Saab 2000-06

Cylinder Head 2

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Removal & Installation



9-5
2.3L Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Run engine at idle speed. Remove fuse No 19 from fuse panel. When engine stops, turn off ignition. Re-install the fuse.
  4.  
  5. Remove the battery cover and intake manifold cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following: Battery and intake manifold coverNegative battery cableLower engine coverRight front wheelSteering servo pipe from the subframe and install a wedge between the oil pan and subframe on the right hand sideRight front engine mount and bracketMass Air Flow (MAF) sensorCrankcase breather pipeFront lifting eyeCharge air pipe and bypass valvePressure/temperature sensor connectorBypass valve vacuum hoseV-beltBelt tensionerAlternator (move the bracket aside)Temperature sensor and ignition discharge module connectorsCoolant hoses from the cylinder headThrottle body lever coverThrottle cable and dipstick tubeFuel hosesCrankcase breather nipple from the timing coverIntake manifold steady barTurbocharger steady barTurbocharger and exhaust manifold heat shieldServo pump and suspend it on the radiator crossmemberLower screw from the steering servo pump bracketBracket for the ignition discharge module-s connector from the rear lifting eyeHeat exchanger pipe bracketIntake manifold and partition and move it rearwardIgnition discharge module and spark plugsCamshaft cover and align the pulley marks with the timing cover and make certain that the camshafts are in line with their timing marksCamshaft sprocket bolts. Make certain that the camshaft does not turnIdler sprocket bolt and remove the chain tensionerCamshaft sprockets and place a rubber band between the chain guidesCylinder head by first removing the bolts from the timing cover

    Battery and intake manifold cover
     
    Negative battery cable
     
    Lower engine cover
     
    Right front wheel
     
    Steering servo pipe from the subframe and install a wedge between the oil pan and subframe on the right hand side
     
    Right front engine mount and bracket
     
    Mass Air Flow (MAF) sensor
     
    Crankcase breather pipe
     
    Front lifting eye
     
    Charge air pipe and bypass valve
     
    Pressure/temperature sensor connector
     
    Bypass valve vacuum hose
     
    V-belt
     
    Belt tensioner
     
    Alternator (move the bracket aside)
     
    Temperature sensor and ignition discharge module connectors
     
    Coolant hoses from the cylinder head
     
    Throttle body lever cover
     
    Throttle cable and dipstick tube
     
    Fuel hoses
     
    Crankcase breather nipple from the timing cover
     
    Intake manifold steady bar
     
    Turbocharger steady bar
     
    Turbocharger and exhaust manifold heat shield
     
    Servo pump and suspend it on the radiator crossmember
     
    Lower screw from the steering servo pump bracket
     
    Bracket for the ignition discharge module-s connector from the rear lifting eye
     
    Heat exchanger pipe bracket
     
    Intake manifold and partition and move it rearward
     
    Ignition discharge module and spark plugs
     
    Camshaft cover and align the pulley marks with the timing cover and make certain that the camshafts are in line with their timing marks
     
    Camshaft sprocket bolts. Make certain that the camshaft does not turn
     
    Idler sprocket bolt and remove the chain tensioner
     
    Camshaft sprockets and place a rubber band between the chain guides
     
    Cylinder head by first removing the bolts from the timing cover
     

  10.  

To install:

  1. Clean all mating surfaces.
  2.  
  3. Install or connect the following: Inner gasket for the camshaft cover partitionCylinder head gasket and turn the crankshaft 45 degrees in the rotational direction of the engine to lower pistons

    Inner gasket for the camshaft cover partition
     
    Cylinder head gasket and turn the crankshaft 45 degrees in the rotational direction of the engine to lower pistons
     

  4.  
  5. Bind chain guides with strap or rubber band and install the new cylinder head gasket and position cylinder head. Make sure chain is not trapped.
  6.  
  7. Install the cylinder head bolts. Torque the bolts in sequence shown as follows: 30 ft. lbs. (40 Nm).44 ft. lbs. (60 Nm).Plus an additional 90 degrees.
    1. 30 ft. lbs. (40 Nm).
    2.  
    3. 44 ft. lbs. (60 Nm).
    4.  
    5. Plus an additional 90 degrees.
    6.  

  8.  
  9. Install or connect the following: 2 bolts between the timing cover and cylinder head and torque the bolts to 16 ft. lbs. (22 Nm). Make certain that the camshafts are aligned with the timing marks and reset the crankshaft to the O mark.Camshaft sprocket and chain starting with the exhaust camshaft. Do not tighten the boltsTiming chain tensioner and torque the bolts to 47 ft. lbs. (63 Nm)Timing chain tensioner plug, push rod and spring and torque the bolt to 16 ft. lbs. (22 Nm)Torque the idler pulley and camshaft sprocket bolts to 47 ft. lbs. (63 Nm). Rotate the crankshaft 2 revolutions and make check the settings of the crankshaft pulley and camshaftsCamshaft cover after lightly coating the opening with clean oil and torque the bolts, in sequence from the front at the timing chain end and working around, to 11 ft. lbs. (15 Nm)Spark plugs and torque the plugs to 21 ft. lbs. (28 Nm)Ignition discharge module and torque the bolt to 8 ft. lbs. (11 Nm)Intake manifold and intermediate partition. Remove the straps and torque the bolts to 16 ft. lbs. (22 Nm).Alternator bracket and make certain that the adjuster sleeve is tapped out slightlyBelt tensioner and tighten the ignition discharge module connector bracketCoolant hoses to the cylinder head and install the bolt securing the pipe to the thermostat housing coverIgnition discharge module electrical connectorTemperature sensor electrical connectorTurbocharger retaining nuts between the exhaust manifold and turbocharger and torque the bolts to 19 ft. lbs. (25 Nm)Turbocharger heat shieldDipstick tubeTurbocharger and intake manifold steady barsFuel hoses and rubber protectorsCrankcase ventilation nipple on the valve coverThrottle cable and adjust as necessaryGround connections to the cylinder headThrottle body coverServo pump and install the V-belt. Torque the pulley bolts to 15 ft. lbs. (20 Nm)Lifting eyeSolenoid valve connectorCharge air pipe and bypass valveBypass valve vacuum hose and pressure/temperature sensor connectorMAF sensorRight side engine mount and bracket. Torque the bolts to 39 ft. lbs. (47 Nm) and the nuts to 78 ft. lbs. (105 Nm). Remove the wedge and secure the servo pump pipe to the subframeRight front wheelCrankcase breather pipe and torque the banjo bolt to 18 ft. lbs. (24 Nm)Lower engine coverNegative battery cableIntake manifold and battery cover

    2 bolts between the timing cover and cylinder head and torque the bolts to 16 ft. lbs. (22 Nm). Make certain that the camshafts are aligned with the timing marks and reset the crankshaft to the O mark.O
     
    Camshaft sprocket and chain starting with the exhaust camshaft. Do not tighten the bolts
     
    Timing chain tensioner and torque the bolts to 47 ft. lbs. (63 Nm)
     
    Timing chain tensioner plug, push rod and spring and torque the bolt to 16 ft. lbs. (22 Nm)
     
    Torque the idler pulley and camshaft sprocket bolts to 47 ft. lbs. (63 Nm). Rotate the crankshaft 2 revolutions and make check the settings of the crankshaft pulley and camshafts
     
    Camshaft cover after lightly coating the opening with clean oil and torque the bolts, in sequence from the front at the timing chain end and working around, to 11 ft. lbs. (15 Nm)
     
    Spark plugs and torque the plugs to 21 ft. lbs. (28 Nm)
     
    Ignition discharge module and torque the bolt to 8 ft. lbs. (11 Nm)
     
    Intake manifold and intermediate partition. Remove the straps and torque the bolts to 16 ft. lbs. (22 Nm).
     
    Alternator bracket and make certain that the adjuster sleeve is tapped out slightly
     
    Belt tensioner and tighten the ignition discharge module connector bracket
     
    Coolant hoses to the cylinder head and install the bolt securing the pipe to the thermostat housing cover
     
    Ignition discharge module electrical connector
     
    Temperature sensor electrical connector
     
    Turbocharger retaining nuts between the exhaust manifold and turbocharger and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Turbocharger heat shield
     
    Dipstick tube
     
    Turbocharger and intake manifold steady bars
     
    Fuel hoses and rubber protectors
     
    Crankcase ventilation nipple on the valve cover
     
    Throttle cable and adjust as necessary
     
    Ground connections to the cylinder head
     
    Throttle body cover
     
    Servo pump and install the V-belt. Torque the pulley bolts to 15 ft. lbs. (20 Nm)
     
    Lifting eye
     
    Solenoid valve connector
     
    Charge air pipe and bypass valve
     
    Bypass valve vacuum hose and pressure/temperature sensor connector
     
    MAF sensor
     
    Right side engine mount and bracket. Torque the bolts to 39 ft. lbs. (47 Nm) and the nuts to 78 ft. lbs. (105 Nm). Remove the wedge and secure the servo pump pipe to the subframe
     
    Right front wheel
     
    Crankcase breather pipe and torque the banjo bolt to 18 ft. lbs. (24 Nm)
     
    Lower engine cover
     
    Negative battery cable
     
    Intake manifold and battery cover
     

  10.  
  11. Fill the cooling system and check all fluid levels.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Run engine at idle speed. Remove fuse No 19 from fuse panel. When engine stops, turn off ignition. Re-install the fuse.
  4.  
  5. Remove the battery cover and intake manifold cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Battery and intake manifold cover
     
    Negative battery cable
     
    Lower engine cover
     
    Right front wheel
     
    Steering servo pipe from the subframe and install a wedge between the oil pan and subframe on the right hand side
     
    Right front engine mount and bracket
     
    Mass Air Flow (MAF) sensor
     
    Crankcase breather pipe
     
    Front lifting eye
     
    Charge air pipe and bypass valve
     
    Pressure/temperature sensor connector
     
    Bypass valve vacuum hose
     
    V-belt
     
    Belt tensioner
     
    Alternator (move the bracket aside)
     
    Temperature sensor and ignition discharge module connectors
     
    Coolant hoses from the cylinder head
     
    Throttle body lever cover
     
    Throttle cable and dipstick tube
     
    Fuel hoses
     
    Crankcase breather nipple from the timing cover
     
    Intake manifold steady bar
     
    Turbocharger steady bar
     
    Turbocharger and exhaust manifold heat shield
     
    Servo pump and suspend it on the radiator crossmember
     
    Lower screw from the steering servo pump bracket
     
    Bracket for the ignition discharge module-s connector from the rear lifting eye
     
    Heat exchanger pipe bracket
     
    Intake manifold and partition and move it rearward
     
    Ignition discharge module and spark plugs
     
    Camshaft cover and align the pulley marks with the timing cover and make certain that the camshafts are in line with their timing marks
     
    Camshaft sprocket bolts. Make certain that the camshaft does not turn
     
    Idler sprocket bolt and remove the chain tensioner
     
    Camshaft sprockets and place a rubber band between the chain guides
     
    Cylinder head by first removing the bolts from the timing cover
     

  10.  

