Saab 2000-06

Cylinder Head 3

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Removal & Installation



900 And 9-3 Models
2.0L And 2.3L Engines
  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. Drain the engine oil.
  8.  
  9. Remove or disconnect the following:

    Battery
     
    Exhaust manifold
     
    Turbocharger unit, if equipped
     
    Oil hoses from the oil cooler if equipped, and plug them
     
    Tensioning pulley and drive belt from the A/C compressor and slacken the securing bolts for the steering pump bracket
     
    Power steering pump drive belt, push the pump aside
     
    Wiring harness clips on the cylinder head
     
    Two bolts in the timing cover, which are screwed into the cylinder head from underneath
     
    Bolts in the right-hand engine mounting, which are screwed into the cylinder head, together with the spacer sleeves
     
    Hose between the thermostat housing and the radiator at the thermostat housing
     
    Fuel pressure regulator and ground leads for the fuel injection system
     
    A/C compressor. Leave lines still attached and carefully put it on the air intake for the heating system.
     
    Bracket for the air conditioning compressor
     
    Intake manifold complete with injectors
     
    Temperature sensor lead
     
    Ignition module cartridge
     
    Valve cover
     
    Crankcase ventilation hose
     
    Semicircular rubber plug halves from the cylinder head
     

  10.  
  11. Line up the 0 mark on the flywheel with the timing mark. Check that the camshaft timing marks are also in line.
    NOTE
    Do not rotate the camshaft or crankshaft after the sprockets have been removed, as rotation of one of the shafts can result in damage to the valves.



    Timing chain tensioner
     
    Camshaft sprockets
     



    Cylinder head bolts
     

  12.  
  13. Siphon off the oil from the cylinder head.
  14.  
  15. Install Guide Pin 83-92-128 in one of the bolt holes and lift off the cylinder head, making sure the pivoting guide for the timing chain is not damaged.
  16.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence-2.0L and 2.3L engines

  1. Align the 0 mark on the flywheel with the timing mark on the housing. Align the marks on the camshafts with their respective timing marks.
  2.  
  3. Install the cylinder head gasket, making sure it is held in position by the guide sleeves in the cylinder head flange.
  4.  
  5. Position the timing chain and pivoting guide for cylinder head installation.
  6.  
  7. Install the cylinder head. Use the guide pin as a pivot for the head, which must be turned slightly to enable it to pass the pivoting guide. Thereafter, alignment will be determined by the guide sleeves.
  8.  
  9. Install the 2 M8 bolts in the underside of the cylinder head.
  10.  
  11. Install the remaining cylinder head bolts and torque them in sequence as follows:
    1. 30 ft. lbs. (44 Nm).
    2.  
    3. 44 ft. lbs. (60 Nm).
    4.  
    5. Plus 90 degrees ( 1 / 4 turn).
    6.  

  12.  
  13. Install or connect the following:

    Camshaft sprockets
     
    Timing chain
     
    Timing chain tensioner
     
    Semi-circular rubber plug halves in the cylinder head
     
    Valve cover and torque the bolts to 11 ft. lbs. (15 Nm)
     
    Crankcase ventilation hose
     
    Ignition module module and torque to 8 ft. lbs. (11 Nm)
     
    Temperature sensor electrical lead
     
    Intake manifold complete with injectors and torque the bolts to 16 ft. lbs. (22 Nm)
     
    A/C compressor bracket
     
    A/C compressor
     
    Fuel pressure regulator
     
    Ground leads for the fuel injection system
     
    Upper radiator hose to thermostat housing
     
    Bolts in the right-hand engine mounting. Screw them into the cylinder head, together with the spacer sleeves.
     
    Wiring harness clips on the cylinder head
     
    Power steering belt
     
    Tensioning pulley and drive belt for the air conditioner compressor
     
    Exhaust manifold and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Negative battery cable
     

  14.  
  15. Fill the engine with clean oil.
  16.  
  17. Fill the cooling system.
  18.  
  19. Start the vehicle, check for leaks and repair if necessary.
  20.  

9000 Models
  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:
    WARNING
    To remove or refit the timing chain, the camshafts and crankshaft must be lined up with their respective timing marks, No. 1 cylinder at Top Dead Center, (TDC). Never rotate the crankshaft or the camshaft once the timing chain has been detached. A fully opened valve could come in contact with a piston at TDC.



    Negative battery cable
     
    Right front wheel
     
    Right front inner fender panel
     
    Radiator expansion tank
     
    Power steering reservoir, set aside and leave the hoses attached
     
    A/C compressor drive belt
     
    A/C compressor electrical leads
     
    Compressor from its mounting bracket. Disconnect the top pipe connected to the air-cooled oil cooler and push the pipe to one side. Carefully rest the compressor on the radiator crossmember.
     
