Saab 2000-06

Oil Pump

Print

Removal & Installation



9-3
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Negative battery cableAir cleaner and relieve the belt tensionRight front wheel and inner wheel well coverCrankshaft pulley and oil pump circlipOil pump cover and gears

    Negative battery cable
     
    Air cleaner and relieve the belt tension
     
    Right front wheel and inner wheel well cover
     
    Crankshaft pulley and oil pump circlip
     
    Oil pump cover and gears
     

  4.  

To install:

  1. Make certain that the markings on the oil pump ring gear faces outward and check the condition of the O-ring, replace if necessary.
  2.  
  3. Install or connect the following: Oil pump gears and coverOil pump circlip with the chamfer facing outward and the opening facing downwardCrankshaft pulley and torque the bolt to 130 ft. lbs. (175 Nm)Right front inner wheel well and front tireAir cleaner and tension the drive beltNegative battery cable

    Oil pump gears and cover
     
    Oil pump circlip with the chamfer facing outward and the opening facing downward
     
    Crankshaft pulley and torque the bolt to 130 ft. lbs. (175 Nm)
     
    Right front inner wheel well and front tire
     
    Air cleaner and tension the drive belt
     
    Negative battery cable
     

  4.  

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

    Negative battery cable
     
    Air cleaner and relieve the belt tension
     
    Right front wheel and inner wheel well cover
     
    Crankshaft pulley and oil pump circlip
     
    Oil pump cover and gears
     

  4.  

To install:

  1. Make certain that the markings on the oil pump ring gear faces outward and check the condition of the O-ring, replace if necessary.
  2.  
  3. Install or connect the following:

    Oil pump gears and cover
     
    Oil pump circlip with the chamfer facing outward and the opening facing downward
     
    Crankshaft pulley and torque the bolt to 130 ft. lbs. (175 Nm)
     
    Right front inner wheel well and front tire
     
    Air cleaner and tension the drive belt
     
    Negative battery cable
     

  4.  

2.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the cooling system.
  6.  
  7. Drain the engine oil.
  8.  
  9. Remove the timing chain, sprockets and front cover.
  10.  
  11. Remove the oil pump.
  12.  

To install:

  1. Install the oil pump against the flat surface at the crankshaft.
  2.  
  3. Install the oil pump bolts and tighten to 17 ft. lbs. (23 Nm).
  4.  
  5. Install the timing chain, sprockets and front cover.
  6.  
  7. Fill the cooling system to the proper level.
  8.  
  9. Fill the engine with clean oil.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Start the vehicle, check for leaks and repair if necessary.
  14.  

9-5
2.3L Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Negative battery cableIntake manifold coverRight front wheelPower steering pump from the subframe. Install a wedge between the oil pan and the subframe and the gearbox and the subframeRight side engine mount and bracket and relieve the belt tensionFlywheel cover plateCrankshaft pulleyOil pan circlipOil pump cover and remove the oil pump

    Negative battery cable
     
    Intake manifold cover
     
    Right front wheel
     
    Power steering pump from the subframe. Install a wedge between the oil pan and the subframe and the gearbox and the subframe
     
    Right side engine mount and bracket and relieve the belt tension
     
    Flywheel cover plate
     
    Crankshaft pulley
     
    Oil pan circlip
     
    Oil pump cover and remove the oil pump
     

  4.  


    Click image to see an enlarged view

    Fig. Exploded view of the oil pump assembly-2.3L Engine


To install:

  1. Clean the oil pan circlip.
  2.  
  3. Make certain that the marking on the oil pump ring gear face out and the pump gear with flange are facing in.
  4.  
  5. Lubricate the O-ring with vaseline.
  6.  
  7. Install or connect the following: Oil pump gearsOil pump cover using the locating arrowsOil pan circlip with the chamfer facing outward and the opening downwardCrankshaft pulley and torque the bolts to 130 ft. lbs. (175 Nm)Flywheel cover plateDrive beltRight side engine mount and bracket and torque the bolts to 37 ft. lbs. (50 Nm)Power steering pump pie to the holderRight front wheelNegative battery cable

    Oil pump gears
     
    Oil pump cover using the locating arrows
     
    Oil pan circlip with the chamfer facing outward and the opening downward
     
    Crankshaft pulley and torque the bolts to 130 ft. lbs. (175 Nm)
     
    Flywheel cover plate
     
    Drive belt
     
    Right side engine mount and bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Power steering pump pie to the holder
     
    Right front wheel
     
    Negative battery cable
     

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

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

    Negative battery cable
     
    Intake manifold cover
     
    Right front wheel
     
    Power steering pump from the subframe. Install a wedge between the oil sump and the subframe and the gearbox and the subframe.
     