To install:

  1. Clean all mating surfaces.
  2.  
  3. Install or connect the following:

    Inner gasket for the camshaft cover partition
     
    Cylinder head gasket and turn the crankshaft 45 degrees in the rotational direction of the engine to lower pistons
     

  4.  
  5. Bind chain guides with strap or rubber band and install the new cylinder head gasket and position cylinder head. Make sure chain is not trapped.
  6.  
  7. Install the cylinder head bolts. Torque the bolts in sequence shown as follows:
    1. 30 ft. lbs. (40 Nm).
    2.  
    3. 44 ft. lbs. (60 Nm).
    4.  
    5. Plus an additional 90 degrees.
    6.  

  8.  
  9. Install or connect the following:

    2 bolts between the timing cover and cylinder head and torque the bolts to 16 ft. lbs. (22 Nm). Make certain that the camshafts are aligned with the timing marks and reset the crankshaft to the O mark.
     
    Camshaft sprocket and chain starting with the exhaust camshaft. Do not tighten the bolts
     
    Timing chain tensioner and torque the bolts to 47 ft. lbs. (63 Nm)
     
    Timing chain tensioner plug, push rod and spring and torque the bolt to 16 ft. lbs. (22 Nm)
     
    Torque the idler pulley and camshaft sprocket bolts to 47 ft. lbs. (63 Nm). Rotate the crankshaft 2 revolutions and make check the settings of the crankshaft pulley and camshafts
     
    Camshaft cover after lightly coating the opening with clean oil and torque the bolts, in sequence from the front at the timing chain end and working around, to 11 ft. lbs. (15 Nm)
     
    Spark plugs and torque the plugs to 21 ft. lbs. (28 Nm)
     
    Ignition discharge module and torque the bolt to 8 ft. lbs. (11 Nm)
     
    Intake manifold and intermediate partition. Remove the straps and torque the bolts to 16 ft. lbs. (22 Nm).
     
    Alternator bracket and make certain that the adjuster sleeve is tapped out slightly
     
    Belt tensioner and tighten the ignition discharge module connector bracket
     
    Coolant hoses to the cylinder head and install the bolt securing the pipe to the thermostat housing cover
     
    Ignition discharge module electrical connector
     
    Temperature sensor electrical connector
     
    Turbocharger retaining nuts between the exhaust manifold and turbocharger and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Turbocharger heat shield
     
    Dipstick tube
     
    Turbocharger and intake manifold steady bars
     
    Fuel hoses and rubber protectors
     
    Crankcase ventilation nipple on the valve cover
     
    Throttle cable and adjust as necessary
     
    Ground connections to the cylinder head
     
    Throttle body cover
     
    Servo pump and install the V-belt. Torque the pulley bolts to 15 ft. lbs. (20 Nm)
     
    Lifting eye
     
    Solenoid valve connector
     
    Charge air pipe and bypass valve
     
    Bypass valve vacuum hose and pressure/temperature sensor connector
     
    MAF sensor
     
    Right side engine mount and bracket. Torque the bolts to 39 ft. lbs. (47 Nm) and the nuts to 78 ft. lbs. (105 Nm). Remove the wedge and secure the servo pump pipe to the subframe
     
    Right front wheel
     
    Crankcase breather pipe and torque the banjo bolt to 18 ft. lbs. (24 Nm)
     
    Lower engine cover
     
    Negative battery cable
     
    Intake manifold and battery cover
     

  10.  
  11. Fill the cooling system and check all fluid levels.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

3.0L Engine - Front Cylinder Head
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove the vent hose and battery.
  4.  
  5. Remove the lower engine cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following: Turbocharger bracket and install wedges between the oil pan and subframe and gearbox and subframeTurbocharger delivery pipe from the charge air coolerMass Air Flow (MAF) sensor and hosePower steering hose from the holderRight side engine mount and bracketV-belt tensionWater pump and power steering pump pulleysBelt tensioner and alternator air intakeTiming coverThrottle cableUpper intake manifold vacuum hoses and pressure sensor connectorVacuum hose and water hoses from the throttle bodyTurbocharger delivery pipe with the bypass pipe and valve from the throttle bodyPressure/temperature sensor connectorThrottle body connector and purge valve hose from the throttle bodyIgnition discharge module connectorFuel injector electrical connectorFuel linesUpper intake manifold and move it asideMiddle intake manifoldLower intake manifoldCoolant bridge and move it asideCrankshaft pulleyTensioner pulley and adjusting rollers and mark the rotation direction of the beltLower adjusting roller and washerTiming belt. Refer to the appropriate section for the timing belt removal and installation.Adjuster roller boltsIgnition discharge moduleCamshaft cover and make sure the O-rings do not fall into the engine. Rotate the engine 60 degrees Before Top Dead Center (BTDC) and note the markingCamshaft sprocketsWater pumpInner timing coverFront exhaust manifold heat shieldHose connections for the front SAI valveSAI pipe and valve from the exhaust manifoldCrankcase ventilation pipe from between the turbocharger intake pipe and the cylinder headTurbocharger intake pipe and outlet hoseWater hose from the thermostat housingFront exhaust manifold from the turbochargerTurbocharger water and oil pipesExhaust camshaft by removing the bolts in stagesBearing caps where the tappets are under loadStuffing boxCylinder head bolts in the proper sequence by loosening them 1/4turn then 1/2turn

    Turbocharger bracket and install wedges between the oil pan and subframe and gearbox and subframe
     
    Turbocharger delivery pipe from the charge air cooler
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    V-belt tension
     
    Water pump and power steering pump pulleys
     
    Belt tensioner and alternator air intake
     
    Timing cover
     
    Throttle cable
     
    Upper intake manifold vacuum hoses and pressure sensor connector
     
    Vacuum hose and water hoses from the throttle body
     
    Turbocharger delivery pipe with the bypass pipe and valve from the throttle body
     
    Pressure/temperature sensor connector
     
    Throttle body connector and purge valve hose from the throttle body
     
    Ignition discharge module connector
     
    Fuel injector electrical connector
     
    Fuel lines
     
    Upper intake manifold and move it aside
     
    Middle intake manifold
     
    Lower intake manifold
     
    Coolant bridge and move it aside
     
    Crankshaft pulley
     
    Tensioner pulley and adjusting rollers and mark the rotation direction of the belt
     
    Lower adjusting roller and washer
     
    Timing belt. Refer to the appropriate section for the timing belt removal and installation.
     
    Adjuster roller bolts
     
    Ignition discharge module
     
    Camshaft cover and make sure the O-rings do not fall into the engine. Rotate the engine 60 degrees Before Top Dead Center (BTDC) and note the marking
     
    Camshaft sprockets
     
    Water pump
     
    Inner timing cover
     
    Front exhaust manifold heat shield
     
    Hose connections for the front SAI valve
     
    SAI pipe and valve from the exhaust manifold
     
    Crankcase ventilation pipe from between the turbocharger intake pipe and the cylinder head
     
    Turbocharger intake pipe and outlet hose
     
    Water hose from the thermostat housing
     
    Front exhaust manifold from the turbocharger
     
    Turbocharger water and oil pipes
     
    Exhaust camshaft by removing the bolts in stages
     
    Bearing caps where the tappets are under load
     
    Stuffing box
     
    Cylinder head bolts in the proper sequence by loosening them 1/4turn then 1/2turn1412
     

  10.  


    Click image to see an enlarged view

    Fig. Remove the cylinder head bolts as shown


To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Make certain that the crankshaft is at 60° BTDC.
  4.  
  5. Be sure that the proper gasket is used and is marked OBEN/TOPOBEN/TOP
  6.  
  7. Install or connect the following: Tappets

    Tappets
     

  8.  


NOTE
Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.

  1. Cylinder head. Torque the new bolts in sequence as follows: 19 ft. lbs. (25 Nm).Plus an additional 90 degrees.Plus an additional 90 degrees.Plus an additional 90 degrees.
    1. 19 ft. lbs. (25 Nm).
    2.  
    3. Plus an additional 90 degrees.
    4.  
    5. Plus an additional 90 degrees.
    6.  
    7. Plus an additional 90 degrees.
    8.  

  2.  
  3. Install or connect the following: Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder headStuffing box and bearing caps. Torque the bolts in 1/2 to 1 turn to 6 ft. lbs. (8 Nm).Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match theRear timing coverCamshaft cover and make certain that the O-rings are in place.Lubricate with a soap solution and place tool (10)-81-52-381 in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).Ignition discharge moduleTurbocharger oil pipes and torque the oil pipe to 15 ft. lbs. (20 Nm); the oil pipe to filter adapter to 19 ft. lbs. (25 Nm) and the oil return pipe to 10 ft. lbs. (15 Nm)Turbocharger water pipes. Torque the water pipes to 19 ft. lbs. (25 Nm) and the cylinder head retaining bolt to 10 ft. lbs. (15 Nm)Water hose to the thermostat housingFront exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)Hose between the turbocharger and charge air coolerCrankcase breather pipe to the turbocharger intake pipe and torque the bolt to 18 ft. lbs. (24 Nm)Turbocharger intake pipe and torque the V-clamp to 2 ft. lbs. (3 Nm) and the U clamp to 10 ft. lbs. (15 Nm)SAI pipe with new gaskets to the front exhaust manifoldSAI hose to the valveCrankcase ventilation pipe between the cylinder head turbocharger intake pipe and torque to 18 ft. lbs. (24 Nm)Water pump and torque the bolts to 19 ft. lbs. (25 Nm)Bracket with the tensioner roller and the upper adjusting roller

    Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head
     
    Stuffing box and bearing caps. Torque the bolts in 1/2 to 1 turn to 6 ft. lbs. (8 Nm).12
     
    Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match the
     
    Rear timing cover
     
    Camshaft cover and make certain that the O-rings are in place.
     
    Lubricate with a soap solution and place tool (10)-81-52-381 in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).
     
