Saab 2000-06

Cylinder Head 1

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Removal & Installation




CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.


CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.


CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.


CAUTION
The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in personal injury.

9-3
2.8L Engine-Front Cylinder Head
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Camshaft cover
     
    Spark plugs
     
    Coolant port
     
    Camshaft solenoid valve (695F)
     
    Camshaft position sensor (555F)
     

  6.  
  7. 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).
  8.  
  9. Fit EN-46106 Flywheel locking attachment.
  10.  
  11. Mark the chain and camshaft sprocket so they can be refitted in the same position.
  12.  
  13. 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).
  14.  
  15. Fit EN-46108-1 Fixing tool to the camshaft chain on the intake side. Check that the tool grips the chain firmly.
  16.  
  17. Fit EN-46108-2 Fixing tool to the camshaft chain on the exhaust side. Check that the tool grips the chain firmly.
  18.  
  19. Tighten EN-46108 Fixing tool so that the chain is unloaded. 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.
  20.  
  21. Remove the camshaft sprocket bolts.
  22.  
  23. Remove the sprockets from the camshafts.
  24.  
  25. 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.
  26.  
  27. Lift out the camshafts and note the rear marking on the camshafts.
  28.  
  29. Remove the roller rockers and the hydraulic adjuster elements. Store them in 83 93 787 Valve stand so they do not get mixed up.
    NOTE
    Cover all return oil ducts in the cylinder head so that the valve cone or contaminants cannot fall down into the engine.

  30.  
  31. Fit EN-46110-eu Valve spring tool.
  32.  
  33. Fit 83 94 173 Air nipple for spark plug hole. Connect compressed air and put the piston and valves under pressure.
  34.  
  35. Press down the valve plate with EN-46110-eu Valve spring tool.
  36.  
  37. 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.
  38.  
  39. Lift out the spring plate and valve spring.
  40.  
  41. Lift out the valve guide seal using 83 94 157 Pliers, valve guide seal.
  42.  
  43. Remove the cylinder head bolts in an alternating sequence by loosening them 1 / 4 turn then 1 / 2 turn
  44.  
  45. Remove the cylinder head.
  46.  

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Install the cylinder head. Torque the new bolts in an alternating sequence as follows:


    1. M8 size bolts torque 11 ft. lbs. (15 Nm).
    2.  
    3. Plus an additional 60 degrees.
    4.  
    5. M11 size bolts torque 33 ft. lbs. (45 Nm).
    6.  
    7. Plus an additional 120 degrees.
    8.  

  4.  
  5. Clean all parts and check contact surfaces and bearing surfaces for wear.
  6.  
  7. Fit the valve guide seal using 83 94 157 Pliers, valve guide seal.
  8.  
  9. Fit the valve spring and spring plate.
  10.  
  11. Press down the valve plate with EN-46110-eu Valve spring tool.
  12.  
  13. Fit the valve cone using EN-46117 Fitting tool.
  14.  
  15. Unload the valve and remove EN-46110-eu Valve spring tool.
  16.  
  17. Disconnect the compressed air and remove the air nipple.
  18.  
  19. Position the camshafts and use EN-46105 Adjustment tool to check that the camshafts are mounted at the correct angle.
  20.  
  21. Fit the bearing caps as marked on the 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).
  22.  
  23. Fit the sprockets with chain on the camshafts. Tighten the bolts by hand.
  24.  
  25. Check that the marks on the chain match the markings on the sprockets.
  26.  
  27. Remove EN-46108-2 and EN-46108-1 Fixing tools
  28.  
  29. Tighten the bolts of both camshaft sprockets, counter holding with an open spanner on the camshaft flats to 48 ft. lbs. (65 Nm).
  30.  
  31. Remove EN-46106 Flywheel locking attachment.
  32.  
  33. Install or connect the following:

    Camshaft position sensor (555F) using a new gasket and tighten the mounting bolt to 7 ft. lbs. (10 Nm)
     
    Camshaft solenoid valve (695F) using a new seal and tighten to 7 ft. lbs. (10 Nm)
     
    Coolant port using a new seal and gasket. Tighten the mounting bolts to 7 ft. lbs. (10 Nm)
     
    Spark plugs
     
    Camshaft cover.
     
    Negative battery cable
     

  34.  
  35. Fill the cooling system to the proper level.
  36.  
  37. Start the vehicle, check for leaks and repair if necessary.
  38.  

2.8L Engine-Rear Cylinder Head
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Camshaft cover
     
    Spark plugs
     
    Camshaft solenoid valve (695R)
     
    Camshaft position sensor (555R)
     

  6.  
  7. Rotate the crankshaft so that the markings on the camshaft sprocket are visible and the indentations align with the cylinder head. Use EN-46105 Adjustment tool as a gauge (the camshafts are now in their neutral position).
  8.  
  9. Fit EN-46106 Flywheel locking attachment.
  10.  
  11. Mark the chain and camshaft sprocket so they can be refitted in the same position.
  12.  
  13. Slightly loosen the bolts holding the camshaft sprockets. Counterhold using an open wrench on the camshaft flats (do not remove the bolts).
  14.  
  15. Fit EN-46108-2 Fixing tool to the camshaft chain on the intake side. Check that the tool grips the chain firmly.
  16.  
  17. Fit EN-46108-1 Fixing tool to the camshaft chain on the exhaust side. Check that the tool grips the chain firmly.
  18.  
  19. Tighten EN-46108 Fixing tool so that the chain is unloaded. 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.
  20.  
  21. Remove the camshaft sprocket bolts.
  22.  
  23. Remove the sprockets from the camshafts.
  24.  
  25. 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.
  26.  
  27. Lift out the camshafts and note the rear marking on the camshafts.
  28.  
  29. Remove the roller rockers and the hydraulic adjuster elements. Store them in 83 93 787 Valve stand so they do not get mixed up.
    NOTE
    Cover all return oil ducts in the cylinder head so that the valve cone or contaminants cannot fall down into the engine.

  30.  
  31. Fit EN-46110-eu Valve spring tool.
  32.  
  33. Fit 83 94 173 Air nipple for spark plug hole. Connect compressed air and put the piston and valves under pressure.
  34.  
  35. Press down the valve plate with EN-46110-eu Valve spring tool.
  36.  
  37. 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.
  38.  
  39. Lift out the spring plate and valve spring.
  40.  
  41. Lift out the valve guide seal using 83 94 157 Pliers, valve guide seal.
  42.  
  43. Remove the cylinder head bolts in an alternating sequence by loosening them 1 / 4 turn then 1 / 2 turn
  44.  
  45. Remove the cylinder head.
  46.  

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Install the cylinder head. Torque the new bolts in an alternating sequence as follows:


    1. M8 size bolts torque 11 ft. lbs. (15 Nm).
    2.  
    3. Plus an additional 60 degrees.
    4.  
    5. M11 size bolts torque 33 ft. lbs. (45 Nm).
    6.  
    7. Plus an additional 120 degrees.
    8.  

  4.  
  5. Clean all parts and check contact surfaces and bearing surfaces for wear.
  6.  
  7. Fit the valve guide seal using 83 94 157 Pliers, valve guide seal.
  8.  
  9. Fit the valve spring and spring plate.
  10.  
  11. Press down the valve plate with EN-46110-eu Valve spring tool.
  12.  
  13. Fit the valve cone using EN-46117 Fitting tool.
  14.  
  15. Unload the valve and remove EN-46110-eu Valve spring tool.
  16.  
  17. Disconnect the compressed air and remove the air nipple.
  18.  
  19. Position the camshafts and use EN-46105-1 Adjustment tool to check that the camshafts are mounted at the correct angle.
  20.  
  21. Fit the bearing caps as marked on the 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).
  22.  
  23. Fit the sprockets with chain on the camshafts. Tighten the bolts by hand.
  24.  
  25. Check that the marks on the chain match the markings on the sprockets.
  26.  
  27. Remove EN-46108-2 and EN-46108-1 Fixing tools.
  28.  
  29. Tighten the bolts of both camshaft sprockets, counter holding with an open spanner on the camshaft flats to 48 ft. lbs. (65 Nm).
  30.  
  31. Remove EN-46106 Flywheel locking attachment.
  32.  
  33. Install or connect the following:

    Camshaft position sensor (555R) using a new gasket and tighten the mounting bolt to 7 ft. lbs. (10 Nm)
     
    Camshaft solenoid valve (695R) using a new seal and tighten to 7 ft. lbs. (10 Nm)
     
    Spark plugs
     
    Camshaft cover.
     
    Negative battery cable
     

  34.  
  35. Fill the cooling system to the proper level.
  36.  
  37. Start the vehicle, check for leaks and repair if necessary.
  38.  

2000-2002 Model
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise the car and remove the turbocharger support.
  4.  
  5. Remove the belt circuit cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:
    CAUTION
    DO NOT pry too hard on tensioner or it could be damaged at its end position.



    Hose clamp between turbocharger inlet pipe and connecting pipe
     
    EVAP canister purge valve
     
    MAF sensor connector and wiring
     
    Air intake box
     
    Engine cover
     
    Exhaust manifold heat shield
     
    Turbocharger delivery pipe
     
    Bypass valve vacuum hose
     
    Pressure/temperature sensor hose
     
    Venturi hose from charge air pipe (manual transmission)
     
    Signal hose from turbocharger wastegate
     
    Turbocharger delivery hose (plug openings)
     
    Cable ties on wiring harness at strut tower
     
    Auxiliary drive belt
     



    Crankcase vent pipe (move aside)
     
    EVAP connector and purge hose
     
    Engine lifting eye
     
    Turbocharger inlet pipe (leaving control valve)
     
    Power steering pump with bracket (position aside)
     
    Vacuum unit
     
    Turbocharger bolts at exhaust manifold
     
    Connector for ignition discharge module, turbo pressure sensor and coolant temperature sensor
     
    Cylinder head coolant hose
     
    Coolant pipe from turbocharger to pressure sensor
     
    Banjo connector at cylinder head
     
    Thermostat hose
     
    Coolant pipe from water pump to cylinder block
     
    Upper throttle body hose at coolant pipe
     
    Dipstick tube (plug hole in block)
     
    Crankcase vent hose (24)
     
    Vacuum hose from camshaft cover (24)
     
    Ties to camshaft cover at non-return valve (24)
     
    Cover at accelerator connection (25)
     
    Grounding connections on wiring harness duct (26)
     
    Fuel lines at quick-disconnect coupling (27)
     
    Vacuum hoses at throttle body, intake manifold and brake servo
     
    Connectors for oxygen sensor, timing sensor, limp-home solenoid, throttle body, MAP sensor and injectors
     
    Tie holding wiring harness to starter solenoid (position harness channel aside)
     
    Top bolt on intake manifold stay
     
    Ignition discharge module
     
    Spark plugs
     

  10.  
  11. Remove the camshaft cover and -zero- the engine by turning the crankshaft in rotating direction until mark on belt pulley is aligned with timing cover mark. Be sure camshafts are aligned with their set marks.
  12.  
  13. Remove the bolts on the camshaft sprockets. Use a wrench on rear end of camshaft as a counter-stay.
    WARNING
    DO NOT allow camshaft to turn during this procedure or damage to valves and pistons may occur.