    Right side engine mount and bracket and relieve the belt tension
     
    Flywheel cover plate
     
    Crankshaft pulley
     
    Oil pan circlip
     
    Oil pump cover and the oil pump
     

  4.  

To install:

  1. Clean the oil pan circlip.
  2.  
  3. Make certain that the marking on the oil pump ring gear face out and the pump gear with flange are facing in.
  4.  
  5. Lubricate the O-ring with vaseline.
  6.  
  7. Install or connect the following:

    Oil pump gears
     
    Oil pump cover using the locating arrows
     
    Oil pan circlip with the chamfer facing outward and the opening downward
     
    Crankshaft pulley and torque the bolts to 130 ft. lbs. (175 Nm)
     
    Flywheel cover plate
     
    Drive belt
     
    Right side engine mount and bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Power steering pump pipe to the holder and remove the wedge
     
    Right front wheel
     
    Negative battery cable
     

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

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold cover
     
    Right front wheel
     
    Power steering pump from the subframe. Install a wedge between the oil pan and the subframe and the gearbox and the subframe
     
    Right side engine mount and bracket and relieve the belt tension
     
    Flywheel cover plate
     
    Crankshaft pulley
     
    Oil pan circlip
     
    Oil pump cover and remove the oil pump

    Click image to see an enlarged view

    Fig. Exploded view of the oil pump assembly-2.3L Engine

     

  4.  

To install:

  1. Clean the oil pan circlip.
  2.  
  3. Make certain that the marking on the oil pump ring gear face out and the pump gear with flange are facing in.
  4.  
  5. Lubricate the O-ring with vaseline.
  6.  
  7. Install or connect the following:

    Oil pump gears
     
    Oil pump cover using the locating arrows
     
    Oil pan circlip with the chamfer facing outward and the opening downward
     
    Crankshaft pulley and torque the bolts to 130 ft. lbs. (175 Nm)
     
    Flywheel cover plate
     
    Drive belt
     
    Right side engine mount and bracket and torque the bolts to 37 ft. lbs. (50 Nm)
     
    Power steering pump pie to the holder
     
    Right front wheel
     
    Negative battery cable
     

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

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following: Negative battery cableEngine coverRight front wheelLower spoiler section and install a lifting eye on the front cylinder head and suspend the engine.Mass Air Flow (MAF) sensor and hosePower steering hose from the holderRight side engine mount and bracketFront exhaust manifold heat shieldCrankcase breather pipe from the turbocharger intake pipeTurbocharger intake pipe and vent valveWater pump and power steering pump pulley boltsTension from the auxiliary drive beltWater pump and power steering pump pulleysBelt tensioner and alternator air intakeTiming coverCrankshaft pulley and make certain that the markings on the camshaft sprockets and timing cover are aligned with the crankshaft marking

    Negative battery cable
     
    Engine cover
     
    Right front wheel
     
    Lower spoiler section and install a lifting eye on the front cylinder head and suspend the engine.
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Front exhaust manifold heat shield
     
    Crankcase breather pipe from the turbocharger intake pipe
     
    Turbocharger intake pipe and vent valve
     
    Water pump and power steering pump pulley bolts
     
    Tension from the auxiliary drive belt
     
    Water pump and power steering pump pulleys
     
    Belt tensioner and alternator air intake
     
    Timing cover
     
    Crankshaft pulley and make certain that the markings on the camshaft sprockets and timing cover are aligned with the crankshaft marking
     

  8.  
  9. Install locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and KM-800-10 for the crankshaft. Tensioning pulley and adjusting rollers. Mark the direction of rotation for the belt and remove the crankshaft tool.Lower adjusting roller and washer. Rotate the crankshaft to 60° BTDCCamshaft sprocketsWater pumpInner timing coverCrankshaft timing belt pulleyAlternator and oil pressure switch connectorFront exhaust pipeOil pan and strainerA/C compressor and bracket and move them asideOil pump housingCover and remove the 2 pump impellers

    Tensioning pulley and adjusting rollers. Mark the direction of rotation for the belt and remove the crankshaft tool.
     
