (40 Nm) and remove the upper locking tool.
  18.  
  19. Rotate the engine 2 complete revolutions to just before 0 TDC and install the locking tool on the crankshaft. Carefully turn the crankshaft until the arm of the locking tool is against the water pump flange and tighten the locking tool. Set a locking tool into position on the front of the camshaft sprockets. Be sure that the timing marks on the camshaft sprockets are aligned with the marks on the tool and that the edge of the timing belt is flush with the edge of the camshaft sprockets.
    NOTE
    Also, check that the alignment marks on the tensioner pulley are still aligned.

  20.  
  21. Install or connect the following:

    Lower intake manifold with new gaskets and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Ignition discharge module connectors
     
    Fuel injector connectors
     
    Water hoses and vacuum hose to the throttle body
     
    Turbocharger pressure hose and charge air bypass pipe
     
    Throttle body connector and vent valve
     
    Upper intake manifold vacuum hoses
     
    Pressure sensor electrical connector
     
    Throttle cable
     
    Crankshaft pulley and torque the bolt to 15 ft. lbs. (20 Nm)
     
    Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Belt tensioner and alternator air intake
     
    Water pump and power steering pump pulleys but do not tighten them
     
    V belt and torque the water pump bolts to 6 ft. lbs. (8 Nm) and the power steering pump bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket and torque the bolts to 47 ft. lbs. (63 Nm)
     
    Power steering hose in the holder
     
    MAF sensor and hose and remove the wedges
     
    Negative battery cable
     
    Lower spoiler section
     

  22.  
  23. Fill the cooling system to the proper level.
  24.  
  25. Start the vehicle, check for leaks and repair if necessary.
  26.  

9000 Models

WARNING
To avoid damage to the valves, DO NOT rotate the camshafts. The crankshaft may only be turned between 0 Top Dead Center (TDC) and 60° Before Top Dead Center (BTDC) when the camshafts are locked in position with the appropriate locking tool.

  1. Properly relieve the fuel system pressure.
  2.  
  3. Drain the cooling system.
  4.  
  5. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  6.  
  7. Remove or disconnect the following:
    NOTE
    When removing the crankshaft pulley, remove the 6 outer bolts only, DO NOT remove the center bolt.



    Negative battery cable
     
    Front exhaust pipe from the exhaust manifolds
     
    Bracket for the check valves
     
    Lower center air deflector
     
    Top engine covers
     
    Cruise control cable and throttle cable
     
    Throttle control rod from the bracket
     
    Bracket mounting bolt and set the bracket with cables attached to the side
     
    Clamps on the air intake pipes at the intake manifold and the Mass Air Flow (MAF) meter
     
    Air intake pipes and raise them slightly
     
    Vacuum hoses and electrical connections and label them for identification
     
    Pipes with resonator attached
     
    Intake plenum bolts
     
    Idle Air Control (IAC) valve connector
     
    Fuel pressure regulator hose
     
    Wiring harness from under the throttle body
     
    Throttle Position Sensor (TPS)
     
    Ignition coil
     
    Traction Control System (TCS) connectors
     
    Intake plenum and plug the intake runners
     
    Fuel injector
     
    Crankshaft Position (CKP) sensor connectors
     
    Fuel line connections
     
    Center intake manifold and fuel rails and set them aside
     
    Spark plug wires
     
    Ignition coil. Bend the ignition coil aside and disconnect the ignition coil bracket.
     
    Lifting eye
     
    Heat shield over the exhaust manifold
     
    Resonator bracket and secondary air injection pipe from the exhaust manifold
     
    Power steering reservoir
     
    Torque arm engine mount connection
     
    Torque arm
     
    Power steering line clamp from the torque arm engine mount
     
    Engine mount
     
    Hose from the coolant expansion tank
     
    Upper alternator air intake
     
    Power steering pump pulley
     
    Water pump pulley
     
    Six outer crankshaft pulley bolts
     



    Drive belt and tensioner
     
    Power steering pump
     
    Timing cover
     
    Crankshaft pulley
     
    Timing chain, tensioner and camshaft sprockets
     

  8.  
  9. Rotate the crankshaft back to 60° BTDC to prevent damage to the valves.
  10.  
  11. Remove or disconnect the following:
    NOTE
    The bearing caps located where valve tappets are compressed should be removed last.