    Ignition discharge module
     
    Turbocharger oil pipes and torque the oil pipe to 15 ft. lbs. (20 Nm); the oil pipe to filter adapter to 19 ft. lbs. (25 Nm) and the oil return pipe to 10 ft. lbs. (15 Nm)
     
    Turbocharger water pipes. Torque the water pipes to 19 ft. lbs. (25 Nm) and the cylinder head retaining bolt to 10 ft. lbs. (15 Nm)
     
    Water hose to the thermostat housing
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Hose between the turbocharger and charge air cooler
     
    Crankcase breather pipe to the turbocharger intake pipe and torque the bolt to 18 ft. lbs. (24 Nm)
     
    Turbocharger intake pipe and torque the V-clamp to 2 ft. lbs. (3 Nm) and the U clamp to 10 ft. lbs. (15 Nm)
     
    SAI pipe with new gaskets to the front exhaust manifold
     
    SAI hose to the valve
     
    Crankcase ventilation pipe between the cylinder head turbocharger intake pipe and torque to 18 ft. lbs. (24 Nm)
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Bracket with the tensioner roller and the upper adjusting roller
     

  4.  
  5. Install locking tool KM-800-1 on No. 1 and 2 camshaft sprockets and tool KM-800-2 on No. 3 and 4 camshaft sprockets
  6.  
  7. Rotate the crankshaft to just before the 0 degree mark and install tool KM-800-10. Carefully rotate the crankshaft in the direction of the engine until the arm is lying against the water pump flange.
  8.  
  9. Install the camshaft belt to the markings on the belt and the marked direction of rotation. Loosely install the lower tensioner pulley and make certain that the washer is in place.
  10.  
  11. Adjust the tensioner pulley counterclockwise by hand and make certain that the markings are aligned properly.
  12.  
  13. Tighten the center adjuster roller bolts lightly. Adjust the lower adjuster roller counterclockwise until a tension of 275-300 Nm is reached. When properly tightened, remove the belt tension meter.
  14.  
  15. Make certain that the adjusting nut o0n the upper adjuster roller rotates freely. Adjust the tensioning pulley until the lines are aligned. Torque the fastener to 15 ft. lbs. (20 Nm).
  16.  
  17. Remove the locking tool from camshafts No. 1-2 and install tool KM-800-20. Adjust the upper roller counterclockwise with tool 83-94-983 until the markings on the camshaft sprocket are aligned with the markings on tool KM-800-20. Torque the fastener to 30 ft. lbs. (40 Nm).
  18.  
  19. Remove all locking tools.
  20.  
  21. Rotate the engine in the proper direction 2 revolutions until just before the 0 mark. Install tool KM-800-10 on the crankshaft.0
  22.  
  23. Rotate the crankshaft in the proper direction until the arm lies against water pump and tighten it.
  24.  
  25. Install tool KM-800-20 and make certain that the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.
  26.  
  27. Install or connect the following: Coolant bridge after lubricate the bolts and torque them to 22 ft. lbs. (30 Nm)Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Fuel linesIgnition discharge module and fuel injector connectorsTurbocharger delivery pipe to the throttle bodyTurbocharger delivery pipe to the charge air cooler and tighten all clampsPressure/temperature sensor electrical connectorBypass pipe and valveWater hoses and vacuum hose to the throttle bodyThrottle body connector and attach the hoses to the purge valve. Torque the bypass pipe to 6 ft. lbs. (8 Nm).Vacuum hoses and pressure/temperature sensor connectors to the intake manifoldThrottle cableCrankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)Belt tensioner and alternator air intakeWater pump and power steering pump pulleysV-belt and torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm)Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)Power steering hose into the holderMAF sensor and hose and remove the wedgesTurbocharger bracketBattery and vent hoseLower engine coverNegative battery cableEngine cover

    Coolant bridge after lubricate the bolts and torque them to 22 ft. lbs. (30 Nm)
     
    Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Ignition discharge module and fuel injector connectors
     
    Turbocharger delivery pipe to the throttle body
     
    Turbocharger delivery pipe to the charge air cooler and tighten all clamps
     
    Pressure/temperature sensor electrical connector
     
    Bypass pipe and valve
     
    Water hoses and vacuum hose to the throttle body
     
    Throttle body connector and attach the hoses to the purge valve. Torque the bypass pipe to 6 ft. lbs. (8 Nm).
     
    Vacuum hoses and pressure/temperature sensor connectors to the intake manifold
     
    Throttle cable
     
    Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Belt tensioner and alternator air intake
     
    Water pump and power steering pump pulleys
     
    V-belt and torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)
     
    Power steering hose into the holder
     
    MAF sensor and hose and remove the wedges
     
    Turbocharger bracket
     
    Battery and vent hose
     
    Lower engine cover
     
    Negative battery cable
     
    Engine cover
     

  28.  
  29. Fill the cooling system to the proper level.
  30.  
  31. Start the vehicle, check for leaks and repair if necessary.
  32.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove the vent hose and battery.
  4.  
  5. Remove the lower engine cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following: Turbocharger bracket and install wedges between the oil pan and subframe and gearbox and subframeTurbocharger delivery pipe from the charge air coolerMass Air Flow (MAF) sensor and hosePower steering hose from the holderRight side engine mount and bracketV-belt tensionWater pump and power steering pump pulleysBelt tensioner and alternator air intakeTiming coverThrottle cableUpper intake manifold vacuum hoses and pressure sensor connectorVacuum hose and water hoses from the throttle bodyTurbocharger delivery pipe with the bypass pipe and valve from the throttle bodyPressure/temperature sensor connectorThrottle body connector and purge valve hose from the throttle bodyIgnition discharge module connectorFuel injector electrical connectorFuel linesUpper intake manifold and move it asideMiddle intake manifoldLower intake manifoldCoolant bridge and move it asideCrankshaft pulleyTensioner pulley and adjusting rollers and mark the rotation direction of the beltLower adjusting roller and washerTiming belt. Refer to the appropriate section for the timing belt removal and installation.Adjuster roller boltsIgnition discharge moduleCamshaft cover and make sure the O-rings do not fall into the engine. Rotate the engine 60 degrees Before Top Dead Center (BTDC) and note the markingCamshaft sprocketsWater pumpInner timing coverFront exhaust manifold heat shieldHose connections for the front SAI valveSAI pipe and valve from the exhaust manifoldCrankcase ventilation pipe from between the turbocharger intake pipe and the cylinder headTurbocharger intake pipe and outlet hoseWater hose from the thermostat housingFront exhaust manifold from the turbochargerTurbocharger water and oil pipesExhaust camshaft by removing the bolts in stagesBearing caps where the tappets are under loadStuffing boxCylinder head bolts in the proper sequence by loosening them 1/4 turn then 1/2 turn

    Turbocharger bracket and install wedges between the oil pan and subframe and gearbox and subframe
     
    Turbocharger delivery pipe from the charge air cooler
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    V-belt tension
     
    Water pump and power steering pump pulleys
     
    Belt tensioner and alternator air intake
     
    Timing cover
     
    Throttle cable
     
    Upper intake manifold vacuum hoses and pressure sensor connector
     
    Vacuum hose and water hoses from the throttle body
     
    Turbocharger delivery pipe with the bypass pipe and valve from the throttle body
     
    Pressure/temperature sensor connector
     
    Throttle body connector and purge valve hose from the throttle body
     
    Ignition discharge module connector
     
    Fuel injector electrical connector
     
    Fuel lines
     
    Upper intake manifold and move it aside
     
    Middle intake manifold
     
    Lower intake manifold
     
    Coolant bridge and move it aside
     
    Crankshaft pulley
     
    Tensioner pulley and adjusting rollers and mark the rotation direction of the belt
     
    Lower adjusting roller and washer
     
    Timing belt. Refer to the appropriate section for the timing belt removal and installation.
     
    Adjuster roller bolts
     
    Ignition discharge module
     
    Camshaft cover and make sure the O-rings do not fall into the engine. Rotate the engine 60 degrees Before Top Dead Center (BTDC) and note the marking
     
    Camshaft sprockets
     
    Water pump
     
    Inner timing cover
     
    Front exhaust manifold heat shield
     
    Hose connections for the front SAI valve
     
    SAI pipe and valve from the exhaust manifold
     
    Crankcase ventilation pipe from between the turbocharger intake pipe and the cylinder head
     
    Turbocharger intake pipe and outlet hose
     
    Water hose from the thermostat housing
     
    Front exhaust manifold from the turbocharger
     
    Turbocharger water and oil pipes
     
    Exhaust camshaft by removing the bolts in stages
     
    Bearing caps where the tappets are under load
     
    Stuffing box
     
    Cylinder head bolts in the proper sequence by loosening them 1/4 turn then 1/2 turn1412
     

  10.  


    Click image to see an enlarged view

    Fig. Remove the cylinder head bolts as shown


To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Make certain that the crankshaft is at 60° BTDC.
  4.  
  5. Be sure that the proper gasket is used and is marked OBEN/TOPOBEN/TOP
  6.  
  7. Install or connect the following: Tappets

    Tappets
     

  8.  
  9. Cylinder head. Torque the new bolts in sequence as follows: 19 ft. lbs. (25 Nm).Plus an additional 90 degrees.Plus an additional 90 degrees.Plus an additional 90 degrees.
    1. 19 ft. lbs. (25 Nm).
    2.  
    3. Plus an additional 90 degrees.
    4.  
    5. Plus an additional 90 degrees.
    6.  
    7. Plus an additional 90 degrees.
    8.  

  10.  
  11. Install or connect the following: Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder headStuffing box and bearing caps. Torque the bolts in 1/2 to 1 turn to 6 ft. lbs. (8 Nm).Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match theRear timing coverCamshaft cover and make certain that the O-rings are in place.Lubricate with a soap solution and place tool (10)-81-52-381 in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).Ignition discharge moduleTurbocharger oil pipes and torque the oil pipe to 15 ft. lbs. (20 Nm); the oil pipe to filter adapter to 19 ft. lbs. (25 Nm) and the oil return pipe to 10 ft. lbs. (15 Nm)Turbocharger water pipes. Torque the water pipes to 19 ft. lbs. (25 Nm) and the cylinder head retaining bolt to 10 ft. lbs. (15 Nm)Water hose to the thermostat housingFront exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)Hose between the turbocharger and charge air coolerCrankcase breather pipe to the turbocharger intake pipe and torque the bolt to 18 ft. lbs. (24 Nm)Turbocharger intake pipe and torque the V-clamp to 2 ft. lbs. (3 Nm) and the U clamp to 10 ft. lbs. (15 Nm)SAI pipe with new gaskets to the front exhaust manifoldSAI hose to the valveCrankcase ventilation pipe between the cylinder head turbocharger intake pipe and torque to 18 ft. lbs. (24 Nm)Water pump and torque the bolts to 19 ft. lbs. (25 Nm)Bracket with the tensioner roller and the upper adjusting roller

    Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head
     
    Stuffing box and bearing caps. Torque the bolts in 1/2 to 1 turn to 6 ft. lbs. (8 Nm).12
     
    Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match the
     
    Rear timing cover
     
    Camshaft cover and make certain that the O-rings are in place.
     
    Lubricate with a soap solution and place tool (10)-81-52-381 in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).
     