    Lower adjusting roller and washer. Rotate the crankshaft to 60° BTDC
     
    Camshaft sprockets
     
    Water pump
     
    Inner timing cover
     
    Crankshaft timing belt pulley
     
    Alternator and oil pressure switch connector
     
    Front exhaust pipe
     
    Oil pan and strainer
     
    A/C compressor and bracket and move them aside
     
    Oil pump housing
     
    Cover and remove the 2 pump impellers
     

  10.  


    Click image to see an enlarged view

    Fig. Exploded view of the 9-5 3.0L oil pump assembly


To install:

  1. Install or connect the following: Oil pump impellers and cover. Torque the bolts to 53 inch lbs. (6 Nm). Make certain that the marks on the impellers are properly aligned.Oil pump housing with a new gasket and torque the bolts to 53 inch lbs. (6 Nm)A/C compressor and bracketRight front wheelOil strainer and oil pan and torque the oil strainer bolts to 6 ft. lbs. (8 Nm) and the oil pan bolts to 10 ft. lbs. (15 Nm)Front exhaust pipe and torque the front bolt to 16 ft. lbs. (22 Nm) and the front pipe to manifold bolt to 30 ft. lbs. (40 Nm)Alternator and oil pressure switch connectorCrankshaft timing belt pulley and torque the bolts to 185 ft. lbs. (250 Nm) plus 45 degreesWater pump and torque the bolts to 19 ft. lbs. (25 Nm)Upper and lower adjusting rollersCamshaft sprockets and torque the bolts to 37 ft. lbs. (50 Nm) plus 60 degreesLocking tools between the camshaft sprockets to lock the camshafts of both heads in position.

    Oil pump impellers and cover. Torque the bolts to 53 inch lbs. (6 Nm). Make certain that the marks on the impellers are properly aligned.
     
    Oil pump housing with a new gasket and torque the bolts to 53 inch lbs. (6 Nm)
     
    A/C compressor and bracket
     
    Right front wheel
     
    Oil strainer and oil pan and torque the oil strainer bolts to 6 ft. lbs. (8 Nm) and the oil pan bolts to 10 ft. lbs. (15 Nm)
     
    Front exhaust pipe and torque the front bolt to 16 ft. lbs. (22 Nm) and the front pipe to manifold bolt to 30 ft. lbs. (40 Nm)
     
    Alternator and oil pressure switch connector
     
    Crankshaft timing belt pulley and torque the bolts to 185 ft. lbs. (250 Nm) plus 45 degrees
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Upper and lower adjusting rollers
     
    Camshaft sprockets and torque the bolts to 37 ft. lbs. (50 Nm) plus 60 degrees
     
    Locking tools between the camshaft sprockets to lock the camshafts of both heads in position.
     

  2.  
  3. Rotate the crankshaft forward to just before 0 TDC and install a crankshaft locking tool on the crankshaft. Carefully rotate the engine until the arm of the tool is against the water pump flange. Be sure the crankshaft is at 0 TDC and all timing marks are aligned. Remove the locking tool.00
  4.  
  5. If reusing the belt, install the timing belt according to its marked direction of rotation and timing marks. Adjust the tensioning roller loosely by hand to prevent the belt from slipping out of the cogs. Always adjust counterclockwise. Refer to the Timing Belt Unit Repair Section.
  6.  
  7. Measure the belt tension.
  8.  
  9. Tighten the center bolts of the adjusting roller lightly. Adjust the adjusting rollers counterclockwise. Begin with the lower roller and adjust it to a belt tension of 275-300 Nm.
  10.  


NOTE
Adjustment of the belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.