  14.  
  15. Remove the idler sprocket bolt, then insert a 27mm socket on the chain tensioner. Remove the tensioner by removing the plug, pin and spring, then remove the chain tensioner.
  16.  
  17. Remove the sprocket and restrain the chain guides together.
  18.  
  19. Remove the cylinder head bolts in sequence as illustrated.
  20.  
  21. Lift off cylinder head with intake and exhaust manifolds.

    Click image to see an enlarged view

    Fig. Disconnecting components near throttle cable-9-3 2.0L engine 2002



    Click image to see an enlarged view

    Fig. Remove the cylinder head bolts in sequence-2.3L engine 9-3 and 9-5

  22.  

To install:

  1. Thoroughly clean all mating surfaces and bolt holes of oil and residue. Wipe combustion chambers to be sure no contamination enters the head or block.
  2.  
  3. Install new gaskets and mount the exhaust manifold and turbocharger to the cylinder head.
  4.  
  5. Apply a 2mm thick by 10-20mm long bead of Loctite 518 to inner part of upper contact surface of timing cover against cylinder head.
  6.  
  7. Turn the crankshaft by 45 degrees to lower the pistons.
  8.  
  9. Wrap a rubber band around the chain guides and install the cylinder head with a new gasket.
  10.  
  11. Verify that cylinder head is correctly seated on the locating sleeves and that the timing chain runs freely.
  12.  
  13. Tighten the cylinder head bolts, in sequence shown, in 3 steps as follows:
    1. Step 1: 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: 44 ft. lbs. (60 Nm)
    4.  
    5. Step 3: Tighten each bolt, in sequence, an additional 90 degrees.
    6.  

  14.  
  15. Install 2 screws between timing cover and cylinder head and torque to 18 ft. lbs. (24 Nm).
  16.  
  17. Align the 0 mark on the crankshaft with the timing marks on the camshafts.
  18.  
  19. Remove the rubber band and fit the camshaft sprockets and camshaft timing chain. Start with the exhaust camshaft. Do not tighten the bolts at this time.
  20.  
  21. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.
  22.  
  23. Install the chain tensioner with a 27mm socket. If necessary, change the tensioner gasket. Torque the bolt to 47 ft. lbs. (63 Nm).
  24.  
  25. Install or connect the following:

    Chain tensioner plug with push rod and spring torqued to 17 ft. lbs. (22 Nm)
     
    Idler sprocket
     
    Top bolt on intake manifold stay
     

  26.  
  27. Make sure chain is positioned correctly on the chain guards. Rotate the crankshaft 2 revolutions and check the setting of the flywheel and camshaft timing marks.
  28.  
  29. Tighten the camshaft sprocket bolts to 47 ft. lbs. (63 Nm).
  30.  
  31. Clean the camshaft cover sealing surface with a safe solvent.
  32.  
  33. Apply soap to the opening the camshaft cover and install the cover.
  34.  
  35. Tighten the bolt located furthest to the front at the timing chain end. Continue with this sequence around the outside and inside. Tighten bolts to 11 ft. lbs. (15 Nm).
  36.  
  37. Install the spark plugs to 21 ft. lbs. (28 Nm).
  38.  
  39. Apply sealant 30 19 312 to rubber seal on the ignition discharge module and install the module.
  40.  
  41. Install the auxiliary drive belt loosely on the pulleys.
  42.  
  43. Install the wiring harness channel and fasten the cable tie to the starter solenoid.
  44.  
  45. Install or connect the following:
    WARNING
    To prevent hoses on delivery side of turbocharger from coming loose under pressure, thoroughly clean all mating areas on inside of hoses and pipes before attaching.



    Connectors for oxygen sensor, timing sensor, limp-home solenoid, throttle body, MAP sensor and fuel injectors
     
    Vacuum hoses to throttle body
     
    Hose between intake manifold and brake servo
     
    3 grounding connections
     
    Fuel lines with couplings and seals
     
    Accelerator cable and cover
     
    Hoses for crankcase vent and camshaft cover
     
    Dipstick tube
     
    Wiring harness ties on camshaft cover by non-return valve
     
    Lower and upper hoses to throttle body and each coolant pipe
     
    Coolant pipe to water pump
     
    Hose from charge air cooler to thermostat housing
     
    Turbocharger cooler pip with banjo coupling (to thermostat housing, with new gaskets) and tightened to 19 ft. lbs. (25 Nm)
     
    Coolant hoses to cylinder head and thermostat housing
     
    Connectors to turbocharger pressure sensor, coolant temperature sensor, and ignition discharge module
     
    Exhaust manifold to turbocharger with Molykote on the studs
     
    Vacuum unit to turbocharger
     
    Power steering pump and bracket, with belt on pulley, then release tensioner
     
    Turbocharger inlet pipe with bracket
     
    V-clamp
     
    Control valve on bracket with connector
     
    EVAP purge hose
     
    Crankcase vent pipe with banjo bolt tightened to 18 ft. lbs. (24 Nm)
     
    Harness ties to strut tower
     
    Heat shield on exhaust manifold
     
    Charge air pipe
     
    Pressure/temperature sensor connector
     
    Hose to bypass valve
     
    Venturi hose to charge air pipe (manual transmission)
     
    3 nuts holding rubber bushings
     



    Connecting hose to turbocharger inlet pipe
     
    MAF sensor cable to clamps on top of air collection box
     
    Evap canister purge valve to air collection box
     
    Negative battery cable
     
    Engine cover
     

  46.  
  47. Raise the car and ensure coolant drain plug is tight. Also tighten bottom bolts on the intake manifold stay and the turbocharger stay.
  48.  
  49. Visually check that auxiliary drive belt is properly positioned on all pulleys.
  50.  
  51. Install the air shields and lower the car
  52.  
  53. Refill the cooling system
  54.  
  55. With the A/C off, ensure coolant is at MAX level. Start the engine and run at varying speeds until the cooling fan comes on.
  56.  
  57. Stop the engine. Open the expansion tank cap and top up the coolant.
  58.  
  59. Start the vehicle and run it until the thermostat opens. Turn off the engine and check coolant level.
  60.  
  61. Check for leaks and repair if necessary.
  62.  
  63. Reset clock and radio code.

    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-9-3 and 9-5 4-cylinder engines 2002

  64.  

2001-02
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Raise the car and remove the turbocharger support.
  4.  
  5. Remove the belt circuit cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following: Hose clamp between turbocharger inlet pipe and connecting pipeEVAP canister purge valveMAF sensor connector and wiringAir intake boxEngine coverExhaust manifold heat shieldTurbocharger delivery pipeBypass valve vacuum hosePressure/temperature sensor hoseVenturi hose from charge air pipe (manual transmission)Signal hose from turbocharger wastegateTurbocharger delivery hose (plug openings)Cable ties on wiring harness at strut towerAuxiliary drive belt

    Hose clamp between turbocharger inlet pipe and connecting pipe
     
    EVAP canister purge valve
     
    MAF sensor connector and wiring
     
    Air intake box
     
    Engine cover
     
    Exhaust manifold heat shield
     
    Turbocharger delivery pipe
     
    Bypass valve vacuum hose
     
    Pressure/temperature sensor hose
     
    Venturi hose from charge air pipe (manual transmission)
     
    Signal hose from turbocharger wastegate
     
    Turbocharger delivery hose (plug openings)
     
    Cable ties on wiring harness at strut tower
     
    Auxiliary drive belt
     

  10.  


CAUTION
DO NOT pry too hard on tensioner or it could be damaged at its end position.



Crankcase vent pipe (move aside)
 
EVAP connector and purge hose
 
Engine lifting eye
 
Turbocharger inlet pipe (leaving control valve)
 
Power steering pump with bracket (position aside)
 
Vacuum unit
 
Turbocharger bolts at exhaust manifold
 
Connector for ignition discharge module, turbo pressure sensor and coolant temperature sensor
 
Cylinder head coolant hose
 
Coolant pipe from turbocharger to pressure sensor
 
Banjo connector at cylinder head
 
Thermostat hose
 
Coolant pipe from water pump to cylinder block
 
Upper throttle body hose at coolant pipe
 
Dipstick tube (plug hole in block)
 
Crankcase vent hose (24)
 
Vacuum hose from camshaft cover (24)
 
Ties to camshaft cover at non-return valve (24)
 
Cover at accelerator connection (25)
 
Grounding connections on wiring harness duct (26)
 
Fuel lines at quick-disconnect coupling (27)
 
Vacuum hoses at throttle body, intake manifold and brake servo
 
Connectors for oxygen sensor, timing sensor, limp-home solenoid, throttle body, MAP sensor and injectors
 
Tie holding wiring harness to starter solenoid (position harness channel aside)
 
Top bolt on intake manifold stay
 
Ignition discharge module
 
Spark plugs
 

  1. Remove the camshaft cover and -zero- the engine by turning the crankshaft in rotating direction until mark on belt pulley is aligned with timing cover mark. Be sure camshafts are aligned with their set marks.
  2.  
  3. Remove the bolts on the camshaft sprockets. Use a wrench on rear end of camshaft as a counter-stay.
  4.  