    Ignition discharge module
     
    Turbocharger oil pipes and torque the oil pipe to 15 ft. lbs. (20 Nm); the oil pipe to filter adapter to 19 ft. lbs. (25 Nm) and the oil return pipe to 10 ft. lbs. (15 Nm)
     
    Turbocharger water pipes. Torque the water pipes to 19 ft. lbs. (25 Nm) and the cylinder head retaining bolt to 10 ft. lbs. (15 Nm)
     
    Water hose to the thermostat housing
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Hose between the turbocharger and charge air cooler
     
    Crankcase breather pipe to the turbocharger intake pipe and torque the bolt to 18 ft. lbs. (24 Nm)
     
    Turbocharger intake pipe and torque the V-clamp to 2 ft. lbs. (3 Nm) and the U clamp to 10 ft. lbs. (15 Nm)
     
    SAI pipe with new gaskets to the front exhaust manifold
     
    SAI hose to the valve
     
    Crankcase ventilation pipe between the cylinder head turbocharger intake pipe and torque to 18 ft. lbs. (24 Nm)
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Bracket with the tensioner roller and the upper adjusting roller
     

  12.  
  13. Install locking tool KM-800-1 on No. 1 and 2 camshaft sprockets and tool KM-800-2 on No. 3 and 4 camshaft sprockets
  14.  
  15. Rotate the crankshaft to just before the 0 degree mark and install tool KM-800-10. Carefully rotate the crankshaft in the direction of the engine until the arm is lying against the water pump flange.
  16.  
  17. Install the camshaft belt to the markings on the belt and the marked direction of rotation. Loosely install the lower tensioner pulley and make certain that the washer is in place.
  18.  
  19. Adjust the tensioner pulley counterclockwise by hand and make certain that the markings are aligned properly.
  20.  
  21. Tighten the center adjuster roller bolts lightly. Adjust the lower adjuster roller counterclockwise until a tension of 275-300 Nm is reached. When properly tightened, remove the belt tension meter.
  22.  
  23. Make certain that the adjusting nut o0n the upper adjuster roller rotates freely. Adjust the tensioning pulley until the lines are aligned. Torque the fastener to 15 ft. lbs. (20 Nm).
  24.  
  25. Remove the locking tool from camshafts No. 1-2 and install tool KM-800-20. Adjust the upper roller counterclockwise with tool 83-94-983 until the markings on the camshaft sprocket are aligned with the markings on tool KM-800-20. Torque the fastener to 30 ft. lbs. (40 Nm).
  26.  
  27. Remove all locking tools.
  28.  
  29. Rotate the engine in the proper direction 2 revolutions until just before the 0 mark. Install tool KM-800-10 on the crankshaft.0
  30.  
  31. Rotate the crankshaft in the proper direction until the arm lies against water pump and tighten it.
  32.  
  33. Install tool KM-800-20 and make certain that the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.
  34.  
  35. Install or connect the following: Coolant bridge after lubricate the bolts and torque them to 22 ft. lbs. (30 Nm)Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Fuel linesIgnition discharge module and fuel injector connectorsTurbocharger delivery pipe to the throttle bodyTurbocharger delivery pipe to the charge air cooler and tighten all clampsPressure/temperature sensor electrical connectorBypass pipe and valveWater hoses and vacuum hose to the throttle bodyThrottle body connector and attach the hoses to the purge valve. Torque the bypass pipe to 6 ft. lbs. (8 Nm).Vacuum hoses and pressure/temperature sensor connectors to the intake manifoldThrottle cableCrankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)Belt tensioner and alternator air intakeWater pump and power steering pump pulleysV-belt and torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm)Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)Power steering hose into the holderMAF sensor and hose and remove the wedgesTurbocharger bracketBattery and vent hoseLower engine coverNegative battery cableEngine cover

    Coolant bridge after lubricate the bolts and torque them to 22 ft. lbs. (30 Nm)
     
    Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Ignition discharge module and fuel injector connectors
     
    Turbocharger delivery pipe to the throttle body
     
    Turbocharger delivery pipe to the charge air cooler and tighten all clamps
     
    Pressure/temperature sensor electrical connector
     
    Bypass pipe and valve
     
    Water hoses and vacuum hose to the throttle body
     
    Throttle body connector and attach the hoses to the purge valve. Torque the bypass pipe to 6 ft. lbs. (8 Nm).
     
    Vacuum hoses and pressure/temperature sensor connectors to the intake manifold
     
    Throttle cable
     
    Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Belt tensioner and alternator air intake
     
    Water pump and power steering pump pulleys
     
    V-belt and torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)
     
    Power steering hose into the holder
     
    MAF sensor and hose and remove the wedges
     
    Turbocharger bracket
     
    Battery and vent hose
     
    Lower engine cover
     
    Negative battery cable
     
    Engine cover
     

  36.  
  37. Fill the cooling system to the proper level.
  38.  
  39. Start the vehicle, check for leaks and repair if necessary.
  40.  


    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-3.0L engine


3.0L Engine - Rear Cylinder Head
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following: Engine and battery coverLower engine cover and install wedges between the oil pan and subframe and the gearbox and subframeMass Air Flow (MAF) sensor and hosePower steering hose from the holderRight side engine mount and bracketWater pump and power steering pump pulley boltsTension from the V-beltWater pump and power steering pump pulleysBelt tensioner and alternator air intakeTiming coverThrottle cableVacuum hoses and pressure sensor connector from the upper intake manifoldOxygen sensor connector from the holder on the rear of the SAI valveSAI pipe from the cylinder head and exhaust manifold connectionsWater hoses and vacuum hose from the throttle bodyTurbocharger delivery hose with the bypass pipeThrottle body connector and hose to the purge valveFuel linesUpper intake manifold and move it asideIgnition discharge module and fuel injector connectorsMiddle intake manifoldLower intake manifoldCoolant bridgeCrankshaft pulley

    Engine and battery cover
     
    Lower engine cover and install wedges between the oil pan and subframe and the gearbox and subframe
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Water pump and power steering pump pulley bolts
     
    Tension from the V-belt
     
    Water pump and power steering pump pulleys
     
    Belt tensioner and alternator air intake
     
    Timing cover
     
    Throttle cable
     
    Vacuum hoses and pressure sensor connector from the upper intake manifold
     
    Oxygen sensor connector from the holder on the rear of the SAI valve
     
    SAI pipe from the cylinder head and exhaust manifold connections
     
    Water hoses and vacuum hose from the throttle body
     
    Turbocharger delivery hose with the bypass pipe
     
    Throttle body connector and hose to the purge valve
     
    Fuel lines
     
    Upper intake manifold and move it aside
     
    Ignition discharge module and fuel injector connectors
     
    Middle intake manifold
     
    Lower intake manifold
     
    Coolant bridge
     
    Crankshaft pulley
     

  6.  


NOTE
Make certain that the markings on the camshaft sprockets and timing cover are aligned along with the crankshaft.



Tensioner pulley and adjusting rollers. Mark the rotation of the belt
 
Lower adjuster roller and washer
 
Timing belt. Refer to the appropriate section for the removal and installation procedure.
 
Bracket with the tensioning roller and the upper adjuster roller
 
Ignition discharge module
 
Camshaft cover with the O-rings. Rotate the crankshaft 60° BTDC
 
Camshaft sprockets
 
Inner timing cover
 
Separate the exhaust pipes
 
Exhaust camshaft
 
Stuffing box
 
Tappets and place them in the proper order for installation
 
Cylinder head bolts in the proper sequence by loosening them 1/4turn then 1/2turn1412
 

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Make certain that the crankshaft is at 60° BTDC.
  4.  
  5. Be sure that the proper gasket is used and is marked OBEN/TOPOBEN/TOP
  6.  
  7. Install the tappets.
  8.  


NOTE
Refer to Section 1 of this manual for the cylinder head torque sequence illustration. The illustration is located after the Torque Specification Chart.

  1. Install the cylinder head. Torque the new bolts in sequence as follows: 19 ft. lbs. (25 Nm).Plus an additional 90 degrees.Plus an additional 90 degrees.Plus an additional 90 degrees.
    1. 19 ft. lbs. (25 Nm).
    2.  
    3. Plus an additional 90 degrees.
    4.  
    5. Plus an additional 90 degrees.
    6.  
    7. Plus an additional 90 degrees.
    8.  

  2.  
  3. Install or connect the following: Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder headStuffing box and bearing caps. Torque the bolts in 1/2 to 1 turn to 6 ft. lbs. (8 Nm).Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match the number on the camshaft. Torque the bolt to 37 ft. lbs. (50 Nm) plus 60 degrees.Rear timing coverCamshaft cover and make certain that the O-rings are in place.Lubricate with a soap solution and place tool (10), 81 52 381, in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).Ignition discharge moduleHose to the SAI pipe and install the pipe with new gaskets to the exhaust manifold and cylinder headOxygen sensor connector in the holderFront and rear exhaust pipes and torque the bolts to 30 ft. lbs. (40 Nm)Water pump and torque the bolts to 19 ft. lbs. (25 Nm)Bracket with the tensioning roller and the upper adjuster roller

    Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head
     
    Stuffing box and bearing caps. Torque the bolts in 1/2 to 1 turn to 6 ft. lbs. (8 Nm).12
     
    Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match the number on the camshaft. Torque the bolt to 37 ft. lbs. (50 Nm) plus 60 degrees.
     
    Rear timing cover
     
    Camshaft cover and make certain that the O-rings are in place.
     
    Lubricate with a soap solution and place tool (10), 81 52 381, in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).
     
    Ignition discharge module
     
    Hose to the SAI pipe and install the pipe with new gaskets to the exhaust manifold and cylinder head
     
    Oxygen sensor connector in the holder
     
    Front and rear exhaust pipes and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Bracket with the tensioning roller and the upper adjuster roller
     

  4.  
  5. Install locking tool KM-800-1 on No. 1 and 2 camshaft sprockets and tool KM-800-2 on No. 3 and 4 camshaft sprockets
  6.  
  7. Rotate the crankshaft to just before the 0 degree mark and install tool KM-800-10. Carefully rotate the crankshaft in the direction of the engine until the arm is lying against the water pump flange.0
  8.  
  9. Install the camshaft belt to the markings on the belt and the marked direction of rotation. Loosely install the lower tensioner pulley and make certain that the washer is in place.
  10.  
  11. Adjust the tensioner pulley counterclockwise by hand and make certain that the markings are aligned properly.
  12.  
  13. Tighten the center adjuster roller bolts lightly. Adjust the lower adjuster roller counterclockwise until a tension of 275-300 Nm is reached. When properly tightened, remove the belt tension meter.
  14.  
  15. Make certain that the adjusting nut on the upper adjuster roller rotates freely. Adjust the tensioning pulley until the lines are aligned. Torque the fastener to 15 ft. lbs. (20 Nm).
  16.  
  17. Remove the locking tool from camshafts No. 1-2 and install tool KM-800-20. Adjust the upper roller counterclockwise with tool 83-94-983 until the markings on the camshaft sprocket are aligned with the markings on tool KM-800-20. Torque the fastener to 30 ft. lbs. (40 Nm).
  18.  
  19. Remove all locking tools.
  20.  
  21. Rotate the engine in the proper direction 2 revolutions until just before the 0 mark. Install tool KM-800-10 on the crankshaft.0
  22.  
  23. Rotate the crankshaft in the proper direction until the arm lies against water pump and tighten it.
  24.  
  25. Install tool KM-800-20 and make certain that the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.
  26.  
  27. Install or connect the following: Coolant bridge after lubricating the bolts and torque them to 22 ft. lbs. (30 Nm)Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Fuel linesIgnition discharge module and fuel injector connectorsTurbocharger delivery pipe to the throttle bodyBypass pipe and valveWater hoses and vacuum hose to the throttle bodyThrottle body connector and attach the hoses to the purge valve and torque the bypass pipe to 6 ft. lbs. (8 Nm)Vacuum hoses and pressure/temperature sensor connectors to the intake manifoldThrottle cableTurbocharger delivery pipe to the charge air coolerVacuum hose and pressure/temperature sensor connector to the upper intake manifoldTurbocharger bypass pipe and valveCrankcase pulley and torque the bolts to 15 ft. lbs. (20 Nm)Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)Belt tensioner and alternator air intakeWater pump and power steering pump pulleysV-belt. Torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm).Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)Power steering hose into the holderMAF sensor and hose. Remove the wedgesTurbocharger bracketBattery and vent hoseLower engine coverNegative battery cableEngine cover