  1. Continue to carry out the adjustment by means of the tensioning roller, mark against mark. Remove the locking tool for camshaft sprockets 1 and 2. Carry out the final adjustment with the upper center adjusting roller until camshaft sprocket No. 2 moves 0.04-0.08 in. (1-2mm) forward.
  2.  
  3. Remove the locking tool for camshaft sprockets 3 and 4 and also remove the crankshaft locking tool.
  4.  
  5. Torque the tensioning roller to 15 ft. lbs. (20 Nm); the upper adjusting roller to 30 ft. lbs. (40 Nm) and the lower adjusting roller to 15 ft. lbs. (20 Nm).
  6.  
  7. Turn the engine over 2 revolutions to the 0 mark and refit the locking tool on the crankshaft. Check that the markings on the camshaft sprockets are in alignment with the markings on the timing cover. Check the positioning by installing the 2 camshaft locking tools, which should fit, and also by fitting tool 83-94-926 on camshaft sprockets 1 and 2 and 3 and 4. Also check the tensioning roller to ensure that the marks are still in alignment.0
  8.  
  9. Install or connect the following: Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)Timing belt cover and torque the bolts to 72 inch lbs. (8 Nm)Belt tensioner and alternator air intakeWater pump and power steering pump pulleysV-belt and torque the water pump pulley bolts to 72 inch lbs. (8 Nm) and the power steering pulley bolts to 15 ft. lbs. (20 Nm)Right side engine mount and bracket and torque the bolts to 47 ft. lbs. (63 Nm)Power steering hose in the holderMAF sensor and hose and remove the engine lifting supportTurbocharger intake pipeCrankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)Front exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (24 Nm)Negative battery cableLower spoiler sectionEngine cover

    Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing belt cover and torque the bolts to 72 inch 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 72 inch lbs. (8 Nm) and the power steering pulley bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket and torque the bolts to 47 ft. lbs. (63 Nm)
     
    Power steering hose in the holder
     
    MAF sensor and hose and remove the engine lifting support
     
    Turbocharger intake pipe
     
    Crankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Front exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Negative battery cable
     
    Lower spoiler section
     
    Engine cover
     

  10.  
  11. Fill the cooling system to the proper level.
  12.  
  13. Fill the engine with clean oil.
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.
  16.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following: Negative battery cableEngine coverRight front wheelLower spoiler section and install a lifting eye on the front cylinder head and suspend the engine.Mass Air Flow (MAF) sensor and hosePower steering hose from the holderRight side engine mount and bracketFront exhaust manifold heat shieldCrankcase breather pipe from the turbocharger intake pipeTurbocharger intake pipe and vent valveWater pump and power steering pump pulley boltsTension from the auxiliary drive beltWater pump and power steering pump pulleysBelt tensioner and alternator air intakeTiming coverCrankshaft pulley and make certain that the markings on the camshaft sprockets and timing cover are aligned with the crankshaft marking

    Negative battery cable
     
    Engine cover
     
    Right front wheel
     
    Lower spoiler section and install a lifting eye on the front cylinder head and suspend the engine.
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Front exhaust manifold heat shield
     
    Crankcase breather pipe from the turbocharger intake pipe
     
    Turbocharger intake pipe and vent valve
     
    Water pump and power steering pump pulley bolts
     
    Tension from the auxiliary drive belt
     
    Water pump and power steering pump pulleys
     
    Belt tensioner and alternator air intake
     
    Timing cover
     
    Crankshaft pulley and make certain that the markings on the camshaft sprockets and timing cover are aligned with the crankshaft marking
     

  8.  
  9. Install locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and KM-800-10 for the crankshaft. Tensioning pulley and adjusting rollers. Mark the direction of rotation for the belt and remove the crankshaft tool.Lower adjusting roller and washer. Rotate the crankshaft to 60° BTDCCamshaft sprocketsWater pumpInner timing coverCrankshaft timing belt pulleyAlternator and oil pressure switch connectorFront exhaust pipeOil pan and strainerA/C compressor and bracket and move them asideOil pump housingCover and remove the 2 pump impellers

    Tensioning pulley and adjusting rollers. Mark the direction of rotation for the belt and remove the crankshaft tool.
     
    Lower adjusting roller and washer. Rotate the crankshaft to 60° BTDC
     
    Camshaft sprockets
     
    Water pump
     
    Inner timing cover
     
    Crankshaft timing belt pulley
     
    Alternator and oil pressure switch connector
     
    Front exhaust pipe
     
    Oil pan and strainer
     
    A/C compressor and bracket and move them aside
     
    Oil pump housing
     
    Cover and remove the 2 pump impellers
     

  10.  