WARNING
DO NOT allow camshaft to turn during this procedure or damage to valves and pistons may occur.

  1. Remove the idler sprocket bolt, then insert a 27mm socket on the chain tensioner. Remove the tensioner by removing the plug, pin and spring, then remove the chain tensioner.
  2.  
  3. Remove the sprocket and restrain the chain guides together.
  4.  
  5. Remove the cylinder head bolts in sequence as illustrated.
  6.  
  7. Lift off cylinder head with intake and exhaust manifolds.
  8.  


    Click image to see an enlarged view

    Fig. Disconnecting components near throttle cable-9-3 2.0L engine (2001-02)



    Click image to see an enlarged view

    Fig. Remove the cylinder head bolts in sequence-2.3L engine (9-3 and 9-5)


To install:

  1. Thoroughly clean all mating surfaces and bolt holes of oil and residue. Wipe combustion chambers to be sure no contamination enters the head or block.
  2.  
  3. Install new gaskets and mount the exhaust manifold and turbocharger to the cylinder head.
  4.  
  5. Apply a 2mm thick by 10-20mm long bead of Loctite 518 to inner part of upper contact surface of timing cover against cylinder head.
  6.  
  7. Turn the crankshaft by 45 degrees to lower the pistons.
  8.  
  9. Wrap a rubber band around the chain guides and install the cylinder head with a new gasket.
  10.  
  11. Verify that cylinder head is correctly seated on the locating sleeves and that the timing chain runs freely.
  12.  
  13. Tighten the cylinder head bolts, in sequence shown, in 3 steps as follows: Step 1: 30 ft. lbs. (40 Nm)Step 2: 44 ft. lbs. (60 Nm)Step 3: Tighten each bolt, in sequence, an additional 90 degrees.
    1. Step 1: 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: 44 ft. lbs. (60 Nm)
    4.  
    5. Step 3: Tighten each bolt, in sequence, an additional 90 degrees.
    6.  

  14.  
  15. Install 2 screws between timing cover and cylinder head and torque to 18 ft. lbs. (24 Nm).
  16.  
  17. Align the 0 mark on the crankshaft with the timing marks on the camshafts.0
  18.  
  19. Remove the rubber band and fit the camshaft sprockets and camshaft timing chain. Start with the exhaust camshaft. Do not tighten the bolts at this time.
  20.  
  21. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.
  22.  
  23. Install the chain tensioner with a 27mm socket. If necessary, change the tensioner gasket. Torque the bolt to 47 ft. lbs. (63 Nm).
  24.  
  25. Install or connect the following: Chain tensioner plug with push rod and spring torqued to 17 ft. lbs. (22 Nm)Idler sprocketTop bolt on intake manifold stay

    Chain tensioner plug with push rod and spring torqued to 17 ft. lbs. (22 Nm)
     
    Idler sprocket
     
    Top bolt on intake manifold stay
     

  26.  
  27. Make sure chain is positioned correctly on the chain guards. Rotate the crankshaft 2 revolutions and check the setting of the flywheel and camshaft timing marks.
  28.  
  29. Tighten the camshaft sprocket bolts to 47 ft. lbs. (63 Nm).
  30.  
  31. Clean the camshaft cover sealing surface with Benzene.
  32.  
  33. Apply soap to the opening the camshaft cover and install the cover.
  34.  
  35. Tighten the bolt located furthest to the front at the timing chain end. Continue with this sequence around the outside and inside. Tighten bolts to 11 ft. lbs. (15 Nm).
  36.  
  37. Install the spark plugs to 21 ft. lbs. (28 Nm).
  38.  
  39. Apply sealant 30 19 312 to rubber seal on the ignition discharge module and install the module.
  40.  
  41. Install the auxiliary drive belt loosely on the pulleys.
  42.  
  43. Install the wiring harness channel and fasten the cable tie to the starter solenoid.
  44.  
  45. Install or connect the following: Connectors for oxygen sensor, timing sensor, limp-home solenoid, throttle body, MAP sensor and fuel injectorsVacuum hoses to throttle bodyHose between intake manifold and brake servo3 grounding connectionsFuel lines with couplings and sealsAccelerator cable and coverHoses for crankcase vent and camshaft coverDipstick tubeWiring harness ties on camshaft cover by non-return valveLower and upper hoses to throttle body and each coolant pipeCoolant pipe to water pumpHose from charge air cooler to thermostat housingTurbocharger cooler pip with banjo coupling (to thermostat housing, with new gaskets) and tightened to 19 ft. lbs. (25 Nm)Coolant hoses to cylinder head and thermostat housingConnectors to turbocharger pressure sensor, coolant temperature sensor, and ignition discharge moduleExhaust manifold to turbocharger with Molykote on the studsVacuum unit to turbochargerPower steering pump and bracket, with belt on pulley, then release tensionerTurbocharger inlet pipe with bracketV-clampControl valve on bracket with connectorEVAP purge hoseCrankcase vent pipe with banjo bolt tightened to 18 ft. lbs. (24 Nm)Harness ties to strut towerHeat shield on exhaust manifoldCharge air pipePressure/temperature sensor connectorHose to bypass valveVenturi hose to charge air pipe (manual transmission)3 nuts holding rubber bushings

    Connectors for oxygen sensor, timing sensor, limp-home solenoid, throttle body, MAP sensor and fuel injectors
     
    Vacuum hoses to throttle body
     
    Hose between intake manifold and brake servo
     
    3 grounding connections
     
    Fuel lines with couplings and seals
     
    Accelerator cable and cover
     
    Hoses for crankcase vent and camshaft cover
     
    Dipstick tube
     
    Wiring harness ties on camshaft cover by non-return valve
     
    Lower and upper hoses to throttle body and each coolant pipe
     
    Coolant pipe to water pump
     
    Hose from charge air cooler to thermostat housing
     
    Turbocharger cooler pip with banjo coupling (to thermostat housing, with new gaskets) and tightened to 19 ft. lbs. (25 Nm)
     
    Coolant hoses to cylinder head and thermostat housing
     
    Connectors to turbocharger pressure sensor, coolant temperature sensor, and ignition discharge module
     
    Exhaust manifold to turbocharger with Molykote on the studs
     
    Vacuum unit to turbocharger
     
    Power steering pump and bracket, with belt on pulley, then release tensioner
     
    Turbocharger inlet pipe with bracket
     
    V-clamp
     
    Control valve on bracket with connector
     
    EVAP purge hose
     
    Crankcase vent pipe with banjo bolt tightened to 18 ft. lbs. (24 Nm)
     
    Harness ties to strut tower
     
    Heat shield on exhaust manifold
     
    Charge air pipe
     
    Pressure/temperature sensor connector
     
    Hose to bypass valve
     
    Venturi hose to charge air pipe (manual transmission)
     
    3 nuts holding rubber bushings
     

  46.  


WARNING
To prevent hoses on delivery side of turbocharger from coming loose under pressure, thoroughly clean all mating areas on inside of hoses and pipes before attaching.



Connecting hose to turbocharger inlet pipe
 
MAF sensor cable to clamps on top of air collection box
 
Evap canister purge valve to air collection box
 
Negative battery cable
 
Engine cover
 

  1. Raise the car and ensure coolant drain plug is tight. Also tighten bottom bolts on the intake manifold stay and the turbocharger stay.
  2.  
  3. Visually check that auxiliary drive belt is properly positioned on all pulleys.
  4.  
  5. Install the air shields and lower the car
  6.  
  7. Refill the cooling system
  8.  
  9. With the A/C off, ensure coolant is at MAX level. Start the engine and run at varying speeds until the cooling fan comes on.
  10.  
  11. Stop the engine. Open the expansion tank cap and top up the coolant.
  12.  
  13. Start the vehicle and run it until the thermostat opens. Turn off the engine and check coolant level.
  14.  
  15. Check for leaks and repair if necessary.
  16.  
  17. Reset clock and radio code.
  18.  


    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-9-3 and 9-5 4-cylinder engines (2001-02)


  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Raise the car and remove the turbocharger support.
  4.  
  5. Remove the belt circuit cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following: Hose clamp between turbocharger inlet pipe and connecting pipeEVAP canister purge valveMAF sensor connector and wiringAir intake boxEngine coverExhaust manifold heat shieldTurbocharger delivery pipeBypass valve vacuum hosePressure/temperature sensor hoseVenturi hose from charge air pipe (manual transmission)Signal hose from turbocharger wastegateTurbocharger delivery hose (plug openings)Cable ties on wiring harness at strut towerAuxiliary drive belt

    Hose clamp between turbocharger inlet pipe and connecting pipe
     
    EVAP canister purge valve
     
    MAF sensor connector and wiring
     
    Air intake box
     
    Engine cover
     
    Exhaust manifold heat shield
     
    Turbocharger delivery pipe
     
    Bypass valve vacuum hose
     
    Pressure/temperature sensor hose
     
    Venturi hose from charge air pipe (manual transmission)
     
    Signal hose from turbocharger wastegate
     
    Turbocharger delivery hose (plug openings)
     
    Cable ties on wiring harness at strut tower
     
    Auxiliary drive belt
     

  10.  


CAUTION
DO NOT pry too hard on tensioner or it could be damaged at its end position.