    Coolant bridge after lubricating the bolts and torque them to 22 ft. lbs. (30 Nm)
     
    Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Ignition discharge module and fuel injector connectors
     
    Turbocharger delivery pipe to the throttle body
     
    Bypass pipe and valve
     
    Water hoses and vacuum hose to the throttle body
     
    Throttle body connector and attach the hoses to the purge valve and torque the bypass pipe to 6 ft. lbs. (8 Nm)
     
    Vacuum hoses and pressure/temperature sensor connectors to the intake manifold
     
    Throttle cable
     
    Turbocharger delivery pipe to the charge air cooler
     
    Vacuum hose and pressure/temperature sensor connector to the upper intake manifold
     
    Turbocharger bypass pipe and valve
     
    Crankcase pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Belt tensioner and alternator air intake
     
    Water pump and power steering pump pulleys
     
    V-belt. Torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm).
     
    Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)
     
    Power steering hose into the holder
     
    MAF sensor and hose. Remove the wedges
     
    Turbocharger bracket
     
    Battery and vent hose
     
    Lower engine cover
     
    Negative battery cable
     
    Engine cover
     

  28.  
  29. Fill the cooling system to the proper level.
  30.  
  31. Start the vehicle, check for leaks and repair if necessary.
  32.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following: Engine and battery coverLower engine cover and install wedges between the oil pan and subframe and the gearbox and subframeMass Air Flow (MAF) sensor and hosePower steering hose from the holderRight side engine mount and bracketWater pump and power steering pump pulley boltsTension from the V-beltWater pump and power steering pump pulleysBelt tensioner and alternator air intakeTiming coverThrottle cableVacuum hoses and pressure sensor connector from the upper intake manifoldOxygen sensor connector from the holder on the rear of the SAI valveSAI pipe from the cylinder head and exhaust manifold connectionsWater hoses and vacuum hose from the throttle bodyTurbocharger delivery hose with the bypass pipeThrottle body connector and hose to the purge valveFuel linesUpper intake manifold and move it asideIgnition discharge module and fuel injector connectorsMiddle intake manifoldLower intake manifoldCoolant bridgeCrankshaft pulley

    Engine and battery cover
     
    Lower engine cover and install wedges between the oil pan and subframe and the gearbox and subframe
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Water pump and power steering pump pulley bolts
     
    Tension from the V-belt
     
    Water pump and power steering pump pulleys
     
    Belt tensioner and alternator air intake
     
    Timing cover
     
    Throttle cable
     
    Vacuum hoses and pressure sensor connector from the upper intake manifold
     
    Oxygen sensor connector from the holder on the rear of the SAI valve
     
    SAI pipe from the cylinder head and exhaust manifold connections
     
    Water hoses and vacuum hose from the throttle body
     
    Turbocharger delivery hose with the bypass pipe
     
    Throttle body connector and hose to the purge valve
     
    Fuel lines
     
    Upper intake manifold and move it aside
     
    Ignition discharge module and fuel injector connectors
     
    Middle intake manifold
     
    Lower intake manifold
     
    Coolant bridge
     
    Crankshaft pulley
     

  6.  


NOTE
Make certain that the markings on the camshaft sprockets and timing cover are aligned along with the crankshaft.



Tensioner pulley and adjusting rollers. Mark the rotation of the belt
 
Lower adjuster roller and washer
 
Timing belt. Refer to the appropriate section for the removal and installation procedure.
 
Bracket with the tensioning roller and the upper adjuster roller
 
Ignition discharge module
 
Camshaft cover with the O-rings. Rotate the crankshaft 60° BTDC
 
Camshaft sprockets
 
Inner timing cover
 
Separate the exhaust pipes
 
Exhaust camshaft
 
Stuffing box
 
Tappets and place them in the proper order for installation
 
Cylinder head bolts in the proper sequence by loosening them 1/4turn then 1/2turn1412
 

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Make certain that the crankshaft is at 60° BTDC.
  4.  
  5. Be sure that the proper gasket is used and is marked OBEN/TOPOBEN/TOP
  6.  
  7. Install the tappets.
  8.  
  9. Install the cylinder head. Torque the new bolts in sequence as follows: 19 ft. lbs. (25 Nm).Plus an additional 90 degrees.Plus an additional 90 degrees.Plus an additional 90 degrees.
    1. 19 ft. lbs. (25 Nm).
    2.  
    3. Plus an additional 90 degrees.
    4.  
    5. Plus an additional 90 degrees.
    6.  
    7. Plus an additional 90 degrees.
    8.  

  10.  
  11. Install or connect the following: Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder headStuffing box and bearing caps. Torque the bolts in 1/2 to 1 turn to 6 ft. lbs. (8 Nm).Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match the number on the camshaft. Torque the bolt to 37 ft. lbs. (50 Nm) plus 60 degrees.Rear timing coverCamshaft cover and make certain that the O-rings are in place.Lubricate with a soap solution and place tool (10), 81 52 381, in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).Ignition discharge moduleHose to the SAI pipe and install the pipe with new gaskets to the exhaust manifold and cylinder headOxygen sensor connector in the holderFront and rear exhaust pipes and torque the bolts to 30 ft. lbs. (40 Nm)Water pump and torque the bolts to 19 ft. lbs. (25 Nm)Bracket with the tensioning roller and the upper adjuster roller

    Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head
     
    Stuffing box and bearing caps. Torque the bolts in 1/2 to 1 turn to 6 ft. lbs. (8 Nm).12
     
    Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match the number on the camshaft. Torque the bolt to 37 ft. lbs. (50 Nm) plus 60 degrees.
     
    Rear timing cover
     
    Camshaft cover and make certain that the O-rings are in place.
     
    Lubricate with a soap solution and place tool (10), 81 52 381, in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).
     
    Ignition discharge module
     
    Hose to the SAI pipe and install the pipe with new gaskets to the exhaust manifold and cylinder head
     
    Oxygen sensor connector in the holder
     
    Front and rear exhaust pipes and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Bracket with the tensioning roller and the upper adjuster roller
     

  12.  
  13. Install locking tool KM-800-1 on No. 1 and 2 camshaft sprockets and tool KM-800-2 on No. 3 and 4 camshaft sprockets
  14.  
  15. Rotate the crankshaft to just before the 0 degree mark and install tool KM-800-10. Carefully rotate the crankshaft in the direction of the engine until the arm is lying against the water pump flange.0
  16.  
  17. Install the camshaft belt to the markings on the belt and the marked direction of rotation. Loosely install the lower tensioner pulley and make certain that the washer is in place.
  18.  
  19. Adjust the tensioner pulley counterclockwise by hand and make certain that the markings are aligned properly.
  20.  
  21. Tighten the center adjuster roller bolts lightly. Adjust the lower adjuster roller counterclockwise until a tension of 275-300 Nm is reached. When properly tightened, remove the belt tension meter.
  22.  
  23. Make certain that the adjusting nut on the upper adjuster roller rotates freely. Adjust the tensioning pulley until the lines are aligned. Torque the fastener to 15 ft. lbs. (20 Nm).
  24.  
  25. Remove the locking tool from camshafts No. 1-2 and install tool KM-800-20. Adjust the upper roller counterclockwise with tool 83-94-983 until the markings on the camshaft sprocket are aligned with the markings on tool KM-800-20. Torque the fastener to 30 ft. lbs. (40 Nm).
  26.  
  27. Remove all locking tools.
  28.  
  29. Rotate the engine in the proper direction 2 revolutions until just before the 0 mark. Install tool KM-800-10 on the crankshaft.0
  30.  
  31. Rotate the crankshaft in the proper direction until the arm lies against water pump and tighten it.
  32.  
  33. Install tool KM-800-20 and make certain that the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.
  34.  
  35. Install or connect the following: Coolant bridge after lubricating the bolts and torque them to 22 ft. lbs. (30 Nm)Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Fuel linesIgnition discharge module and fuel injector connectorsTurbocharger delivery pipe to the throttle bodyBypass pipe and valveWater hoses and vacuum hose to the throttle bodyThrottle body connector and attach the hoses to the purge valve and torque the bypass pipe to 6 ft. lbs. (8 Nm)Vacuum hoses and pressure/temperature sensor connectors to the intake manifoldThrottle cableTurbocharger delivery pipe to the charge air coolerVacuum hose and pressure/temperature sensor connector to the upper intake manifoldTurbocharger bypass pipe and valveCrankcase pulley and torque the bolts to 15 ft. lbs. (20 Nm)Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)Belt tensioner and alternator air intakeWater pump and power steering pump pulleysV-belt. Torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm).Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)Power steering hose into the holderMAF sensor and hose. Remove the wedgesTurbocharger bracketBattery and vent hoseLower engine coverNegative battery cableEngine cover

    Coolant bridge after lubricating the bolts and torque them to 22 ft. lbs. (30 Nm)
     
    Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Ignition discharge module and fuel injector connectors
     
    Turbocharger delivery pipe to the throttle body
     
    Bypass pipe and valve
     
    Water hoses and vacuum hose to the throttle body
     
    Throttle body connector and attach the hoses to the purge valve and torque the bypass pipe to 6 ft. lbs. (8 Nm)
     
    Vacuum hoses and pressure/temperature sensor connectors to the intake manifold
     
    Throttle cable
     
    Turbocharger delivery pipe to the charge air cooler
     
    Vacuum hose and pressure/temperature sensor connector to the upper intake manifold
     
    Turbocharger bypass pipe and valve
     
    Crankcase pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Belt tensioner and alternator air intake
     
    Water pump and power steering pump pulleys
     
    V-belt. Torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm).
     
    Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)
     
    Power steering hose into the holder
     
    MAF sensor and hose. Remove the wedges
     
    Turbocharger bracket
     
    Battery and vent hose
     
    Lower engine cover
     
    Negative battery cable
     
    Engine cover
     

  36.  
  37. Fill the cooling system to the proper level.
  38.  
  39. Start the vehicle, check for leaks and repair if necessary.
  40.  

3.0L Engine-Front Cylinder Head
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the vent hose and battery.
  4.  
  5. Remove the lower engine cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove or disconnect the following:

    Turbocharger bracket and install wedges between the oil pan and subframe and gearbox and subframe
     
    Turbocharger delivery pipe from the charge air cooler
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    V-belt tension
     
    Water pump and power steering pump pulleys
     
    Belt tensioner and alternator air intake
     
    Timing cover
     
    Throttle cable
     
    Upper intake manifold vacuum hoses and pressure sensor connector
     
    Vacuum hose and water hoses from the throttle body
     
    Turbocharger delivery pipe with the bypass pipe and valve from the throttle body
     
    Pressure/temperature sensor connector
     
    Throttle body connector and purge valve hose from the throttle body
     
    Ignition discharge module connector
     
    Fuel injector electrical connector
     
    Fuel lines
     
    Upper intake manifold and move it aside
     
    Middle intake manifold
     
    Lower intake manifold
     
    Coolant bridge and move it aside
     
    Crankshaft pulley
     
    Tensioner pulley and adjusting rollers and mark the rotation direction of the belt
     
    Lower adjusting roller and washer
     
    Timing belt. Refer to the appropriate section for the timing belt removal and installation.
     
    Adjuster roller bolts
     
    Ignition discharge module
     
    Camshaft cover and make sure the O-rings do not fall into the engine. Rotate the engine 60 degrees Before Top Dead Center (BTDC) and note the marking
     
    Camshaft sprockets
     
    Water pump
     
    Inner timing cover
     
    Front exhaust manifold heat shield
     
    Hose connections for the front SAI valve
     
    SAI pipe and valve from the exhaust manifold
     
    Crankcase ventilation pipe from between the turbocharger intake pipe and the cylinder head
     
    Turbocharger intake pipe and outlet hose
     
    Water hose from the thermostat housing
     
    Front exhaust manifold from the turbocharger
     
    Turbocharger water and oil pipes
     
    Exhaust camshaft by removing the bolts in stages
     
    Bearing caps where the tappets are under load
     
    Stuffing box
     
    Cylinder head bolts in the proper sequence by loosening them 1 / 4 turn then 1 / 2 turn

    Click image to see an enlarged view

    Fig. Remove the cylinder head bolts as shown

     

  10.  

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Make certain that the crankshaft is at 60° BTDC.
  4.  
  5. Be sure that the proper gasket is used and is marked OBEN/TOP
  6.  
  7. Install or connect the following:

    Tappets
     

  8.  
  9. Cylinder head. Torque the new bolts in sequence as follows:
    1. 19 ft. lbs. (25 Nm).
    2.  
    3. Plus an additional 90 degrees.
    4.  
    5. Plus an additional 90 degrees.
    6.  
    7. Plus an additional 90 degrees.
    8.  

  10.  
  11. Install or connect the following:

    Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head
     
    Stuffing box and bearing caps. Torque the bolts in 1 / 2 to 1 turn to 6 ft. lbs. (8 Nm).
     
    Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match the
     
    Rear timing cover
     
    Camshaft cover and make certain that the O-rings are in place.
     
    Lubricate with a soap solution and place tool (10)-81-52-381 in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).
     
    Ignition discharge module
     
    Turbocharger oil pipes and torque the oil pipe to 15 ft. lbs. (20 Nm); the oil pipe to filter adapter to 19 ft. lbs. (25 Nm) and the oil return pipe to 10 ft. lbs. (15 Nm)
     
    Turbocharger water pipes. Torque the water pipes to 19 ft. lbs. (25 Nm) and the cylinder head retaining bolt to 10 ft. lbs. (15 Nm)
     
    Water hose to the thermostat housing
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Hose between the turbocharger and charge air cooler
     
    Crankcase breather pipe to the turbocharger intake pipe and torque the bolt to 18 ft. lbs. (24 Nm)
     
    Turbocharger intake pipe and torque the V-clamp to 2 ft. lbs. (3 Nm) and the U clamp to 10 ft. lbs. (15 Nm)
     
    SAI pipe with new gaskets to the front exhaust manifold
     
    SAI hose to the valve
     
    Crankcase ventilation pipe between the cylinder head turbocharger intake pipe and torque to 18 ft. lbs. (24 Nm)
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Bracket with the tensioner roller and the upper adjusting roller
     

  12.  
  13. Install locking tool KM-800-1 on No. 1 and 2 camshaft sprockets and tool KM-800-2 on No. 3 and 4 camshaft sprockets
  14.  
  15. Rotate the crankshaft to just before the 0 degree mark and install tool KM-800-10. Carefully rotate the crankshaft in the direction of the engine until the arm is lying against the water pump flange.
  16.  
  17. Install the camshaft belt to the markings on the belt and the marked direction of rotation. Loosely install the lower tensioner pulley and make certain that the washer is in place.
  18.  
  19. Adjust the tensioner pulley counterclockwise by hand and make certain that the markings are aligned properly.
  20.  
  21. Tighten the center adjuster roller bolts lightly. Adjust the lower adjuster roller counterclockwise until a tension of 275-300 Nm is reached. When properly tightened, remove the belt tension meter.
  22.  
  23. Make certain that the adjusting nut o0n the upper adjuster roller rotates freely. Adjust the tensioning pulley until the lines are aligned. Torque the fastener to 15 ft. lbs. (20 Nm).
  24.  
  25. Remove the locking tool from camshafts No. 1-2 and install tool KM-800-20. Adjust the upper roller counterclockwise with tool 83-94-983 until the markings on the camshaft sprocket are aligned with the markings on tool KM-800-20. Torque the fastener to 30 ft. lbs. (40 Nm).
  26.  
  27. Remove all locking tools.
  28.  
  29. Rotate the engine in the proper direction 2 revolutions until just before the 0 mark. Install tool KM-800-10 on the crankshaft.
  30.  
  31. Rotate the crankshaft in the proper direction until the arm lies against water pump and tighten it.
  32.  
  33. Install tool KM-800-20 and make certain that the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.
  34.  
  35. Install or connect the following:

    Coolant bridge after lubricate the bolts and torque them to 22 ft. lbs. (30 Nm)
     
    Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Ignition discharge module and fuel injector connectors
     
    Turbocharger delivery pipe to the throttle body
     
    Turbocharger delivery pipe to the charge air cooler and tighten all clamps
     
    Pressure/temperature sensor electrical connector
     
    Bypass pipe and valve
     
    Water hoses and vacuum hose to the throttle body
     
    Throttle body connector and attach the hoses to the purge valve. Torque the bypass pipe to 6 ft. lbs. (8 Nm).
     
    Vacuum hoses and pressure/temperature sensor connectors to the intake manifold
     
    Throttle cable
     
    Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Belt tensioner and alternator air intake
     
    Water pump and power steering pump pulleys
     
    V-belt and torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)
     
    Power steering hose into the holder
     
    MAF sensor and hose and remove the wedges
     
    Turbocharger bracket
     
    Battery and vent hose
     
    Lower engine cover
     
    Negative battery cable
     
    Engine cover
     

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

    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence-6-cylinder engine

  40.  

3.0L 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:
    NOTE
    Make certain that the markings on the camshaft sprockets and timing cover are aligned along with the crankshaft.



    Engine and battery cover
     
    Lower engine cover and install wedges between the oil pan and subframe and the gearbox and subframe
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Water pump and power steering pump pulley bolts
     
    Tension from the V-belt
     
    Water pump and power steering pump pulleys
     
    Belt tensioner and alternator air intake
     
    Timing cover
     
    Throttle cable
     
    Vacuum hoses and pressure sensor connector from the upper intake manifold
     
    Oxygen sensor connector from the holder on the rear of the SAI valve
     
    SAI pipe from the cylinder head and exhaust manifold connections
     
    Water hoses and vacuum hose from the throttle body
     
    Turbocharger delivery hose with the bypass pipe
     
    Throttle body connector and hose to the purge valve
     
    Fuel lines
     
    Upper intake manifold and move it aside
     
    Ignition discharge module and fuel injector connectors
     
    Middle intake manifold
     
    Lower intake manifold
     
    Coolant bridge
     
    Crankshaft pulley
     



    Tensioner pulley and adjusting rollers. Mark the rotation of the belt
     
    Lower adjuster roller and washer
     
    Timing belt. Refer to the appropriate section for the removal and installation procedure.
     
    Bracket with the tensioning roller and the upper adjuster roller
     
    Ignition discharge module
     
    Camshaft cover with the O-rings. Rotate the crankshaft 60° BTDC
     
    Camshaft sprockets
     
    Inner timing cover
     
    Separate the exhaust pipes
     
    Exhaust camshaft
     
    Stuffing box
     
    Tappets and place them in the proper order for installation
     
    Cylinder head bolts in the proper sequence by loosening them 1 / 4 turn then 1 / 2 turn
     

  6.  

To install:

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Make certain that the crankshaft is at 60° BTDC.
  4.  
  5. Be sure that the proper gasket is used and is marked OBEN/TOP
  6.  
  7. Install the tappets.
  8.  
  9. Install the cylinder head. Torque the new bolts in sequence as follows:
    1. 19 ft. lbs. (25 Nm).
    2.  
    3. Plus an additional 90 degrees.
    4.  
    5. Plus an additional 90 degrees.
    6.  
    7. Plus an additional 90 degrees.
    8.  

  10.  
  11. Install or connect the following:

    Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head
     
    Stuffing box and bearing caps. Torque the bolts in 1 / 2 to 1 turn to 6 ft. lbs. (8 Nm).
     
    Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match the number on the camshaft. Torque the bolt to 37 ft. lbs. (50 Nm) plus 60 degrees.
     
    Rear timing cover
     
    Camshaft cover and make certain that the O-rings are in place.
     
    Lubricate with a soap solution and place tool (10), 81 52 381, in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).
     