    Click image to see an enlarged view

    Fig. Exploded view of the 9-5 3.0L oil pump assembly


To install:

  1. Install or connect the following: Oil pump impellers and cover. Torque the bolts to 53 inch lbs. (6 Nm). Make certain that the marks on the impellers are properly aligned.Oil pump housing with a new gasket and torque the bolts to 53 inch lbs. (6 Nm)A/C compressor and bracketRight front wheelOil strainer and oil pan and torque the oil strainer bolts to 6 ft. lbs. (8 Nm) and the oil pan bolts to 10 ft. lbs. (15 Nm)Front exhaust pipe and torque the front bolt to 16 ft. lbs. (22 Nm) and the front pipe to manifold bolt to 30 ft. lbs. (40 Nm)Alternator and oil pressure switch connectorCrankshaft timing belt pulley and torque the bolts to 185 ft. lbs. (250 Nm) plus 45 degreesWater pump and torque the bolts to 19 ft. lbs. (25 Nm)Upper and lower adjusting rollersCamshaft sprockets and torque the bolts to 37 ft. lbs. (50 Nm) plus 60 degreesLocking tools between the camshaft sprockets to lock the camshafts of both heads in position.

    Oil pump impellers and cover. Torque the bolts to 53 inch lbs. (6 Nm). Make certain that the marks on the impellers are properly aligned.
     
    Oil pump housing with a new gasket and torque the bolts to 53 inch lbs. (6 Nm)
     
    A/C compressor and bracket
     
    Right front wheel
     
    Oil strainer and oil pan and torque the oil strainer bolts to 6 ft. lbs. (8 Nm) and the oil pan bolts to 10 ft. lbs. (15 Nm)
     
    Front exhaust pipe and torque the front bolt to 16 ft. lbs. (22 Nm) and the front pipe to manifold bolt to 30 ft. lbs. (40 Nm)
     
    Alternator and oil pressure switch connector
     
    Crankshaft timing belt pulley and torque the bolts to 185 ft. lbs. (250 Nm) plus 45 degrees
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Upper and lower adjusting rollers
     
    Camshaft sprockets and torque the bolts to 37 ft. lbs. (50 Nm) plus 60 degrees
     
    Locking tools between the camshaft sprockets to lock the camshafts of both heads in position.
     

  2.  
  3. Rotate the crankshaft forward to just before 0 TDC and install a crankshaft locking tool on the crankshaft. Carefully rotate the engine until the arm of the tool is against the water pump flange. Be sure the crankshaft is at 0 TDC and all timing marks are aligned. Remove the locking tool.00
  4.  
  5. If reusing the belt, install the timing belt according to its marked direction of rotation and timing marks. Adjust the tensioning roller loosely by hand to prevent the belt from slipping out of the cogs. Always adjust counterclockwise.
  6.  
  7. Measure the belt tension.
  8.  
  9. Tighten the center bolts of the adjusting roller lightly. Adjust the adjusting rollers counterclockwise. Begin with the lower roller and adjust it to a belt tension of 275-300 Nm.
  10.  


NOTE
Adjustment of the belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.

  1. Continue to carry out the adjustment by means of the tensioning roller, mark against mark. Remove the locking tool for camshaft sprockets 1 and 2. Carry out the final adjustment with the upper center adjusting roller until camshaft sprocket No. 2 moves 0.04-0.08 in. (1-2mm) forward.
  2.  
  3. Remove the locking tool for camshaft sprockets 3 and 4 and also remove the crankshaft locking tool.
  4.  
  5. Torque the tensioning roller to 15 ft. lbs. (20 Nm); the upper adjusting roller to 30 ft. lbs. (40 Nm) and the lower adjusting roller to 15 ft. lbs. (20 Nm).
  6.  
  7. Turn the engine over 2 revolutions to the 0 mark and refit the locking tool on the crankshaft. Check that the markings on the camshaft sprockets are in alignment with the markings on the timing cover. Check the positioning by installing the 2 camshaft locking tools, which should fit, and also by fitting tool 83-94-926 on camshaft sprockets 1 and 2 and 3 and 4. Also check the tensioning roller to ensure that the marks are still in alignment.0
  8.  
  9. Install or connect the following: Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)Timing belt cover and torque the bolts to 72 inch lbs. (8 Nm)Belt tensioner and alternator air intakeWater pump and power steering pump pulleysV-belt and torque the water pump pulley bolts to 72 inch lbs. (8 Nm) and the power steering pulley bolts to 15 ft. lbs. (20 Nm)Right side engine mount and bracket and torque the bolts to 47 ft. lbs. (63 Nm)Power steering hose in the holderMAF sensor and hose and remove the engine lifting supportTurbocharger intake pipeCrankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)Front exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (24 Nm)Negative battery cableLower spoiler sectionEngine cover

    Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing belt cover and torque the bolts to 72 inch 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 72 inch lbs. (8 Nm) and the power steering pulley bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket and torque the bolts to 47 ft. lbs. (63 Nm)
     
    Power steering hose in the holder
     
    MAF sensor and hose and remove the engine lifting support
     
    Turbocharger intake pipe
     
    Crankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Front exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Negative battery cable
     
    Lower spoiler section
     
    Engine cover
     

  10.  
  11. Fill the cooling system to the proper level.
  12.  
  13. Fill the engine with clean oil.
  14.  
  15. Start the vehicle, check for leaks and repair if necessary.
  16.  

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

    Negative battery cable
     
    Engine cover
     
    Right front wheel
     
    Lower spoiler section and install a lifting eye on the front cylinder head and suspend the engine.
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Front exhaust manifold heat shield
     
    Crankcase breather pipe from the turbocharger intake pipe
     
    Turbocharger intake pipe and vent valve
     
    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
     
    Crankshaft pulley and make certain that the markings on the camshaft sprockets and timing cover are aligned with the crankshaft marking.
     

  8.  
  9. Install locking Tool KM-800-1 and KM-800-2 for the camshaft sprockets and KM-800-10 for the crankshaft.

    Tensioning pulley and adjusting rollers. Mark the direction of rotation for the belt and remove the crankshaft tool.
     
    Lower adjusting roller and washer. Rotate the crankshaft to 60 degrees Before Top Dead Center (BTDC).
     
    Camshaft sprockets
     
    Water pump
     
    Inner timing cover
     
    Crankshaft timing belt pulley
     
    Alternator and oil pressure switch connector
     
    Front exhaust pipe
     
    Oil pan and strainer
     
    A/C compressor and bracket and move them aside
     
    Oil pump housing
     
    Cover and remove the 2 pump impellers

    Click image to see an enlarged view

    Fig. Exploded view of the 9-5- 3.0L oil pump assembly

     

  10.  

To install:

  1. Install or connect the following:

    Oil pump impellers and cover. Torque the bolts to 53 inch lbs. (6 Nm). Make certain that the marks on the impellers are properly aligned.
     
    Oil pump housing with a new gasket and torque the bolts to 53 inch lbs. (6 Nm)
     
    A/C compressor and bracket
     
    Right front wheel
     
    Oil strainer and oil pan and torque the oil strainer bolts to 6 ft. lbs. (8 Nm) and the oil pan bolts to 10 ft. lbs. (15 Nm)
     
    Front exhaust pipe and torque the front bolt to 16 ft. lbs. (22 Nm) and the front pipe to manifold bolt to 30 ft. lbs. (40 Nm)
     
    Alternator and oil pressure switch connector
     
    Crankshaft timing belt pulley and torque the bolts to 185 ft. lbs. (250 Nm) plus 45 degrees
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Upper and lower adjusting rollers
     
    Camshaft sprockets and torque the bolts to 37 ft. lbs. (50 Nm) plus 60 degrees
     
    Locking tools between the camshaft sprockets to lock the camshafts of both heads in position.
     

  2.  
  3. Rotate the crankshaft forward to just before 0 Top Dead Center (TDC) and install a crankshaft locking tool on the crankshaft. Carefully rotate the engine until the arm of the tool is against the water pump flange. Be sure the crankshaft is at 0 TDC and all timing marks are aligned. Remove the locking tool.
  4.  
  5. If reusing the belt, install the timing belt according to its marked direction of rotation and timing marks. Adjust the tensioning roller loosely by hand to prevent the belt from slipping out of the cogs. Always adjust counterclockwise.
  6.  
  7. Measure the belt tension.
  8.  
  9. Tighten the center bolts of the adjusting roller lightly. Adjust the adjusting rollers counterclockwise. Begin with the lower roller and adjust it to a belt tension of 275-300 Newtons.
    NOTE
    Adjustment of the belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.