Crankcase vent pipe (move aside)
 
EVAP connector and purge hose
 
Engine lifting eye
 
Turbocharger inlet pipe (leaving control valve)
 
Power steering pump with bracket (position aside)
 
Vacuum unit
 
Turbocharger bolts at exhaust manifold
 
Connector for ignition discharge module, turbo pressure sensor and coolant temperature sensor
 
Cylinder head coolant hose
 
Coolant pipe from turbocharger to pressure sensor
 
Banjo connector at cylinder head
 
Thermostat hose
 
Coolant pipe from water pump to cylinder block
 
Upper throttle body hose at coolant pipe
 
Dipstick tube (plug hole in block)
 
Crankcase vent hose (24)
 
Vacuum hose from camshaft cover (24)
 
Ties to camshaft cover at non-return valve (24)
 
Cover at accelerator connection (25)
 
Grounding connections on wiring harness duct (26)
 
Fuel lines at quick-disconnect coupling (27)
 
Vacuum hoses at throttle body, intake manifold and brake servo
 
Connectors for oxygen sensor, timing sensor, limp-home solenoid, throttle body, MAP sensor and injectors
 
Tie holding wiring harness to starter solenoid (position harness channel aside)
 
Top bolt on intake manifold stay
 
Ignition discharge module
 
Spark plugs
 

  1. Remove the camshaft cover and -zero- the engine by turning the crankshaft in rotating direction until mark on belt pulley is aligned with timing cover mark. Be sure camshafts are aligned with their set marks.
  2.  
  3. Remove the bolts on the camshaft sprockets. Use a wrench on rear end of camshaft as a counter-stay.
  4.  


WARNING
DO NOT allow camshaft to turn during this procedure or damage to valves and pistons may occur.

  1. Remove the idler sprocket bolt, then insert a 27mm socket on the chain tensioner. Remove the tensioner by removing the plug, pin and spring, then remove the chain tensioner.
  2.  
  3. Remove the sprocket and restrain the chain guides together.
  4.  
  5. Remove the cylinder head bolts in sequence as illustrated.
  6.  
  7. Lift off cylinder head with intake and exhaust manifolds.
  8.  


    Click image to see an enlarged view

    Fig. Disconnecting components near throttle cable-9-3 2.0L engine 2001-02



    Click image to see an enlarged view

    Fig. Remove the cylinder head bolts in sequence-2.3L engine 9-3 and 9-5


To install:

  1. Thoroughly clean all mating surfaces and bolt holes of oil and residue. Wipe combustion chambers to be sure no contamination enters the head or block.
  2.  
  3. Install new gaskets and mount the exhaust manifold and turbocharger to the cylinder head.
  4.  
  5. Apply a 2mm thick by 10-20mm long bead of Loctite 518 to inner part of upper contact surface of timing cover against cylinder head.
  6.  
  7. Turn the crankshaft by 45 degrees to lower the pistons.
  8.  
  9. Wrap a rubber band around the chain guides and install the cylinder head with a new gasket.
  10.  
  11. Verify that cylinder head is correctly seated on the locating sleeves and that the timing chain runs freely.
  12.  
  13. Tighten the cylinder head bolts, in sequence shown, in 3 steps as follows: Step 1: 30 ft. lbs. (40 Nm)Step 2: 44 ft. lbs. (60 Nm)Step 3: Tighten each bolt, in sequence, an additional 90 degrees.
    1. Step 1: 30 ft. lbs. (40 Nm)
    2.  
    3. Step 2: 44 ft. lbs. (60 Nm)
    4.  
    5. Step 3: Tighten each bolt, in sequence, an additional 90 degrees.
    6.  

  14.  
  15. Install 2 screws between timing cover and cylinder head and torque to 18 ft. lbs. (24 Nm).
  16.  
  17. Align the 0 mark on the crankshaft with the timing marks on the camshafts.0
  18.  
  19. Remove the rubber band and fit the camshaft sprockets and camshaft timing chain. Start with the exhaust camshaft. Do not tighten the bolts at this time.
  20.  
  21. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.
  22.  
  23. Install the chain tensioner with a 27mm socket. If necessary, change the tensioner gasket. Torque the bolt to 47 ft. lbs. (63 Nm).
  24.  
  25. Install or connect the following: Chain tensioner plug with push rod and spring torqued to 17 ft. lbs. (22 Nm)Idler sprocketTop bolt on intake manifold stay

    Chain tensioner plug with push rod and spring torqued to 17 ft. lbs. (22 Nm)
     
    Idler sprocket
     
    Top bolt on intake manifold stay
     

  26.  
  27. Make sure chain is positioned correctly on the chain guards. Rotate the crankshaft 2 revolutions and check the setting of the flywheel and camshaft timing marks.
  28.  
  29. Tighten the camshaft sprocket bolts to 47 ft. lbs. (63 Nm).
  30.  
  31. Clean the camshaft cover sealing surface with a safe solvent.
  32.  
  33. Apply soap to the opening the camshaft cover and install the cover.
  34.  
  35. Tighten the bolt located furthest to the front at the timing chain end. Continue with this sequence around the outside and inside. Tighten bolts to 11 ft. lbs. (15 Nm).
  36.  
  37. Install the spark plugs to 21 ft. lbs. (28 Nm).
  38.  
  39. Apply sealant 30 19 312 to rubber seal on the ignition discharge module and install the module.
  40.  
  41. Install the auxiliary drive belt loosely on the pulleys.
  42.  
  43. Install the wiring harness channel and fasten the cable tie to the starter solenoid.
  44.  
  45. Install or connect the following: Connectors for oxygen sensor, timing sensor, limp-home solenoid, throttle body, MAP sensor and fuel injectorsVacuum hoses to throttle bodyHose between intake manifold and brake servo3 grounding connectionsFuel lines with couplings and sealsAccelerator cable and coverHoses for crankcase vent and camshaft coverDipstick tubeWiring harness ties on camshaft cover by non-return valveLower and upper hoses to throttle body and each coolant pipeCoolant pipe to water pumpHose from charge air cooler to thermostat housingTurbocharger cooler pip with banjo coupling (to thermostat housing, with new gaskets) and tightened to 19 ft. lbs. (25 Nm)Coolant hoses to cylinder head and thermostat housingConnectors to turbocharger pressure sensor, coolant temperature sensor, and ignition discharge moduleExhaust manifold to turbocharger with Molykote on the studsVacuum unit to turbochargerPower steering pump and bracket, with belt on pulley, then release tensionerTurbocharger inlet pipe with bracketV-clampControl valve on bracket with connectorEVAP purge hoseCrankcase vent pipe with banjo bolt tightened to 18 ft. lbs. (24 Nm)Harness ties to strut towerHeat shield on exhaust manifoldCharge air pipePressure/temperature sensor connectorHose to bypass valveVenturi hose to charge air pipe (manual transmission)3 nuts holding rubber bushings

    Connectors for oxygen sensor, timing sensor, limp-home solenoid, throttle body, MAP sensor and fuel injectors
     
    Vacuum hoses to throttle body
     
    Hose between intake manifold and brake servo
     
    3 grounding connections
     
    Fuel lines with couplings and seals
     
    Accelerator cable and cover
     
    Hoses for crankcase vent and camshaft cover
     
    Dipstick tube
     
    Wiring harness ties on camshaft cover by non-return valve
     
    Lower and upper hoses to throttle body and each coolant pipe
     
    Coolant pipe to water pump
     
    Hose from charge air cooler to thermostat housing
     
    Turbocharger cooler pip with banjo coupling (to thermostat housing, with new gaskets) and tightened to 19 ft. lbs. (25 Nm)
     
    Coolant hoses to cylinder head and thermostat housing
     
    Connectors to turbocharger pressure sensor, coolant temperature sensor, and ignition discharge module
     
    Exhaust manifold to turbocharger with Molykote on the studs
     
    Vacuum unit to turbocharger
     
    Power steering pump and bracket, with belt on pulley, then release tensioner
     
    Turbocharger inlet pipe with bracket
     
    V-clamp
     
    Control valve on bracket with connector
     
    EVAP purge hose
     
    Crankcase vent pipe with banjo bolt tightened to 18 ft. lbs. (24 Nm)
     
    Harness ties to strut tower
     
    Heat shield on exhaust manifold
     
    Charge air pipe
     
    Pressure/temperature sensor connector
     
    Hose to bypass valve
     
    Venturi hose to charge air pipe (manual transmission)
     
    3 nuts holding rubber bushings
     

  46.  


WARNING
To prevent hoses on delivery side of turbocharger from coming loose under pressure, thoroughly clean all mating areas on inside of hoses and pipes before attaching.



Connecting hose to turbocharger inlet pipe
 
MAF sensor cable to clamps on top of air collection box
 
Evap canister purge valve to air collection box
 
Negative battery cable
 
Engine cover
 

  1. Raise the car and ensure coolant drain plug is tight. Also tighten bottom bolts on the intake manifold stay and the turbocharger stay.
  2.  
  3. Visually check that auxiliary drive belt is properly positioned on all pulleys.
  4.  
  5. Install the air shields and lower the car
  6.  
  7. Refill the cooling system
  8.  
  9. With the A/C off, ensure coolant is at MAX level. Start the engine and run at varying speeds until the cooling fan comes on.
  10.  
  11. Stop the engine. Open the expansion tank cap and top up the coolant.
  12.  
  13. Start the vehicle and run it until the thermostat opens. Turn off the engine and check coolant level.
  14.  
  15. Check for leaks and repair if necessary.
  16.  
  17. Reset clock and radio code.
  18.  