    Valve cover. Be sure the O-rings stay in position and do not fall into the engine.
     
    Bearing caps. Note the position markings on the bearing caps and loosen the bearing cap bolts in stages of 1 / 2 to 1 turn at a time.
     



    Camshafts
     

  12.  

To install:

  1. Be sure the crankshaft is still positioned at 60° BTDC.
  2.  
  3. Be sure all gasket contact surfaces are clean.
    NOTE
    The camshaft bearing caps are marked L1-8 for the Front or Left bank and R1-8 for the Rear or Right bank and the camshaft bearing seats in each head are numbered 1-8.

  4.  
  5. Thoroughly lubricate the camshafts and install the camshafts with new front camshaft gaskets. Be sure the locating pins are properly positioned. Install the bearing caps in their proper location and position. Tighten the bearing cap bolts in sequence 1 / 2 to 1 turn at a time, to a torque of 72 inch lbs. (8 Nm).
  6.  
  7. Install or connect the following:

    Timing covers
     

  8.  
  9. Check to be sure that the camshaft locating pins are in the proper position. Check the locating pins, if they are hollow, replace them with solid pins.
    NOTE
    The locating pins of both camshafts 1 & 2 should be point towards the inboard bolts of the camshaft bearing caps. The locating pin for the intake camshaft No, 3 should be pointing downwards, in line with the inboard bolt of the bearing caps. The locating pin for the exhaust No. 4 camshaft should be pointing upwards, in line with the edge of the camshaft sensor.



    Camshaft sprockets
     
    Tensioner
     
    Timing chain
     
    Crankcase ventilation housing
     

  10.  
  11. Be sure the valve cover O-rings are still in position and clean. Lubricate the O-rings with soapy water, apply (81-52-381) sealer at the corners of the large end bearing caps.

    Valve cover
     
    Timing cover
     
    Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Water pump pulley
     
    Power steering pump pulley
     
    Drive belt tensioner, and drive belt
     
    Upper alternator air intake
     
    Torque arm engine mount
     
    Power steering line clamp
     
    Torque arm and bolt the connection to the torque arm engine mount
     
    Upper hose to the coolant expansion tank
     
    Power steering reservoir
     
    Lifting eye
     
    Secondary air injection pipe to the exhaust manifold
     
    Exhaust manifold heat shield
     
    Resonator bracket
     
    Ignition coil bracket
     
    Ignition coil
     
    Spark plugs and torque them to 19 ft. lbs. (25 Nm)
     
    Spark plug wires
     
    Center intake manifold with fuel rail
     
    Center intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    CKP sensor
     
    Fuel injector connectors
     
    Intake plenum into position and connect the TCS throttle body and torque to 15 ft. lbs. (20 Nm)
     
    TPS connector
     
    Ignition coil connector
     
    TCS connector
     
    Wiring harness
     
    Fuel pressure regulator hose
     
    IAC valve connector
     
    Labeled electrical and vacuum connections on the intake manifold
     
    Air intake pipes, with resonator attached
     
    Vacuum hoses and electrical connection to air intake
     
    Air intake pipes to the mass airflow meter and intake manifold
     
    Throttle control bracket with cables
     
    Throttle control rod
     
    Throttle cable and cruise control cable. Adjust the kick-down cable and the throttle cable.
     
    Upper engine covers
     
    Lower center air deflector
     
    Bracket for the check valves
     
    Front exhaust pipe to the exhaust manifold
     
    Negative battery cable
     

  12.  
  13. Fill the cooling system.
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.
  16.  

 
label.common.footer.alt.autozoneLogo