  10.  
  11. Continue to carry out the adjustment by means of the tensioning roller, mark against mark. Remove the locking tool for camshaft sprockets 1 and 2. Carry out the final adjustment with the upper center adjusting roller until camshaft sprocket No. 2 moves 0.04-0.08 in. (1-2mm) forward.
  12.  
  13. Remove the locking tool for camshaft sprockets 3 and 4 and also remove the crankshaft locking tool.
  14.  
  15. Torque the tensioning roller to 15 ft. lbs. (20 Nm); the upper adjusting roller to 30 ft. lbs. (40 Nm) and the lower adjusting roller to 15 ft. lbs. (20 Nm).
  16.  
  17. Turn the engine over 2 revolutions to the 0 mark and refit the locking tool on the crankshaft. Check that the markings on the camshaft sprockets are in alignment with the markings on the timing cover. Check the positioning by installing the 2 camshaft locking tools, which should fit, and also by fitting tool 83-94-926 on camshaft sprockets 1 and 2 and 3 and 4. Also check the tensioning roller to ensure that the marks are still in alignment.
  18.  
  19. Install or connect the following:

    Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing belt cover and torque the bolts to 72 inch 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 72 inch lbs. (8 Nm) and the power steering pulley bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket and torque the bolts to 47 ft. lbs. (63 Nm)
     
    Power steering hose in the holder
     
    MAF sensor and hose and remove the engine lifting support
     
    Turbocharger intake pipe
     
    Crankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Front exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Negative battery cable
     
    Lower spoiler section
     
    Engine cover
     

  20.  
  21. Fill the cooling system to the proper level.
  22.  
  23. Fill the engine with clean oil.
  24.  
  25. Start the vehicle, check for leaks and repair if necessary.
  26.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain the cooling system.
  4.  
  5. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Right front wheel
     
    Lower spoiler section and install a lifting eye on the front cylinder head and suspend the engine.
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Front exhaust manifold heat shield
     
    Crankcase breather pipe from the turbocharger intake pipe
     
    Turbocharger intake pipe and vent valve
     
    Water pump and power steering pump pulley bolts
     
    Tension from the auxiliary drive belt
     
    Water pump and power steering pump pulleys
     
    Belt tensioner and alternator air intake
     
    Timing cover
     
    Crankshaft pulley and make certain that the markings on the camshaft sprockets and timing cover are aligned with the crankshaft marking
     

  8.  
  9. Install locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and KM-800-10 for the crankshaft.

    Tensioning pulley and adjusting rollers. Mark the direction of rotation for the belt and remove the crankshaft tool.
     
    Lower adjusting roller and washer. Rotate the crankshaft to 60° BTDC
     
    Camshaft sprockets
     
    Water pump
     
    Inner timing cover
     
    Crankshaft timing belt pulley
     
    Alternator and oil pressure switch connector
     
    Front exhaust pipe
     
    Oil pan and strainer
     
    A/C compressor and bracket and move them aside
     
    Oil pump housing
     
    Cover and remove the 2 pump impellers

    Click image to see an enlarged view

    Fig. Exploded view of the 9-5 3.0L oil pump assembly

     

  10.  

To install:

  1. Install or connect the following:

    Oil pump impellers and cover. Torque the bolts to 53 inch lbs. (6 Nm). Make certain that the marks on the impellers are properly aligned.
     
    Oil pump housing with a new gasket and torque the bolts to 53 inch lbs. (6 Nm)
     
    A/C compressor and bracket
     
    Right front wheel
     
    Oil strainer and oil pan and torque the oil strainer bolts to 6 ft. lbs. (8 Nm) and the oil pan bolts to 10 ft. lbs. (15 Nm)
     
    Front exhaust pipe and torque the front bolt to 16 ft. lbs. (22 Nm) and the front pipe to manifold bolt to 30 ft. lbs. (40 Nm)
     
    Alternator and oil pressure switch connector
     
    Crankshaft timing belt pulley and torque the bolts to 185 ft. lbs. (250 Nm) plus 45 degrees
     
    Water pump and torque the bolts to 19 ft. lbs. (25 Nm)
     
    Upper and lower adjusting rollers
     
    Camshaft sprockets and torque the bolts to 37 ft. lbs. (50 Nm) plus 60 degrees
     
    Locking tools between the camshaft sprockets to lock the camshafts of both heads in position.
     