    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-9-3 and 9-5 4-cylinder engines 2001-02


2003-04
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Cap from expansion tankOxygen sensor connectorTemperature sensor connectorHeat shield over turbochargerTurbocharger oil delivery pipeUpper oxygen sensorCatalytic converter connection from turbochargerRight front wheel and fenderwell linerLower spoiler shieldHose and connector from headlamp washersDrain the cooling systemLower turbocharger pressure pipeFront exhaust pipe from muffler (cut about 3.5 inches (87 mm) from the end of the muffler)Front pipe from catalytic converterSteering gear heat shieldCatalytic converter heat shieldTemperature sensorLower oxygen sensorBracket from catalytic converter and blockCatalytic converterDrain remaining coolantTurbocharger oil return pipeStay from intake manifold and cylinder blockStarter positive cablePower steering pipe clamps on subframeRear torsion bar bolts (loosen slightly)

    Cap from expansion tank
     
    Oxygen sensor connector
     
    Temperature sensor connector
     
    Heat shield over turbocharger
     
    Turbocharger oil delivery pipe
     
    Upper oxygen sensor
     
    Catalytic converter connection from turbocharger
     
    Right front wheel and fenderwell liner
     
    Lower spoiler shield
     
    Hose and connector from headlamp washers
     
    Drain the cooling system
     
    Lower turbocharger pressure pipe
     
    Front exhaust pipe from muffler (cut about 3.5 inches (87 mm) from the end of the muffler)
     
    Front pipe from catalytic converter
     
    Steering gear heat shield
     
    Catalytic converter heat shield
     
    Temperature sensor
     
    Lower oxygen sensor
     
    Bracket from catalytic converter and block
     
    Catalytic converter
     
    Drain remaining coolant
     
    Turbocharger oil return pipe
     
    Stay from intake manifold and cylinder block
     
    Starter positive cable
     
    Power steering pipe clamps on subframe
     
    Rear torsion bar bolts (loosen slightly)
     

  4.  
  5. Fit an engine centering tool kit, 83 96 152, to subframe, as illustrated. Adjust the centering tool bolts so adjuster screw slots are completely visible.
  6.  
  7. Lower the car and remove the upper engine cover.
  8.  
  9. Remove or disconnect the following: Turbocharger delivery hose from throttle body and pipeTurbocharger inlet pipe (plug openings)MAF sensor connectorAir cleaner assembly

    Turbocharger delivery hose from throttle body and pipe
     
    Turbocharger inlet pipe (plug openings)
     
    MAF sensor connector
     
    Air cleaner assembly
     

  10.  
  11. Release any fuel pressure by carefully pressing the service valve needle. Collect spilled fuel.
  12.  
  13. Detach both fuel lines for the fuel rail while gripping the lower nut. Plug the fuel line openings.
  14.  
  15. Remove or disconnect the following: Quick-release coupling for ventilation lineFuel lines and vent lines from camshaft cover (bend up hose and out of the way)Ignition coil coverIgnition coil connectorsTurbocharger solenoid connectorConnectors for A/C pressure sensor connector, coolant temperature sensor, engine control module, bypass solenoid valve, throttle body, MAP sensor, atmospheric pressure sensor, IDM moduleGround connection on ECMHose from turbocharger wastegate and solenoid valveWiring harness duct and bracket from camshaft cover (bend wiring harness aside)Wiring harness from oil filter housing and inlet pipeIgnition coilsCrankcase vent hose from camshaft coverGround lead from camshaft coverCamshaft cover

    Quick-release coupling for ventilation line
     
    Fuel lines and vent lines from camshaft cover (bend up hose and out of the way)
     
    Ignition coil cover
     
    Ignition coil connectors
     
    Turbocharger solenoid connector
     
    Connectors for A/C pressure sensor connector, coolant temperature sensor, engine control module, bypass solenoid valve, throttle body, MAP sensor, atmospheric pressure sensor, IDM module
     
    Ground connection on ECM
     
    Hose from turbocharger wastegate and solenoid valve
     
    Wiring harness duct and bracket from camshaft cover (bend wiring harness aside)
     
    Wiring harness from oil filter housing and inlet pipe
     
    Ignition coils
     
    Crankcase vent hose from camshaft cover
     
    Ground lead from camshaft cover
     
    Camshaft cover
     

  16.  
  17. Zero the engine by turning the crankshaft clockwise until the marking on the crankshaft pulley with aligned with the marking on the timing cover. The No. 1 cylinder cams on the intake and exhaust camshafts should be pointing up and inward.
  18.  
  19. Remove or disconnect the following: Coolant hose from cylinder headRight engine mountIDM moduleCouplings from vacuum pumpPower steering pumpEVAP canister purge valve and bracketThrottle bodyECMFuel injector connectorsDipstick tube boltVacuum hose and purge hose from intake manifoldVacuum hose from fuel pressure regulatorIntake manifoldTiming chain tensionerCamshaft pinions (hold camshaft flats with wrench)

    Coolant hose from cylinder head
     
    Right engine mount
     
    IDM module
     
    Couplings from vacuum pump
     
    Power steering pump
     
    EVAP canister purge valve and bracket
     
    Throttle body
     
    ECM
     
    Fuel injector connectors
     
    Dipstick tube bolt
     
    Vacuum hose and purge hose from intake manifold
     
    Vacuum hose from fuel pressure regulator
     
    Intake manifold
     
    Timing chain tensioner
     
    Camshaft pinions (hold camshaft flats with wrench)
     

  20.  
  21. Fit a cable tie to the exhaust camshaft pinion and chain. Remove the camshaft pinions and lower the exhaust camshaft pinion with the chain.
  22.  
  23. Remove the cylinder head plug.
  24.  
  25. Remove the bolts (61) for the chain guide on the intake side. Move the guide away and install the bolt again.
  26.  
  27. Remove the cylinder head. Remove the cylinder head bolts in an alternating pattern (62).
  28.  


    Click image to see an enlarged view

    Fig. Showing cylinder head bolt locations-9-3 4-cylinder engines (2001-04)


To install:

  1. Thoroughly clean all mating surfaces. Blow out bolt holes. Check for any warping or damage.
  2.  
  3. Check that marks on the pulley and timing cover are aligned.
  4.  
  5. Place a new gasket on the cylinder block. Lift up the sprocket and pull the chain guides together to lower the cylinder head.
  6.  
  7. Remove the exhaust camshaft and intake camshaft No. 2 bearing caps. Fit an adjustment tools, 83 96 046, to the camshafts (5). Tighten retaining bolts.
  8.  
  9. Install cylinder head bolts, in sequence as illustrated. DO NOT drop bolts into place or threads will be damaged. Tighten cylinder head bolts in 3 steps as follows: Step 1: 22 ft. lbs. (30 Nm)Step 2: Each bolt, in sequence, an additional 75 degreesStep 3: Each bolt, in sequence, an additional 80 degrees
    1. Step 1: 22 ft. lbs. (30 Nm)
    2.  
    3. Step 2: Each bolt, in sequence, an additional 75 degrees
    4.  
    5. Step 3: Each bolt, in sequence, an additional 80 degrees
    6.  

  10.  
  11. Install and tighten transmission section bolts to 26 ft. lbs. (35 Nm).
  12.  
  13. Remove the bolt for the chain guide. Put the guide in place an install and tighten the bolt.
  14.  
  15. Install the plug on the front of the cylinder head, with a new sealing washer. Tighten the plug to 18 ft. lbs. (25 Nm).
  16.  
  17. Fit the pinion on the exhaust camshaft and intake camshaft without tightening. Verify that the engine is still -zeroed-.
  18.  
  19. Install the chain tensioner reset with a new seal. The groove on the end of the chain tensioner should be vertical when installed. Torque tensioner reset to 55 ft. lbs. (75 Nm).
  20.  
  21. Torque the camshaft pinions while gripping the respective camshaft with a wrench on the flats. Torque to 63 ft. lbs. (85 Nm), plus an additional 30 degrees. Remove the cable tie.
  22.  
  23. Remove the camshaft adjustment tool and fit the camshaft No. 2 bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).
  24.  
  25. Turn the engine over twice and zero it so the markings are aligned. Remove camshaft bearing caps No. 2 and No. 7 and install that camshaft adjustment tool, 83 96 046, to check that camshaft setting is correct. Remove the tools and install the bearing caps.
  26.  
  27. Clean the sealing surfaces on the intake manifold and cylinder head. Install the intake manifold with a new gasket. Torque the nuts to 7 ft. lbs. (10 Nm).
  28.  
  29. Install or connect the following: Vacuum hose to fuel pressure regulatorDipstick tube boltVacuum hose and purge hose to intake manifoldFuel injector connectorsThrottle body and ECM (leaving upper right screw for ground cable)Bracket and coupling to EVAP canister purge valvePower steering pump, with a new seal, to 16 ft. lbs. (22 Nm)Hose to vacuum pumpIDM moduleCoolant hose to pipe on cylinder headRight side engine mount: body bolts to 30 ft. lbs. (40 Nm), plus an additional 60 degrees and bracket bolts to 52 ft. lbs. (70 Nm), plus an additional 60 degreesRemaining coolant hose to cylinder head pipeCamshaft cover, with a new seal, to 7 ft. lbs. (10 Nm)Ground cable to camshaft coverCrankcase vent hose to camshaft coverIgnition coilsWiring harness to intake manifold and oil filter housingWiring harness duct and bracket to camshaft coverHose to turbocharger wastegate and solenoid valveConnectors for A/C pressure sensor, coolant temperature sensor, ECM, wastegate solenoid, throttle body, MAP sensor, barometric pressure sensor, IDM moduleGround cable to ECMIgnition module connectors (ensure cables are not pinched by cover)Turbocharger solenoid valve connectors with cable clipsCover over ignition coilsFuel lines and vent lines into clips on camshaft coverCoupling for vent lineBoth fuel lines, with new seals, to fuel rail while gripping lower nut to 7 ft. lbs. (10 Nm)Air cleaner assembly

    Vacuum hose to fuel pressure regulator
     
    Dipstick tube bolt
     
    Vacuum hose and purge hose to intake manifold
     
    Fuel injector connectors
     
    Throttle body and ECM (leaving upper right screw for ground cable)
     
    Bracket and coupling to EVAP canister purge valve
     
    Power steering pump, with a new seal, to 16 ft. lbs. (22 Nm)
     
    Hose to vacuum pump
     
    IDM module
     
    Coolant hose to pipe on cylinder head
     
    Right side engine mount: body bolts to 30 ft. lbs. (40 Nm), plus an additional 60 degrees and bracket bolts to 52 ft. lbs. (70 Nm), plus an additional 60 degrees
     
    Remaining coolant hose to cylinder head pipe
     
    Camshaft cover, with a new seal, to 7 ft. lbs. (10 Nm)
     
    Ground cable to camshaft cover
     
    Crankcase vent hose to camshaft cover
     
    Ignition coils
     
    Wiring harness to intake manifold and oil filter housing
     
    Wiring harness duct and bracket to camshaft cover
     
    Hose to turbocharger wastegate and solenoid valve
     
    Connectors for A/C pressure sensor, coolant temperature sensor, ECM, wastegate solenoid, throttle body, MAP sensor, barometric pressure sensor, IDM module
     
    Ground cable to ECM
     
    Ignition module connectors (ensure cables are not pinched by cover)
     
    Turbocharger solenoid valve connectors with cable clips
     
    Cover over ignition coils
     
    Fuel lines and vent lines into clips on camshaft cover
     
    Coupling for vent line
     
    Both fuel lines, with new seals, to fuel rail while gripping lower nut to 7 ft. lbs. (10 Nm)
     
    Air cleaner assembly
     

  30.  


