Saab 2000-06

Rocker Arm (Valve) Cover

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Removal & Installation



2.0L 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 cableEngine coverCrankcase breather hose from the rocker arm coverTurbocharger delivery pipeFront wiring harness channel from the cylinder headFuel lines from the rocker arm cover and engine mountRocker arm cover and discard the gasket

    Negative battery cable
     
    Engine cover
     
    Crankcase breather hose from the rocker arm cover
     
    Turbocharger delivery pipe
     
    Front wiring harness channel from the cylinder head
     
    Fuel lines from the rocker arm cover and engine mount
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following: Rocker arm cover with a new gasket and torque the bolts to 6 ft. lbs. (8 Nm)Fuel lines to the fastenersWiring harness channel to the cylinder headTurbocharger delivery pipeCrankcase breather hoseEngine coverNegative battery cable

    Rocker arm cover with a new gasket and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Fuel lines to the fasteners
     
    Wiring harness channel to the cylinder head
     
    Turbocharger delivery pipe
     
    Crankcase breather hose
     
    Engine cover
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Negative battery cableEngine coverCrankcase breather hose from the rocker arm coverTurbocharger delivery pipeFront wiring harness channel from the cylinder headFuel lines from the rocker arm cover and engine mountRocker arm cover and discard the gasket

    Negative battery cable
     
    Engine cover
     
    Crankcase breather hose from the rocker arm cover
     
    Turbocharger delivery pipe
     
    Front wiring harness channel from the cylinder head
     
    Fuel lines from the rocker arm cover and engine mount
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following: Rocker arm cover with a new gasket and torque the bolts to 72 inch lbs. (8 Nm)Fuel lines to the fastenersWiring harness channel to the cylinder headTurbocharger delivery pipeCrankcase breather hoseEngine coverNegative battery cable

    Rocker arm cover with a new gasket and torque the bolts to 72 inch lbs. (8 Nm)
     
    Fuel lines to the fasteners
     
    Wiring harness channel to the cylinder head
     
    Turbocharger delivery pipe
     
    Crankcase breather hose
     
    Engine cover
     
    Negative battery cable
     

  2.  

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

    Negative battery cable
     
    Engine cover
     
    Crankcase breather hose from the rocker arm cover
     
    Turbocharger delivery pipe
     
    Front wiring harness channel from the cylinder head
     
    Fuel lines from the rocker arm cover and engine mount
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following:

    Rocker arm cover with a new gasket and torque the bolts to 72 inch lbs. (8 Nm)
     
    Fuel lines to the fasteners
     
    Wiring harness channel to the cylinder head
     
    Turbocharger delivery pipe
     
    Crankcase breather hose
     
    Engine cover
     
    Negative battery cable
     

  2.  

2.3L Engines
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Negative battery cableIgnition discharge module/ignition cables from the rocker arm coverTurbocharger pipes, if necessary for accessSpark plugsRocker arm cover and discard the gasket

    Negative battery cable
     
    Ignition discharge module/ignition cables from the rocker arm cover
     
    Turbocharger pipes, if necessary for access
     
    Spark plugs
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:



Click image to see an enlarged view

Fig. Torque the rocker arm cover bolts as illustrated

  1. Install or connect the following: Rocker arm cover with a new gasket and torque the bolts, in sequence, to 11 ft. lbs. (15 Nm)Spark plugs and torque to 21 ft. lbs. (28 Nm)Turbocharger pipes, if removedIgnition discharge module/ignition cables and torque to 8 ft. lbs. (11 Nm)Negative battery cable

    Rocker arm cover with a new gasket and torque the bolts, in sequence, to 11 ft. lbs. (15 Nm)
     
    Spark plugs and torque to 21 ft. lbs. (28 Nm)
     
    Turbocharger pipes, if removed
     
    Ignition discharge module/ignition cables and torque to 8 ft. lbs. (11 Nm)
     
    Negative battery cable
     

  2.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Negative battery cableIgnition discharge module/ignition cables from the rocker arm coverTurbocharger pipes, if necessary for accessSpark plugsRocker arm cover and discard the gasket

    Negative battery cable
     
    Ignition discharge module/ignition cables from the rocker arm cover
     
    Turbocharger pipes, if necessary for access
     
    Spark plugs
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:



Click image to see an enlarged view

Fig. Torque the rocker arm cover bolts as illustrated

  1. Install or connect the following: Rocker arm cover with a new gasket and torque the bolts, in sequence, to 11 ft. lbs. (15 Nm)Spark plugs and torque to 21 ft. lbs. (28 Nm)Turbocharger pipes, if removedIgnition discharge module/ignition cables and torque to 96 inch lbs. (11 Nm)Negative battery cable

    Rocker arm cover with a new gasket and torque the bolts, in sequence, to 11 ft. lbs. (15 Nm)
     
    Spark plugs and torque to 21 ft. lbs. (28 Nm)
     
    Turbocharger pipes, if removed
     
    Ignition discharge module/ignition cables and torque to 96 inch lbs. (11 Nm)
     
    Negative battery cable
     

  2.  