    Compressor mounting bracket
     
    Front exhaust pipe flange, unhook the rubber hangers.
     
    Turbocharger unit stay bar and the oil return pipe, if equipped
     
    Hose from the intercooler at the turbocharger unit, if equipped
     
    Oil supply pipe from the turbocharger, if equipped
     
    Hose between the air mass meter and the turbocharger unit, if equipped
     
    Coolant hose from the thermostat housing and the hose from the cylinder head
     
    Oil supply hose or pipe so as not to obstruct the removal of the exhaust manifold. If necessary, remove the clip holding the pipe to the cylinder head and slave cylinder.
     
    Exhaust manifold complete with the turbocharger unit (if equipped), pushing the oil supply pipe aside at the same time
     
    Temperature transducer electrical connector
     
    Engine stay bracket
     
    Bolt securing the engine stay bracket to the cylinder head
     
    Intake manifold
     
    Breather hose for crankcase ventilation from the camshaft cover
     
    Ignition module cartridge
     
    Camshaft cover and align the crankshaft with the 0 timing mark and check that the camshaft timing marks also coincide
     
    Bolts securing exhaust then intake camshaft sprockets. Using a wrench installed over the flats on the camshaft, hold the camshaft and remove the bolt securing the camshaft sprocket
     



    Timing chain tensioner
     
    Two cylinder head bolts adjacent to the timing cover, which are accessible from below
     
    Starter motor lead from the clip on the thermostat housing
     
    Cylinder head bolts
     

  6.  
  7. Install a guide pin in the drilled hole in the right top corner of the cylinder head. Be sure the timing chain is positioned such that the pivoting chain guide will not obstruct the cylinder head and carefully lift the cylinder head from the engine block.
  8.  

To install:

Click image to see an enlarged view

Fig. Cylinder head bolt torque sequence

  1. Before installation, clean both the cylinder head and the engine block surfaces. Install a new gasket. Be sure the crankshaft is aligned in the 0 position and that the camshafts are aligned with their respective timing marks.
    NOTE
    When the pistons of the No. 1 and No. 4 cylinders are at TDC, the crankshaft 0 mark on the flywheel must be aligned with the mark on the clutch cover or the end plate, if the clutch cover has been removed. The marks on the camshafts must be aligned with those on the cam bearing caps. This indicates the exhaust valves for No. 1 and No. 4 cylinders are closed.

  2.  
  3. Install a guide pin in the drilled hole in the top of the right corner of the cylinder head and lower the cylinder head carefully into position on the engine block. Locate the cylinder head on the guide sleeves.
  4.  
  5. Install the cylinder head bolts and torque them in sequence, as follows:
    1. 44 ft. lbs. (60 Nm).
    2.  
    3. 59 ft. lbs. (80 Nm).
    4.  
    5. An additional 90 degrees ( 1 / 4 turn).
    6.  

  6.  
  7. Install or connect the following:

    Timing chain
     
    Both halves of the split seal and the camshaft cover and torque the bolts in sequence to 16 ft. lbs. (22 Nm)
     
    Ignition module cartridge
     
    Clip securing the starter motor lead to the thermostat housing
     
    Intake manifold and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Engine stay bracket to the cylinder head
     
    Exhaust manifold and gasket to the cylinder head
     
    Oil supply pipe and clip
     
    Slave cylinder bolt
     
    Oil return line
     
    Steady bar for the turbocharger, if equipped
     
    Hose between turbocharger unit and intercooler, if equipped
     
    Cooler hose to the thermostat housing and cylinder head
     
    Air mass meter connector to the turbocharger, if equipped
     
    Hose between the intercooler and the turbocharger unit, if equipped
     
    Nuts securing the front section of the exhaust pipe to the turbocharger compressor, if equipped
     
    A/C compressor mounting bracket to both cylinder head and block
     
    A/C compressor. Leave the coolant hose in the bracket when installing the compressor
     
    A/C compressor electrical leads and be sure the lead is clear of the compressor pulley
     
    Steering servo reservoir
     
    Coolant expansion tank and clamp
     
    Top pipe to the air-cooled oil cooler, secure the cooler to the radiator
     
    Overflow line between the expansion tank and the radiator
     
    Compressor belt, adjust the tension and tighten the belt tensioner bolt
     
    Inner right wheel arch and wheel
     
    Negative battery cable
     

  8.  
  9. Fill the cooling system.
  10.  
  11. Start the engine, check for leaks and repair if necessary.
  12.  

 
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