WARNING
To prevent hoses on delivery side of turbocharger from coming loose under pressure, thoroughly clean all mating areas on inside of hoses and pipes before attaching.



Air cleaner cover
 
MAF sensor connector
 
Turbocharger inlet pipe to air cleaner
 
Hoses to inlet pipe
 
Turbocharger hose to throttle body and turbo delivery pipe
 

  1. Raise the car and remove the engine centering tool from the subframe.
  2.  
  3. Torque the rear torsion arm bolts to 52 ft. lbs. (70 Nm), plus an additional 90 degrees.
  4.  
  5. Install or connect the following: Bolts on power steering pipe clamps on subframePositive cable to starterStay between intake manifold and cylinder block to 16 ft. lbs. (22 Nm)Oil return line to turbocharger with new gasket and O-ring; torque to 11 ft. lbs. (15 Nm)Stay between exhaust manifold and cylinder block to 16 ft. lbs. (22 Nm)New seals on turbocharger coolant pipe; torque to 30 ft. lbs. (40 Nm)Catalytic converter and bracket to studs on engine block and to turbocharger connectionCatalytic converter bracket bolts into engine block and new nuts on studs

    Bolts on power steering pipe clamps on subframe
     
    Positive cable to starter
     
    Stay between intake manifold and cylinder block to 16 ft. lbs. (22 Nm)
     
    Oil return line to turbocharger with new gasket and O-ring; torque to 11 ft. lbs. (15 Nm)
     
    Stay between exhaust manifold and cylinder block to 16 ft. lbs. (22 Nm)
     
    New seals on turbocharger coolant pipe; torque to 30 ft. lbs. (40 Nm)
     
    Catalytic converter and bracket to studs on engine block and to turbocharger connection
     
    Catalytic converter bracket bolts into engine block and new nuts on studs
     

  6.  
  7. Lower the car and install the catalytic converter with new nuts so it is evenly positioned to the turbocharger. Use thread paste on the studs.
  8.  
  9. Raise the car and tighten the catalytic converter bracket nuts and bolts to 18 ft. lbs. (25 Nm).
  10.  
  11. Sparingly apply thread paste to the lower oxygen sensor threads and install it. Be sure wiring is not twisted or damaged. Torque oxygen sensor to 30 ft. lbs. (40 Nm).
  12.  
  13. Install or connect the following: Catalytic converter heat shieldSteering gear heat shieldFront exhaust pipe to catalytic converter with new gasket and nuts torqued to 18 ft. lbs. (25 Nm)Joining clamp centered on exhaust pipe at cut; torque nuts to 30 ft. lbs. (40 Nm)Lower turbocharger delivery pipeHeadlamp washer hose and connectorLower spoiler shieldChassis reinforcement front support frame, if equippedRight front fenderwell liner and front wheelUpper oxygen sensor, with thread paste sparingly, torqued to 30 ft. lbs. (40 Nm)Turbocharger oil delivery pipe, with new seals, to 16 ft. lbs. (22 Nm)Turbocharger heat shieldNegative battery cable and battery cover

    Catalytic converter heat shield
     
    Steering gear heat shield
     
    Front exhaust pipe to catalytic converter with new gasket and nuts torqued to 18 ft. lbs. (25 Nm)
     
    Joining clamp centered on exhaust pipe at cut; torque nuts to 30 ft. lbs. (40 Nm)
     
    Lower turbocharger delivery pipe
     
    Headlamp washer hose and connector
     
    Lower spoiler shield
     
    Chassis reinforcement front support frame, if equipped
     
    Right front fenderwell liner and front wheel
     
    Upper oxygen sensor, with thread paste sparingly, torqued to 30 ft. lbs. (40 Nm)
     
    Turbocharger oil delivery pipe, with new seals, to 16 ft. lbs. (22 Nm)
     
    Turbocharger heat shield
     
    Negative battery cable and battery cover
     

  14.  
  15. Check engine oil level and top as needed. Fill cooling system.
  16.  
  17. With the A/C off, ensure coolant is at MAX level. Start the engine and run at varying speeds until the cooling fan comes on.
  18.  
  19. Stop the engine. Open the expansion tank cap and top up the coolant.
  20.  
  21. Start the vehicle and run it until the thermostat opens. Turn off the engine and check coolant level.
  22.  
  23. Check for leaks and repair if necessary.
  24.  
  25. Install upper engine cover.
  26.  
  27. Reset clock and radio and other electrical accessories as needed.
  28.  
  29. Use scan tool to reprogram ECM. Follow tool instructions.
  30.  


    Click image to see an enlarged view

    Fig. Using camshaft adjusting tools-9-3 4-cylinder engine (2003-04)



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-9-3 4-cylinder engine (2003-04)


  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Cap from expansion tankOxygen sensor connectorTemperature sensor connectorHeat shield over turbochargerTurbocharger oil delivery pipeUpper oxygen sensorCatalytic converter connection from turbochargerRight front wheel and fenderwell linerLower spoiler shieldHose and connector from headlamp washersDrain the cooling systemLower turbocharger pressure pipeFront exhaust pipe from muffler (cut about 3.5 inches (87 mm) from the end of the muffler)Front pipe from catalytic converterSteering gear heat shieldCatalytic converter heat shieldTemperature sensorLower oxygen sensorBracket from catalytic converter and blockCatalytic converterDrain remaining coolantTurbocharger oil return pipeStay from intake manifold and cylinder blockStarter positive cablePower steering pipe clamps on subframeRear torsion bar bolts (loosen slightly)

    Cap from expansion tank
     
    Oxygen sensor connector
     
    Temperature sensor connector
     
    Heat shield over turbocharger
     
    Turbocharger oil delivery pipe
     
    Upper oxygen sensor
     
    Catalytic converter connection from turbocharger
     
    Right front wheel and fenderwell liner
     
    Lower spoiler shield
     
    Hose and connector from headlamp washers
     
    Drain the cooling system
     
    Lower turbocharger pressure pipe
     
    Front exhaust pipe from muffler (cut about 3.5 inches (87 mm) from the end of the muffler)
     
    Front pipe from catalytic converter
     
    Steering gear heat shield
     
    Catalytic converter heat shield
     
    Temperature sensor
     
    Lower oxygen sensor
     
    Bracket from catalytic converter and block
     
    Catalytic converter
     
    Drain remaining coolant
     
    Turbocharger oil return pipe
     
    Stay from intake manifold and cylinder block
     
    Starter positive cable
     
    Power steering pipe clamps on subframe
     
    Rear torsion bar bolts (loosen slightly)
     

  4.  
  5. Fit an engine centering tool kit, 83 96 152, to subframe, as illustrated. Adjust the centering tool bolts so adjuster screw slots are completely visible.
  6.  
  7. Lower the car and remove the upper engine cover.
  8.  
  9. Remove or disconnect the following: Turbocharger delivery hose from throttle body and pipeTurbocharger inlet pipe (plug openings)MAF sensor connectorAir cleaner assembly

    Turbocharger delivery hose from throttle body and pipe
     
    Turbocharger inlet pipe (plug openings)
     
    MAF sensor connector
     
    Air cleaner assembly
     

  10.  
  11. Release any fuel pressure by carefully pressing the service valve needle. Collect spilled fuel.
  12.  
  13. Detach both fuel lines for the fuel rail while gripping the lower nut. Plug the fuel line openings.
  14.  
  15. Remove or disconnect the following: Quick-release coupling for ventilation lineFuel lines and vent lines from camshaft cover (bend up hose and out of the way)Ignition coil coverIgnition coil connectorsTurbocharger solenoid connectorConnectors for A/C pressure sensor connector, coolant temperature sensor, engine control module, bypass solenoid valve, throttle body, MAP sensor, atmospheric pressure sensor, IDM moduleGround connection on ECMHose from turbocharger wastegate and solenoid valveWiring harness duct and bracket from camshaft cover (bend wiring harness aside)Wiring harness from oil filter housing and inlet pipeIgnition coilsCrankcase vent hose from camshaft coverGround lead from camshaft coverCamshaft cover

    Quick-release coupling for ventilation line
     
    Fuel lines and vent lines from camshaft cover (bend up hose and out of the way)
     
    Ignition coil cover
     
    Ignition coil connectors
     
    Turbocharger solenoid connector
     
    Connectors for A/C pressure sensor connector, coolant temperature sensor, engine control module, bypass solenoid valve, throttle body, MAP sensor, atmospheric pressure sensor, IDM module
     
    Ground connection on ECM
     
    Hose from turbocharger wastegate and solenoid valve
     
    Wiring harness duct and bracket from camshaft cover (bend wiring harness aside)
     
    Wiring harness from oil filter housing and inlet pipe
     
    Ignition coils
     
    Crankcase vent hose from camshaft cover
     
    Ground lead from camshaft cover
     
    Camshaft cover
     

  16.  
  17. Zero the engine by turning the crankshaft clockwise until the marking on the crankshaft pulley with aligned with the marking on the timing cover. The No. 1 cylinder cams on the intake and exhaust camshafts should be pointing up and inward.
  18.  
  19. Remove or disconnect the following: Coolant hose from cylinder headRight engine mountIDM moduleCouplings from vacuum pumpPower steering pumpEVAP canister purge valve and bracketThrottle bodyECMFuel injector connectorsDipstick tube boltVacuum hose and purge hose from intake manifoldVacuum hose from fuel pressure regulatorIntake manifoldTiming chain tensionerCamshaft pinions (hold camshaft flats with wrench)

    Coolant hose from cylinder head
     
    Right engine mount
     
    IDM module
     
    Couplings from vacuum pump
     
    Power steering pump
     
    EVAP canister purge valve and bracket
     
    Throttle body
     
    ECM
     
    Fuel injector connectors
     
    Dipstick tube bolt
     
    Vacuum hose and purge hose from intake manifold
     
    Vacuum hose from fuel pressure regulator
     
    Intake manifold
     
    Timing chain tensioner
     
    Camshaft pinions (hold camshaft flats with wrench)
     

  20.  
  21. Fit a cable tie to the exhaust camshaft pinion and chain. Remove the camshaft pinions and lower the exhaust camshaft pinion with the chain.
  22.  
  23. Remove the cylinder head plug.
  24.  
  25. Remove the bolts (61) for the chain guide on the intake side. Move the guide away and install the bolt again.
  26.  
  27. Remove the cylinder head. Remove the cylinder head bolts in an alternating pattern (62).
  28.  


