Saab 2000-06

Camshaft & Valve Lifters

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Removal & Installation



2.0L And 2.3L Engines-2000-2002 Models
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    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.
  6.  
  7. Remove or disconnect the following:
    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
     

  8.  
  9. Mark the bearing cap positions and relation to the front of the engine. The caps must be installed in their original location.
  10.  
  11. 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.
  12.  

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).
    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).

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

  12.  
  13. Start the engine, check for leaks and repair if necessary.
  14.  

2.0L And 2.3L Engines-2003-06 Models
  1. Before servicing the vehicle, refer to the Precautions 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 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.  

2.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove the camshaft covers.
  8.  
  9. Remove the spark plugs.
  10.  
  11. Remove the coolant port.
  12.  
  13. Remove the camshaft solenoid valve.
  14.  
  15. Remove the camshaft position sensor.
  16.  
  17. Rotate the crankshaft so that the markings on the camshaft sprocket are visible and the indentations align with the cylinder head. Use EN-46105-1 Adjustment tool as a gauge (the camshafts are now in their neutral position).
  18.  
  19. Fit EN-46106 Flywheel locking attachment.
  20.  
  21. Mark the chain and camshaft sprocket so they can be refitted in the same position.
  22.  
  23. Reduce the tightening torque of the bolts holding the camshaft sprockets. Counterhold using an open wrench on the camshaft flats (do not remove the bolts).
  24.  
  25. Fit EN-46108-1 Fixing tool to the camshaft chain on the intake side. Check that the tool grips the chain firmly.
  26.  
  27. Fit EN-46108-2 Fixing tool to the camshaft chain on the exhaust side. Check that the tool grips the chain firmly.
  28.  
  29. Tighten EN-46108 Fixing tool so that the chain is unloaded.
    NOTE
    It is extremely important that tool no. EN-46108 is properly fitted. If the chain is not unloaded when the camshaft sprocket bolts are removed, the automatic chain tensioner is triggered. If this occurs, the timing cover must be removed to adjust the chain tensioner.

  30.  
  31. Remove the camshaft sprocket bolts.
  32.  
  33. Remove the sprockets from the camshafts.
  34.  
  35. Remove the camshaft bearing caps by loosening the bolts in stages-1/2 to 1 turn. It is important that removal ends at the bearing cap where the tappets are loaded. Note the markings on the bearing caps when refitting to ensure that they are in the correct spots.
  36.  
  37. Lift out the camshafts and note the rear marking on the camshafts.
  38.  
  39. Remove the roller rockers and the hydraulic adjuster elements. Store them in order so they do not get mixed up.
  40.  
  41. Cover all return oil ducts in the cylinder head so that the valve cone or contaminants cannot fall down into the engine.
  42.  
  43. Fit EN-46110-eu Valve spring tool.
  44.  
  45. Fit 83 94 173 Air nipple for spark plug hole. Connect compressed air and put the piston and valves under pressure.
  46.  
  47. Press down the valve plate with EN-46110-eu Valve spring tool.
  48.  
  49. Remove the valve cone with a magnet. The compressed air must not be disconnected when the valve cone is removed. Do not press on the valve stem either as counter pressure in the cylinder could reduce and the valve could fall down into the cylinder.
  50.  
  51. Lift out the spring plate and valve spring.
  52.  
  53. Lift out the valve guide seal using 83 94 157 Pliers, valve guide seal.
  54.  

To install:

  1. Clean all parts and check contact surfaces and bearing surfaces for wear.
  2.  
  3. Fit the valve guide seal using 83 94 157 Pliers, valve guide seal.
  4.  
  5. Fit the valve spring and spring plate.
  6.  
  7. Press down the valve plate with EN-46110-eu Valve spring tool.
  8.  
  9. Fit the valve cone using EN-46117 Fitting tool.
  10.  
  11. Unload the valve and remove EN-46110-eu Valve spring tool.
  12.  
  13. Disconnect the compressed air and remove the air nipple.
  14.  
  15. Position the camshafts and use EN-46105 Adjustment tool to check that the camshafts are mounted at the correct angle.
  16.  
  17. Install the bearing caps in order (markings on caps). Start where the cams point down and load the tappets. Tighten the bolts in stages-1/2 to 1 turn. Tighten to 7 ft. lbs. (10 Nm).
  18.  
  19. Install the sprockets with chain on the camshafts. Tighten the bolts by hand.
  20.  
  21. Check that the marks on the chain match the markings on the sprockets.
  22.  
  23. Remove EN-46108-2 and EN-46108-1 Fixing tools.
  24.  
  25. Tighten the bolts of both camshaft sprockets, counter holding with an open wrench on the camshaft flats. Tighten to 48 ft. lbs. (65 Nm).
  26.  
  27. Remove EN-46106 Flywheel locking attachment.
  28.  
  29. Install the camshaft position sensor (555F) using a new gasket. Torque to 7 ft. lbs. (10 Nm).
  30.  
  31. Install the camshaft solenoid valve (695F) using a new seal. Torque to 7 ft. lbs. (10 Nm).
  32.  
  33. Install the coolant port using a new seal and gasket.
  34.  
  35. Install the spark plugs.
  36.  
  37. Install the camshaft covers.
  38.  
  39. Refill the cooling system.
  40.  
  41. Connect the negative battery cable.
  42.  
  43. Start the engine, check for leaks and repair if necessary.
  44.  

3.0L Engines

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 Section.
  4.  
  5. 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 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
     



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

  6.  
  7. Rotate the crankshaft back to 60° Before Top Dead Center (BTDC), to prevent damage to the valves.
  8.  
  9. 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
     

  10.  

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-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.

  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 and timing belt.
     
    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)
     
    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
     

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

 
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