  2.  
  3. Rotate the crankshaft forward to just before 0 TDC and install a crankshaft locking tool on the crankshaft. Carefully rotate the engine until the arm of the tool is against the water pump flange. Be sure the crankshaft is at 0 TDC and all timing marks are aligned. Remove the locking tool.
  4.  
  5. If reusing the belt, install the timing belt according to its marked direction of rotation and timing marks. Adjust the tensioning roller loosely by hand to prevent the belt from slipping out of the cogs. Always adjust counterclockwise.
  6.  
  7. Measure the belt tension.
  8.  
  9. Tighten the center bolts of the adjusting roller lightly. Adjust the adjusting rollers counterclockwise. Begin with the lower roller and adjust it to a belt tension of 275-300 Nm.
    NOTE
    Adjustment of the belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.

  10.  
  11. Continue to carry out the adjustment by means of the tensioning roller, mark against mark. Remove the locking tool for camshaft sprockets 1 and 2. Carry out the final adjustment with the upper center adjusting roller until camshaft sprocket No. 2 moves 0.04-0.08 in. (1-2mm) forward.
  12.  
  13. Remove the locking tool for camshaft sprockets 3 and 4 and also remove the crankshaft locking tool.
  14.  
  15. Torque the tensioning roller to 15 ft. lbs. (20 Nm); the upper adjusting roller to 30 ft. lbs. (40 Nm) and the lower adjusting roller to 15 ft. lbs. (20 Nm).
  16.  
  17. Turn the engine over 2 revolutions to the 0 mark and refit the locking tool on the crankshaft. Check that the markings on the camshaft sprockets are in alignment with the markings on the timing cover. Check the positioning by installing the 2 camshaft locking tools, which should fit, and also by fitting tool 83-94-926 on camshaft sprockets 1 and 2 and 3 and 4. Also check the tensioning roller to ensure that the marks are still in alignment.
  18.  
  19. Install or connect the following:

    Crankshaft pulley and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Timing belt cover and torque the bolts to 72 inch 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 72 inch lbs. (8 Nm) and the power steering pulley bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket and torque the bolts to 47 ft. lbs. (63 Nm)
     
    Power steering hose in the holder
     
    MAF sensor and hose and remove the engine lifting support
     
    Turbocharger intake pipe
     
    Crankcase breather pipe and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Front exhaust manifold heat shield and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Negative battery cable
     
    Lower spoiler section
     
    Engine cover
     

  20.  
  21. Fill the cooling system to the proper level.
  22.  
  23. Fill the engine with clean oil.
  24.  
  25. Start the vehicle, check for leaks and repair if necessary.
  26.  

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. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner and relieve the belt tension
     
    Right front wheel and inner wheel well cover
     
    Crankshaft pulley and oil pump circlip
     
    Oil pump cover and gears

    Click image to see an enlarged view

    Fig. Exploded view of the oil pump assembly 2.0L-2.3L Engines

     

  4.  

To install:

  1. Make certain that the markings on the oil pump ring gear faces outward and check the condition of the O-ring, replace if necessary.
  2.  
  3. Install or connect the following:

    Oil pump gears and cover
     
    Oil pump circlip with the chamfer facing outward and the opening facing downward
     
    Crankshaft pulley and torque the bolt to 130 ft. lbs. (175 Nm)
     
    Right front inner wheel well and front tire
     
    Air cleaner and tension the drive belt
     
    Negative battery cable
     

  4.  

9000 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air filter assembly
     
    Drive belt. Using a 3 / 8 in. ratchet extension release the pressure. Place a short drill bit in tensioner housing to hold in the non-tension position.
     
    Right front wheel
     
    Crankshaft access cover
     
    Crankshaft pulley
     
    Crankshaft Position (CKP) sensor
     
    Idler pulley
     
    Oil pump
     

  4.  

To install:

  1. Insert oil pump gears making sure that the marking on the oil pump ring gear faces outward.
  2.  
  3. Install or connect the following:

    Oil pump cover and torque the bolts to 72 inch lbs. (8 Nm)
     
    Idler pulley
     
    CKP sensor
     
    Crankshaft pulley and torque the bolt to 130 ft. lbs. (175 Nm)
     
    Crankshaft cover
     
    Right front wheel
     
    Drive belt
     
    Air filter assembly
     
    Negative battery cable
     

  4.  
  5. Test drive the vehicle and check that the drive belt is seated properly.
  6.  

 
label.common.footer.alt.autozoneLogo