    Click image to see an enlarged view

    Fig. Showing cylinder head bolt locations-9-3 4-cylinder engines 2001-04


To install:

  1. Thoroughly clean all mating surfaces. Blow out bolt holes. Check for any warping or damage.
  2.  
  3. Check that marks on the pulley and timing cover are aligned.
  4.  
  5. Place a new gasket on the cylinder block. Lift up the sprocket and pull the chain guides together to lower the cylinder head.
  6.  
  7. Remove the exhaust camshaft and intake camshaft No. 2 bearing caps. Fit an adjustment tools, 83 96 046, to the camshafts (5). Tighten retaining bolts.
  8.  
  9. Install cylinder head bolts, in sequence as illustrated. DO NOT drop bolts into place or threads will be damaged. Tighten cylinder head bolts in 3 steps as follows: Step 1: 22 ft. lbs. (30 Nm)Step 2: Each bolt, in sequence, an additional 75 degreesStep 3: Each bolt, in sequence, an additional 80 degrees
    1. Step 1: 22 ft. lbs. (30 Nm)
    2.  
    3. Step 2: Each bolt, in sequence, an additional 75 degrees
    4.  
    5. Step 3: Each bolt, in sequence, an additional 80 degrees
    6.  

  10.  
  11. Install and tighten transmission section bolts to 26 ft. lbs. (35 Nm).
  12.  
  13. Remove the bolt for the chain guide. Put the guide in place an install and tighten the bolt.
  14.  
  15. Install the plug on the front of the cylinder head, with a new sealing washer. Tighten the plug to 18 ft. lbs. (25 Nm).
  16.  
  17. Fit the pinion on the exhaust camshaft and intake camshaft without tightening. Verify that the engine is still -zeroed-.
  18.  
  19. Install the chain tensioner reset with a new seal. The groove on the end of the chain tensioner should be vertical when installed. Torque tensioner reset to 55 ft. lbs. (75 Nm).
  20.  
  21. Torque the camshaft pinions while gripping the respective camshaft with a wrench on the flats. Torque to 63 ft. lbs. (85 Nm), plus an additional 30 degrees. Remove the cable tie.
  22.  
  23. Remove the camshaft adjustment tool and fit the camshaft No. 2 bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).
  24.  
  25. Turn the engine over twice and zero it so the markings are aligned. Remove camshaft bearing caps No. 2 and No. 7 and install that camshaft adjustment tool, 83 96 046, to check that camshaft setting is correct. Remove the tools and install the bearing caps.
  26.  
  27. Clean the sealing surfaces on the intake manifold and cylinder head. Install the intake manifold with a new gasket. Torque the nuts to 84 inch lbs. (10 Nm).
  28.  
  29. Install or connect the following: Vacuum hose to fuel pressure regulatorDipstick tube boltVacuum hose and purge hose to intake manifoldFuel injector connectorsThrottle body and ECM (leaving upper right screw for ground cable)Bracket and coupling to EVAP canister purge valvePower steering pump, with a new seal, to 16 ft. lbs. (22 Nm)Hose to vacuum pumpIDM moduleCoolant hose to pipe on cylinder headRight side engine mount: body bolts to 30 ft. lbs. (40 Nm), plus an additional 60 degrees and bracket bolts to 52 ft. lbs. (70 Nm), plus an additional 60 degreesRemaining coolant hose to cylinder head pipeCamshaft cover, with a new seal, to 84 inch lbs. (10 Nm)Ground cable to camshaft coverCrankcase vent hose to camshaft coverIgnition coilsWiring harness to intake manifold and oil filter housingWiring harness duct and bracket to camshaft coverHose to turbocharger wastegate and solenoid valveConnectors for A/C pressure sensor, coolant temperature sensor, ECM, wastegate solenoid, throttle body, MAP sensor, barometric pressure sensor, IDM moduleGround cable to ECMIgnition module connectors (ensure cables are not pinched by cover)Turbocharger solenoid valve connectors with cable clipsCover over ignition coilsFuel lines and vent lines into clips on camshaft coverCoupling for vent lineBoth fuel lines, with new seals, to fuel rail while gripping lower nut to 84 inch lbs. (10 Nm)Air cleaner assembly

    Vacuum hose to fuel pressure regulator
     
    Dipstick tube bolt
     
    Vacuum hose and purge hose to intake manifold
     
    Fuel injector connectors
     
    Throttle body and ECM (leaving upper right screw for ground cable)
     
    Bracket and coupling to EVAP canister purge valve
     
    Power steering pump, with a new seal, to 16 ft. lbs. (22 Nm)
     
    Hose to vacuum pump
     
    IDM module
     
    Coolant hose to pipe on cylinder head
     
    Right side engine mount: body bolts to 30 ft. lbs. (40 Nm), plus an additional 60 degrees and bracket bolts to 52 ft. lbs. (70 Nm), plus an additional 60 degrees
     
    Remaining coolant hose to cylinder head pipe
     
    Camshaft cover, with a new seal, to 84 inch lbs. (10 Nm)
     
    Ground cable to camshaft cover
     
    Crankcase vent hose to camshaft cover
     
    Ignition coils
     
    Wiring harness to intake manifold and oil filter housing
     
    Wiring harness duct and bracket to camshaft cover
     
    Hose to turbocharger wastegate and solenoid valve
     
    Connectors for A/C pressure sensor, coolant temperature sensor, ECM, wastegate solenoid, throttle body, MAP sensor, barometric pressure sensor, IDM module
     
    Ground cable to ECM
     
    Ignition module connectors (ensure cables are not pinched by cover)
     
    Turbocharger solenoid valve connectors with cable clips
     
    Cover over ignition coils
     
    Fuel lines and vent lines into clips on camshaft cover
     
    Coupling for vent line
     
    Both fuel lines, with new seals, to fuel rail while gripping lower nut to 84 inch lbs. (10 Nm)
     
    Air cleaner assembly
     

  30.  


WARNING
To prevent hoses on delivery side of turbocharger from coming loose under pressure, thoroughly clean all mating areas on inside of hoses and pipes before attaching.



Air cleaner cover
 
MAF sensor connector
 
Turbocharger inlet pipe to air cleaner
 
Hoses to inlet pipe
 
Turbocharger hose to throttle body and turbo delivery pipe
 

  1. Raise the car and remove the engine centering tool from the subframe.
  2.  
  3. Torque the rear torsion arm bolts to 52 ft. lbs. (70 Nm), plus an additional 90 degrees.
  4.  
  5. Install or connect the following: Bolts on power steering pipe clamps on subframePositive cable to starterStay between intake manifold and cylinder block to 16 ft. lbs. (22 Nm)Oil return line to turbocharger with new gasket and O-ring; torque to 11 ft. lbs. (15 Nm)Stay between exhaust manifold and cylinder block to 16 ft. lbs. (22 Nm)New seals on turbocharger coolant pipe; torque to 30 ft. lbs. (40 Nm)Catalytic converter and bracket to studs on engine block and to turbocharger connectionCatalytic converter bracket bolts into engine block and new nuts on studs

    Bolts on power steering pipe clamps on subframe
     
    Positive cable to starter
     
    Stay between intake manifold and cylinder block to 16 ft. lbs. (22 Nm)
     
    Oil return line to turbocharger with new gasket and O-ring; torque to 11 ft. lbs. (15 Nm)
     
    Stay between exhaust manifold and cylinder block to 16 ft. lbs. (22 Nm)
     
    New seals on turbocharger coolant pipe; torque to 30 ft. lbs. (40 Nm)
     
    Catalytic converter and bracket to studs on engine block and to turbocharger connection
     
    Catalytic converter bracket bolts into engine block and new nuts on studs
     

  6.  
  7. Lower the car and install the catalytic converter with new nuts so it is evenly positioned to the turbocharger. Use thread paste on the studs.
  8.  
  9. Raise the car and tighten the catalytic converter bracket nuts and bolts to 18 ft. lbs. (25 Nm).
  10.  
  11. Sparingly apply thread paste to the lower oxygen sensor threads and install it. Be sure wiring is not twisted or damaged. Torque oxygen sensor to 30 ft. lbs. (40 Nm).
  12.  
  13. Install or connect the following: Catalytic converter heat shieldSteering gear heat shieldFront exhaust pipe to catalytic converter with new gasket and nuts torqued to 18 ft. lbs. (25 Nm)Joining clamp centered on exhaust pipe at cut; torque nuts to 30 ft. lbs. (40 Nm)Lower turbocharger delivery pipeHeadlamp washer hose and connectorLower spoiler shieldChassis reinforcement front support frame, if equippedRight front fenderwell liner and front wheelUpper oxygen sensor, with thread paste sparingly, torqued to 30 ft. lbs. (40 Nm)Turbocharger oil delivery pipe, with new seals, to 16 ft. lbs. (22 Nm)Turbocharger heat shieldNegative battery cable and battery cover

    Catalytic converter heat shield
     
    Steering gear heat shield
     
    Front exhaust pipe to catalytic converter with new gasket and nuts torqued to 18 ft. lbs. (25 Nm)
     
    Joining clamp centered on exhaust pipe at cut; torque nuts to 30 ft. lbs. (40 Nm)
     
    Lower turbocharger delivery pipe
     
    Headlamp washer hose and connector
     
    Lower spoiler shield
     
    Chassis reinforcement front support frame, if equipped
     
    Right front fenderwell liner and front wheel
     
    Upper oxygen sensor, with thread paste sparingly, torqued to 30 ft. lbs. (40 Nm)
     
    Turbocharger oil delivery pipe, with new seals, to 16 ft. lbs. (22 Nm)
     
    Turbocharger heat shield
     
    Negative battery cable and battery cover
     

  14.  
  15. Check engine oil level and top as needed. Fill cooling system.
  16.  
  17. With the A/C off, ensure coolant is at MAX level. Start the engine and run at varying speeds until the cooling fan comes on.
  18.  
  19. Stop the engine. Open the expansion tank cap and top up the coolant.
  20.  
  21. Start the vehicle and run it until the thermostat opens. Turn off the engine and check coolant level.
  22.  
  23. Check for leaks and repair if necessary.
  24.  
  25. Install upper engine cover.
  26.  
  27. Reset clock and radio and other electrical accessories as needed.
  28.  
  29. Use scan tool to reprogram ECM. Follow tool instructions.
  30.  