    Ignition discharge module
     
    Hose to the SAI pipe and install the pipe with new gaskets to the exhaust manifold and cylinder head
     
    Oxygen sensor connector in the holder
     
    Front and rear exhaust pipes and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Bracket with the tensioning roller and the upper adjuster roller
     

  12.  
  13. Install locking tool KM-800-1 on No. 1 and 2 camshaft sprockets and tool KM-800-2 on No. 3 and 4 camshaft sprockets
  14.  
  15. Rotate the crankshaft to just before the 0 degree mark and install tool KM-800-10. Carefully rotate the crankshaft in the direction of the engine until the arm is lying against the water pump flange.
  16.  
  17. Install the camshaft belt to the markings on the belt and the marked direction of rotation. Loosely install the lower tensioner pulley and make certain that the washer is in place.
  18.  
  19. Adjust the tensioner pulley counterclockwise by hand and make certain that the markings are aligned properly.
  20.  
  21. Tighten the center adjuster roller bolts lightly. Adjust the lower adjuster roller counterclockwise until a tension of 275-300 Nm is reached. When properly tightened, remove the belt tension meter.
  22.  
  23. Make certain that the adjusting nut on the upper adjuster roller rotates freely. Adjust the tensioning pulley until the lines are aligned. Torque the fastener to 15 ft. lbs. (20 Nm).
  24.  
  25. Remove the locking tool from camshafts No. 1-2 and install tool KM-800-20. Adjust the upper roller counterclockwise with tool 83-94-983 until the markings on the camshaft sprocket are aligned with the markings on tool KM-800-20. Torque the fastener to 30 ft. lbs. (40 Nm).
  26.  
  27. Remove all locking tools.
  28.  
  29. Rotate the engine in the proper direction 2 revolutions until just before the 0 mark. Install tool KM-800-10 on the crankshaft.
  30.  
  31. Rotate the crankshaft in the proper direction until the arm lies against water pump and tighten it.
  32.  
  33. Install tool KM-800-20 and make certain that the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.
  34.  
  35. Install or connect the following:

    Coolant bridge after lubricating the bolts and torque them to 22 ft. lbs. (30 Nm)
     
    Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Ignition discharge module and fuel injector connectors
     
    Turbocharger delivery pipe to the throttle body
     
    Bypass pipe and valve
     
    Water hoses and vacuum hose to the throttle body
     
    Throttle body connector and attach the hoses to the purge valve and torque the bypass pipe to 6 ft. lbs. (8 Nm)
     
    Vacuum hoses and pressure/temperature sensor connectors to the intake manifold
     
    Throttle cable
     
    Turbocharger delivery pipe to the charge air cooler
     
    Vacuum hose and pressure/temperature sensor connector to the upper intake manifold
     
    Turbocharger bypass pipe and valve
     
    Crankcase pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Belt tensioner and alternator air intake
     
    Water pump and power steering pump pulleys
     
    V-belt. Torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm).
     
    Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)
     
    Power steering hose into the holder
     
    MAF sensor and hose. Remove the wedges
     
    Turbocharger bracket
     
    Battery and vent hose
     
    Lower engine cover
     
    Negative battery cable
     
    Engine cover
     

  36.  
  37. Fill the cooling system to the proper level.
  38.  
  39. Start the vehicle, check for leaks and repair if necessary.
  40.  

9-5 Models
2.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Remove or disconnect the following:

    Battery and intake manifold cover
     
    Negative battery cable
     
    Lower engine cover
     
    Right front wheel
     
    Steering servo pipe from the subframe and install a wedge between the oil sump and subframe on the right hand side
     
    Right front engine mount and bracket
     
    Mass Air Flow (MAF) sensor
     
    Crankcase breather pipe
     
    Front lifting eye
     
    Charge air pipe and bypass valve
     
    Pressure/temperature sensor connector
     
    Bypass valve vacuum hose
     
    V-belt
     
    Belt tensioner and alternator. Move the bracket aside.
     
    Temperature sensor and ignition discharge module connectors
     
    Coolant hoses from the cylinder head
     
    Throttle body lever cover
     
    Throttle cable and dipstick tube
     
    Fuel hoses
     
    Crankcase breather nipple from the timing cover
     
    Intake manifold steady bar
     
    Turbocharger steady bar
     
    Turbocharger and exhaust manifold heat shield
     
    Servo pump and suspend it on the radiator crossmember
     
    Lower screw from the steering servo pump bracket
     
    Bracket for the ignition discharge module-s connector from the rear lifting eye
     
    Heat exchanger pipe bracket
     
    Intake manifold and partition and move it rearward
     
    Ignition discharge module and spark plugs
     
    Camshaft cover and align the pulley marks with the timing cover and make certain that the camshafts are in line with their timing marks
     
    Camshaft sprocket bolts. Make certain that the camshaft does not turn.
     
    Idler sprocket bolt and remove the chain tensioner
     
    Camshaft sprockets and place a rubber band between the chain guides
     
    Inner gasket from the camshaft cover partition
     
    Cylinder head by first removing the bolts from the timing cover

    Click image to see an enlarged view

    Fig. Remove the cylinder head bolts in sequence



    Click image to see an enlarged view

    Fig. Cylinder head bolt torque sequence

     

  6.  

To install:

  1. Clean all mating surfaces.
  2.  
  3. Install or connect the following:

    Inner gasket for the camshaft cover partition
     
    Cylinder head gasket and turn the crankshaft 45 degrees in the rotational direction of the engine
     

  4.  
  5. Install the cylinder head. Torque the bolts in sequence as follows:
    1. 30 ft. lbs. (40 Nm).
    2.  
    3. 44 ft. lbs. (60 Nm).
    4.  
    5. Plus an additional 90 degrees.
    6.  

  6.  
  7. Install or connect the following:

    Bolts between the timing cover and cylinder head and torque the bolts to 16 ft. lbs. (22 Nm). Make certain that the camshafts are aligned with the timing marks and reset the crankshaft to the O mark.
     
    Camshaft sprocket and chain starting with the exhaust camshaft. Do not tighten the bolts.
     
    Timing chain tensioner and torque the bolts to 47 ft. lbs. (63 Nm)
     
    Timing chain tensioner plug, push rod and spring and torque the bolt to 16 ft. lbs. (22 Nm)
     

  8.  
  9. Torque the idler pulley and camshaft sprocket bolts to 47 ft. lbs. (63 Nm). Rotate the crankshaft 2 revolutions and make check the settings of the crankshaft pulley and camshafts.

    Camshaft cover after lightly coating the opening with clean oil and torque the bolts, in sequence to 11 ft. lbs. (15 Nm)
     
    Spark plugs and torque the plugs to 21 ft. lbs. (28 Nm)
     
    Ignition discharge module and torque the bolt to 8 ft. lbs. (11 Nm)
     
    Intake manifold and intermediate partition. Remove the straps and torque the bolts to 16 ft. lbs. ()22 Nm).
     
    Alternator bracket and make certain that the adjuster sleeve is tapped out slightly
     
    Belt tensioner and tighten the ignition discharge module connector bracket
     
    Coolant hoses to the cylinder head and install the bolt securing the pipe to the thermostat housing cover
     
    Ignition discharge module electrical connector
     
    Temperature sensor electrical connector
     
    Turbocharger retaining nuts between the exhaust manifold and turbocharger and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Turbocharger heat shield
     
    Dipstick tube
     
    Turbocharger and intake manifold steady bars
     
    Fuel hoses and rubber protectors
     
    Crankcase ventilation nipple on the valve cover
     
    Throttle cable and adjust as necessary
     
    Ground connections to the cylinder head
     
    Throttle body cover
     
    Servo pump
     
    V-belt and torque the pulley bolts to 15 ft. lbs. (20 Nm)
     
    Lifting eye
     
    Solenoid valve connector
     
    Charge air pipe and bypass valve
     
    Bypass valve vacuum hose and pressure/temperature sensor connector
     
    MAF sensor
     
    Right side engine mount and bracket. Torque the bolts to 39 ft. lbs. (47 Nm) and the nuts to 78 ft. lbs. (105 Nm). Remove the wedge and secure the servo pump pipe to the subframe.
     
    Right front wheel
     
    Crankcase breather pipe and torque the banjo bolt to 18 ft. lbs. (24 Nm)
     
    Lower engine cover
     
    Negative battery cable
     
    Intake manifold and battery cover
     

  10.  
  11. Fill the cooling system and check all fluid levels.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

3.0L Engine Front
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:

    Engine cover
     
    Battery and vent hose
     
    Lower engine cover
     
    Turbocharger bracket and install wedges between the oil sump and subframe and gearbox and subframe
     
    Turbocharger delivery pipe from the charge air cooler
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    V-belt tension
     
    Water pump and power steering pump pulleys
     
    Belt tensioner and alternator air intake
     
    Timing cover
     
    Throttle cable
     
    Upper intake manifold vacuum hoses and pressure sensor connector
     
    Vacuum hose and water hoses from the throttle body
     
    Turbocharger delivery pipe with the bypass pipe and valve from the throttle body
     
    Pressure/temperature sensor connector
     
    Throttle body connector and purge valve hose from the throttle body
     
    Ignition discharge module connector
     
    Fuel injector electrical connector
     
    Fuel lines
     
    Upper intake manifold and move it aside
     
    Middle intake manifold
     
    Lower intake manifold
     
    Coolant bridge and move it aside
     
    Crankshaft pulley

    Click image to see an enlarged view

    Fig. Make certain that the markings on the camshaft sprockets and timing cover are aligned along with the crankshaft.

     



    Tensioner pulley and adjusting rollers and mark the rotation direction of the belt
     
    Lower adjusting roller and washer
     
    Timing belt
     
    Adjuster roller bolts
     
    Ignition discharge module
     
    Camshaft cover and make sure the O-rings do not fall into the engine. Rotate the engine 60 degrees Before Top Dead Center (BTDC) and note the marking
     
    Camshaft sprockets
     
    Water pump
     
    Inner timing cover
     
    Front exhaust manifold heat shield
     
    Hose connections for the front Secondary Air Injection (SAI) valve
     
    SAI pipe and valve from the exhaust manifold
     
    Crankcase ventilation pipe from between the turbocharger intake pipe and the cylinder head
     
    Turbocharger intake pipe and outlet hose
     
    Water hose from the thermostat housing
     
    Front exhaust manifold from the turbocharger
     
    Turbocharger water and oil pipes
     
    Exhaust camshaft by removing the bolts in stages
     
    Bearing caps where the tappets are under load
     
    Tappets
     
    Stuffing box
     
    Cylinder head bolts in the proper sequence by loosening them 1 / 4 turn then 1 / 2 turn
     
    Cylinder head gasket

    Click image to see an enlarged view

    Fig. Remove the cylinder head bolts as shown-3.0L

     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.0L

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Make certain that the crankshaft is at 60 degrees BTDC.
  4.  
  5. Be sure that the proper gasket is used and is marked OBEN/TOP
  6.  
  7. Install or connect the following:

    Tappets
     

  8.  
  9. Cylinder head with a new gasket. Torque the new bolts in sequence as follows:
    1. 18 ft. lbs. (24 Nm).
    2.  
    3. Plus an additional 90 degrees.
    4.  
    5. Plus an additional 90 degrees.
    6.  

  10.  
  11. Install or connect the following:

    Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head.
     
    Stuffing box and bearing caps. Torque the bolts in 1 / 2 to 1 turn to 6 ft. lbs. (8 Nm).
     
    Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match the number on the camshaft
     
    Rear timing cover
     
    Camshaft cover and make certain that the O-rings are in place.
     

  12.  
  13. Lubricate with a soap solution and place tool 10-81-52-381 in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).