    Click image to see an enlarged view

    Fig. Using camshaft adjusting tools-9-3 4-cylinder engine 2003-04



    Click image to see an enlarged view

    Fig. Cylinder head bolt tightening sequence-9-3 4-cylinder engine 2003-04


2003-06 Model (Except 2.8L Engine)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Cap from expansion tank
     
    Oxygen sensor connector
     
    Temperature sensor connector
     
    Heat shield over turbocharger
     
    Turbocharger oil delivery pipe
     
    Upper oxygen sensor
     
    Catalytic converter connection from turbocharger
     
    Right front wheel and fenderwell liner
     
    Lower spoiler shield
     
    Hose and connector from headlamp washers
     
    Drain the cooling system
     
    Lower turbocharger pressure pipe
     
    Front exhaust pipe from muffler (cut about 3.5 inches (87 mm) from the end of the muffler)
     
    Front pipe from catalytic converter
     
    Steering gear heat shield
     
    Catalytic converter heat shield
     
    Temperature sensor
     
    Lower oxygen sensor
     
    Bracket from catalytic converter and block
     
    Catalytic converter
     
    Drain remaining coolant
     
    Turbocharger oil return pipe
     
    Stay from intake manifold and cylinder block
     
    Starter positive cable
     
    Power steering pipe clamps on subframe
     
    Rear torsion bar bolts (loosen slightly)
     

  4.  
  5. Fit an engine centering tool kit, 83 96 152, to subframe, as illustrated. Adjust the centering tool bolts so adjuster screw slots are completely visible.
  6.  
  7. Lower the car and remove the upper engine cover.
  8.  
  9. Remove or disconnect the following:

    Turbocharger delivery hose from throttle body and pipe
     
    Turbocharger inlet pipe (plug openings)
     
    MAF sensor connector
     
    Air cleaner assembly
     

  10.  
  11. Release any fuel pressure by carefully pressing the service valve needle. Collect spilled fuel.
  12.  
  13. Detach both fuel lines for the fuel rail while gripping the lower nut. Plug the fuel line openings.
  14.  
  15. Remove or disconnect the following:

    Quick-release coupling for ventilation line
     
    Fuel lines and vent lines from camshaft cover (bend up hose and out of the way)
     
    Ignition coil cover
     
    Ignition coil connectors
     
    Turbocharger solenoid connector
     
    Connectors for A/C pressure sensor connector, coolant temperature sensor, engine control module, bypass solenoid valve, throttle body, MAP sensor, atmospheric pressure sensor, IDM module
     
    Ground connection on ECM
     
    Hose from turbocharger wastegate and solenoid valve
     
    Wiring harness duct and bracket from camshaft cover (bend wiring harness aside)
     
    Wiring harness from oil filter housing and inlet pipe
     
    Ignition coils
     
    Crankcase vent hose from camshaft cover
     
    Ground lead from camshaft cover
     
    Camshaft cover
     

  16.  
  17. Zero the engine by turning the crankshaft clockwise until the marking on the crankshaft pulley with aligned with the marking on the timing cover. The No. 1 cylinder cams on the intake and exhaust camshafts should be pointing up and inward.
  18.  
  19. Remove or disconnect the following:

    Coolant hose from cylinder head
     
    Right engine mount
     
    IDM module
     
    Couplings from vacuum pump
     
    Power steering pump
     
    EVAP canister purge valve and bracket
     
    Throttle body
     
    ECM
     
    Fuel injector connectors
     
    Dipstick tube bolt
     
    Vacuum hose and purge hose from intake manifold
     
    Vacuum hose from fuel pressure regulator
     
    Intake manifold
     
    Timing chain tensioner
     
    Camshaft pinions (hold camshaft flats with wrench)
     

  20.  
  21. Fit a cable tie to the exhaust camshaft pinion and chain. Remove the camshaft pinions and lower the exhaust camshaft pinion with the chain.
  22.  
  23. Remove the cylinder head plug.
  24.  
  25. Remove the bolts (61) for the chain guide on the intake side. Move the guide away and install the bolt again.
  26.  
  27. Remove the cylinder head. Remove the cylinder head bolts in an alternating pattern (62).

    Click image to see an enlarged view

    Fig. Showing cylinder head bolt locations-9-3 4-cylinder engines

  28.  

To install:

  1. Thoroughly clean all mating surfaces. Blow out bolt holes. Check for any warping or damage.
  2.  
  3. Check that marks on the pulley and timing cover are aligned.
  4.  
  5. Place a new gasket on the cylinder block. Lift up the sprocket and pull the chain guides together to lower the cylinder head.
  6.  
  7. Remove the exhaust camshaft and intake camshaft No. 2 bearing caps. Fit an adjustment tools, 83 96 046, to the camshafts (5). Tighten retaining bolts.
  8.  
  9. Install cylinder head bolts, in sequence as illustrated. DO NOT drop bolts into place or threads will be damaged. Tighten cylinder head bolts in 3 steps as follows:
    1. Step 1: 22 ft. lbs. (30 Nm)
    2.  
    3. Step 2: Each bolt, in sequence, an additional 75 degrees
    4.  
    5. Step 3: Each bolt, in sequence, an additional 80 degrees
    6.  

  10.  
  11. Install and tighten transmission section bolts to 26 ft. lbs. (35 Nm).
  12.  
  13. Remove the bolt for the chain guide. Put the guide in place an install and tighten the bolt.
  14.  
  15. Install the plug on the front of the cylinder head, with a new sealing washer. Tighten the plug to 18 ft. lbs. (25 Nm).
  16.  
  17. Fit the pinion on the exhaust camshaft and intake camshaft without tightening. Verify that the engine is still -zeroed-.
  18.  
  19. Install the chain tensioner reset with a new seal. The groove on the end of the chain tensioner should be vertical when installed. Torque tensioner reset to 55 ft. lbs. (75 Nm).
  20.  
  21. Torque the camshaft pinions while gripping the respective camshaft with a wrench on the flats. Torque to 63 ft. lbs. (85 Nm), plus an additional 30 degrees. Remove the cable tie.
  22.  
  23. Remove the camshaft adjustment tool and fit the camshaft No. 2 bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).
  24.  
  25. Turn the engine over twice and zero it so the markings are aligned. Remove camshaft bearing caps No. 2 and No. 7 and install that camshaft adjustment tool, 83 96 046, to check that camshaft setting is correct. Remove the tools and install the bearing caps.
  26.  
  27. Clean the sealing surfaces on the intake manifold and cylinder head. Install the intake manifold with a new gasket. Torque the nuts to 84 inch lbs. (10 Nm).
  28.  
  29. Install or connect the following:
    WARNING
    To prevent hoses on delivery side of turbocharger from coming loose under pressure, thoroughly clean all mating areas on inside of hoses and pipes before attaching.



    Vacuum hose to fuel pressure regulator
     
    Dipstick tube bolt
     
    Vacuum hose and purge hose to intake manifold
     
    Fuel injector connectors
     
    Throttle body and ECM (leaving upper right screw for ground cable)
     
    Bracket and coupling to EVAP canister purge valve
     
    Power steering pump, with a new seal, to 16 ft. lbs. (22 Nm)
     
    Hose to vacuum pump
     
    IDM module
     
    Coolant hose to pipe on cylinder head
     
    Right side engine mount: body bolts to 30 ft. lbs. (40 Nm), plus an additional 60 degrees and bracket bolts to 52 ft. lbs. (70 Nm), plus an additional 60 degrees
     
    Remaining coolant hose to cylinder head pipe
     
    Camshaft cover, with a new seal, to 84 inch lbs. (10 Nm)
     
    Ground cable to camshaft cover
     
    Crankcase vent hose to camshaft cover
     
    Ignition coils
     
    Wiring harness to intake manifold and oil filter housing
     
    Wiring harness duct and bracket to camshaft cover
     
    Hose to turbocharger wastegate and solenoid valve
     
    Connectors for A/C pressure sensor, coolant temperature sensor, ECM, wastegate solenoid, throttle body, MAP sensor, barometric pressure sensor, IDM module
     
    Ground cable to ECM
     
    Ignition module connectors (ensure cables are not pinched by cover)
     
    Turbocharger solenoid valve connectors with cable clips
     
    Cover over ignition coils
     
    Fuel lines and vent lines into clips on camshaft cover
     
    Coupling for vent line
     
    Both fuel lines, with new seals, to fuel rail while gripping lower nut to 84 inch lbs. (10 Nm)
     
    Air cleaner assembly
     



    Air cleaner cover
     
    MAF sensor connector
     
    Turbocharger inlet pipe to air cleaner
     
    Hoses to inlet pipe
     
    Turbocharger hose to throttle body and turbo delivery pipe
     

  30.  
  31. Raise the car and remove the engine centering tool from the subframe.
  32.  
  33. Torque the rear torsion arm bolts to 52 ft. lbs. (70 Nm), plus an additional 90 degrees.
  34.  
  35. Install or connect the following:

    Bolts on power steering pipe clamps on subframe
     
    Positive cable to starter
     
    Stay between intake manifold and cylinder block to 16 ft. lbs. (22 Nm)
     
    Oil return line to turbocharger with new gasket and O-ring; torque to 11 ft. lbs. (15 Nm)