    Ignition discharge module
     
    Turbocharger oil pipes and torque the oil pipe to 15 ft. lbs. (20 Nm); the oil pipe to filter adapter to 19 ft. lbs. (25 Nm) and the oil return pipe to 10 ft. lbs. (15 Nm).
     
    Turbocharger water pipes. Torque the water pipes to 19 ft. lbs. (25 Nm) and the cylinder head retaining bolt to 10 ft. lbs. (15 Nm)
     
    Water hose to the thermostat housing
     
    Front exhaust pipe to the turbocharger and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Hose between the turbocharger and charge air cooler
     
    Crankcase breather pipe to the turbocharger intake pipe and torque the bolt to 18 ft. lbs. (24 Nm)
     
    Turbocharger intake pipe and torque the V clamp to 2 ft. lbs. (3 Nm) and the U clamp to 10 ft. lbs. (15 Nm)
     
    SAI pipe with new gaskets to the front exhaust manifold
     
    SAI hose to the valve
     
    Crankcase ventilation pipe between the cylinder head turbocharger intake pipe and torque to 18 ft. lbs. (24 Nm)
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Bracket with the tensioner roller and the upper adjusting roller
     

  14.  
  15. Install Locking Tool KM-800-1 on No. 1 and 2 camshaft sprockets and Tool KM-800-2 on No. 3 and 4 camshaft sprockets
  16.  
  17. Rotate the crankshaft to just before the 0 degree mark and install Tool KM-800-10. Carefully rotate the crankshaft in the direction of the engine until the arm is lying against the water pump flange.
  18.  
  19. Install the camshaft belt to the markings on the belt and the marked direction of rotation. Loosely install the lower tensioner pulley and make certain that the washer is in place.
  20.  
  21. Adjust the tensioner pulley counterclockwise by hand and make certain that the markings are aligned properly.
  22.  
  23. Tighten the center adjuster roller bolts lightly. Adjust the lower adjuster roller counterclockwise until a tension of 275-300 Nm is reached. When properly tightened, remove the belt tension meter.
  24.  
  25. Make certain that the adjusting nut o0n the upper adjuster roller rotates freely. Adjust the tensioning pulley until the lines are aligned. Torque the fastener to 15 ft. lbs. (20 Nm).
  26.  
  27. Remove the locking tool from camshafts No. 1-2 and install tool KM-800-20. Adjust the upper roller counterclockwise with tool 83-94-983 until the markings on the camshaft sprocket are aligned with the markings on tool KM-800-20. Torque the fastener to 30 ft. lbs. (40 Nm).
  28.  
  29. Remove all locking tools.
  30.  
  31. Rotate the engine in the proper direction 2 revolutions until just before the 0 mark. Install Tool KM-800-10 on the crankshaft.
  32.  
  33. Rotate the crankshaft in the proper direction until the arm lies against water pump and tighten it.
  34.  
  35. Install Tool KM-800-20 and make certain that the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.
  36.  
  37. Install or connect the following:

    Coolant bridge after lubricate the bolts and torque them to 22 ft. lbs. (30 Nm)
     
    Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Ignition discharge module and fuel injector connectors
     
    Turbocharger delivery pipe to the throttle body
     
    Turbocharger delivery pipe to the charge air cooler and tighten all clamps
     
    Pressure/temperature sensor electrical connector
     
    Bypass pipe and valve
     
    Water hoses and vacuum hose to the throttle body
     
    Throttle body connector and attach the hoses to the purge valve. Torque the bypass pipe to 6 ft. lbs. (8 Nm).
     
    Vacuum hoses and pressure/temperature sensor connectors to the intake manifold
     
    Throttle cable
     
    Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Belt tensioner and alternator air intake
     
    Water pump and power steering pump pulleys
     
    V-belt and torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)
     
    Power steering hose into the holder
     
    MAF sensor and hose and remove the wedges
     
    Turbocharger bracket
     
    Battery and vent hose
     
    Lower engine cover
     
    Negative battery cable
     
    Engine cover
     

  38.  
  39. Fill the cooling system to the proper level.
  40.  
  41. Start the vehicle, check for leaks and repair if necessary.
  42.  

3.0L Engine-Rear
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Drain the cooling system.
  6.  
  7. Remove or disconnect the following:
    NOTE
    Make certain that the markings on the camshaft sprockets and timing cover are aligned along with the crankshaft.



    Engine and battery cover
     
    Lower engine cover and install wedges between the oil sump and subframe and the gearbox and subframe
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Water pump and power steering pump pulley bolts
     
    Tension from the V belt
     
    Water pump and power steering pump pulleys
     
    Belt tensioner and alternator air intake
     
    Timing cover
     
    Throttle cable
     
    Vacuum hoses and pressure sensor connector from the upper intake manifold
     
    Oxygen (O 2 S) sensor connector from the holder on the rear of the Secondary Air Injection (SAI) valve
     
    SAI pipe from the cylinder head and exhaust manifold connections
     
    Water hoses and vacuum hose from the throttle body
     
    Turbocharger delivery hose with the bypass pipe
     
    Throttle body connector and hose to the purge valve
     
    Fuel lines
     
    Upper intake manifold and move it aside
     
    Ignition discharge module and fuel injector connectors
     
    Middle intake manifold
     
    Lower intake manifold
     
    Coolant bridge
     
    Crankshaft pulley
     



    Tensioner pulley and adjusting rollers. Mark the rotation of the belt.
     
    Lower adjuster roller and washer
     
    Timing belt
     
    Bracket with the tensioning roller and the upper adjuster roller
     
    Ignition discharge module
     
    Camshaft cover with the O-rings. Rotate the crankshaft 60 degrees Before Top Dead Center (BTDC)
     
    Camshaft sprockets
     
    Inner timing cover
     
    Separate the exhaust pipes
     
    Exhaust camshaft
     
    Stuffing box
     
    Tappets and place them in the proper order for installation
     
    Cylinder head bolts in the proper sequence by loosening them 1 / 4 turn then 1 / 2 turn
     
    Cylinder head gaskets

    Click image to see an enlarged view

    Fig. Cylinder head bolt removal sequence-3.0L engine

     

  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-3.0L engine

  1. Clean all mating surfaces of any residual gasket material.
  2.  
  3. Make certain that the crankshaft is at 60 degrees BTDC.
  4.  
  5. Be sure that the proper gasket is used and is marked OBEN/TOP
  6.  
  7. Install the tappets.
  8.  
  9. Install the cylinder head with a new gasket. Torque the new bolts in sequence as follows:
    1. 18 ft. lbs. (24 Nm).
    2.  
    3. Plus an additional 90 degrees.
    4.  
    5. Plus an additional 90 degrees.
    6.  

  10.  
  11. Install or connect the following:

    Exhaust camshaft into position after lubricating it with clean engine oil. The locating pins for the intake camshaft should be in line with the inside bolts for the bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head.
     
    Stuffing box and bearing caps. Torque the bolts in 1 / 2 to 1 turn to 6 ft. lbs. (8 Nm).
     
    Camshafts sprockets in relation to the locating pins. The number in the sprocket hub should match the number on the camshaft. Torque the bolt to 37 ft. lbs. (50 Nm) plus 60 degrees.
     
    Rear timing cover
     
    Camshaft cover and make certain that the O-rings are in place
     

  12.  
  13. Lubricate with a soap solution and place Tool 10-81-52-381 in the corners at the camshaft bearing caps. Torque the bolts to 6 ft. lbs. (8 Nm).

    Ignition discharge module
     
    Hose to the SAI pipe and install the pipe with new gaskets to the exhaust manifold and cylinder head
     
    O 2 S connector in the holder
     
    Front and rear exhaust pipes and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Bracket with the tensioning roller and the upper adjuster roller
     

  14.  
  15. Install Locking Tool KM-800-1 on No. 1 and 2 camshaft sprockets and Tool KM-800-2 on No. 3 and 4 camshaft sprockets
  16.  
  17. Rotate the crankshaft to just before the 0 degree mark and install Tool KM-800-10. Carefully rotate the crankshaft in the direction of the engine until the arm is lying against the water pump flange.
  18.  
  19. Install the camshaft belt to the markings on the belt and the marked direction of rotation. Loosely install the lower tensioner pulley and make certain that the washer is in place.
  20.  
  21. Adjust the tensioner pulley counterclockwise by hand and make certain that the markings are aligned properly.
  22.  
  23. Tighten the center adjuster roller bolts lightly. Adjust the lower adjuster roller counterclockwise until a tension of 275-300 Nm is reached. When properly tightened, remove the belt tension meter.
  24.  
  25. Make certain that the adjusting nut o0n the upper adjuster roller rotates freely. Adjust the tensioning pulley until the lines are aligned. Torque the fastener to 15 ft. lbs. (20 Nm).
  26.  
  27. Remove the locking tool from camshafts No. 1-2 and install Tool KM-800-20. Adjust the upper roller counterclockwise with tool 83-94-983 until the markings on the camshaft sprocket are aligned with the markings on Tool KM-800-20. Torque the fastener to 30 ft. lbs. (40 Nm).
  28.  
  29. Remove all locking tools.
  30.  
  31. Rotate the engine in the proper direction 2 revolutions until just before the 0 mark. Install Tool KM-800-10 on the crankshaft.
  32.  
  33. Rotate the crankshaft in the proper direction until the arm lies against water pump and tighten it.
  34.  
  35. Install Tool KM-800-20 and make certain that the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket.
  36.  
  37. Install or connect the following:

    Coolant bridge after lubricating the bolts and torque them to 22 ft. lbs. (30 Nm)
     
    Lower intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Middle intake manifold and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Fuel lines
     
    Ignition discharge module and fuel injector connectors
     
    Turbocharger delivery pipe to the throttle body
     
    Bypass pipe and valve
     
    Water hoses and vacuum hose to the throttle body
     
    Throttle body connector and attach the hoses to the purge valve and torque the bypass pipe to 6 ft. lbs. (8 Nm)
     
    Vacuum hoses and pressure/temperature sensor connectors to the intake manifold
     
    Throttle cable
     
    Turbocharger delivery pipe to the charge air cooler
     
    Vacuum hose and pressure/temperature sensor connector to the upper intake manifold
     
    Turbocharger bypass pipe and valve
     
    Crankcase pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing cover and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Belt tensioner and alternator air intake
     
    Water pump and power steering pump pulleys
     
    V-belt. Torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm).
     
    Right side engine mount and bracket and torque the bolts to 46 ft. lbs. (63 Nm)
     
    Power steering hose into the holder
     
    MAF sensor and hose and remove the wedges
     
    Turbocharger bracket
     
    Battery and vent hose
     
    Lower engine cover
     
    Negative battery cable
     
    Engine cover
     

  38.  
  39. Fill the cooling system to the proper level.
  40.  
  41. Start the vehicle, check for leaks and repair if necessary.
  42.  

 
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