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

    Negative battery cable
     
    Ignition discharge module/ignition cables from the rocker arm cover
     
    Turbocharger pipes, if necessary for access
     
    Spark plugs
     
    Rocker arm cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

Click image to see an enlarged view

Fig. Torque the rocker arm cover bolts as illustrated

  1. Install or connect the following:

    Rocker arm cover with a new gasket and torque the bolts, in sequence, to 11 ft. lbs. (15 Nm)
     
    Spark plugs and torque to 21 ft. lbs. (28 Nm)
     
    Turbocharger pipes, if removed
     
    Ignition discharge module/ignition cables and torque to 96 inch lbs. (11 Nm)
     
    Negative battery cable
     

  2.  

2.8L Engines
Front Cover
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the heat shield between the engine and turbo.
  6.  
  7. Remove the bleeder pipe.
  8.  
  9. Remove the front secondary air pipe complete with valve and bracket.
  10.  
  11. Remove the power steering fluid reservoir's bolt.
  12.  
  13. Remove the left grounding point.
  14.  
  15. Unplug the connectors and remove ignition coils 2, 4 and 6.
  16.  
  17. Raise the heat shield and unplug the coolant temperature sensor connector.
  18.  
  19. Release the right ground cable from the wiring harness.
  20.  
  21. Remove the wiring harness from the camshaft cover.
  22.  
  23. Unplug the connectors from the camshaft position sensor and the camshaft solenoid valve.
  24.  
  25. Raise the wiring harness slightly.
  26.  
  27. Remove the ground cable of the engine control module.
  28.  
  29. Unplug the engine control module connectors (608A and 608B).
  30.  
  31. Detach the cable duct from the intake manifold.
  32.  
  33. Unplug the atmospheric pressure sensor connector.
  34.  
  35. Detach the corner bracket and move it aside.
  36.  
  37. Remove the bolt holding the injector bracket in place and unplug the connector.
  38.  
  39. Detach the brake vacuum hose from the intake manifold.
  40.  
  41. Detach the crankcase ventilation from the intake manifold.
  42.  
  43. Unplug the fuel pressure sensor connector.
  44.  
  45. Detach the fuel line, wiping up any fuel spill with a cloth.
  46.  
  47. Remove the intake manifold.
  48.  
  49. Loosen the lifting eye. Remove one of the bolts and fold the lifting eye down.
  50.  
  51. Remove the camshaft cover bolts and seals.
  52.  
  53. Remove the camshaft cover.
  54.  
  55. Remove the camshaft cover gasket and seals around the spark plug holes.
  56.  

To install:

  1. Fit new seals on the camshaft cover.
  2.  
  3. Add a spot of sealant to each mating surface between the cylinder head and timing cover.
  4.  
  5. Position the camshaft cover.
  6.  
  7. Install the bolts using new seals and tighten to 7 ft. lbs. (10 Nm).
  8.  
  9. Fold the eye up and fit the bolt. Tighten the bolt to 48 ft. lbs. (65 Nm).
  10.  
  11. Install the intake manifold.
  12.  
  13. Fit the fuel line.
  14.  
  15. Fit the fuel pressure sensor connector.
  16.  
  17. Fit the crankcase ventilation to the intake manifold.
  18.  
  19. Fit the brake vacuum hose to the intake manifold.
  20.  
  21. Plug in the injector connectors and fit the bracket.
  22.  
  23. Reposition the corner bracket and fit the bolts.
  24.  
  25. Plug in the atmospheric pressure sensor connector.
  26.  
  27. Fit the cable duct to the intake manifold.
  28.  
  29. Plug in the engine control module connectors (608A and 608B).
  30.  
  31. Fit the ground cable of the engine control module.
  32.  
  33. Plug in the connectors of the camshaft position sensor and the camshaft solenoid valve.
  34.  
  35. Fit the wiring harness to the camshaft cover using new cable ties.
  36.  
  37. Secure the ground cable to the wiring harness.
  38.  
  39. Plug in the coolant temperature sensor connector and press down the heat shield.
  40.  
  41. Fit ignition coils 2, 4 and 6. Plug in the connectors.
  42.  
  43. Fit the left grounding point.
  44.  
  45. Fit the power steering fluid reservoir's bolt and tighten to 7 ft. lbs. (10 Nm).
  46.  
  47. Fit the secondary air pipe complete with valve and bracket. Use a new gasket. Tighten the bolts to the exhaust manifold to 16 ft. lbs. (22 Nm), and the bracket bolts to 48 ft. lbs. (65 Nm).
  48.  
  49. Fit the bleeder pipe and tighten fasteners to 7 ft. lbs. (10 Nm).
  50.  
  51. Install the heat shield between the engine and turbo.
  52.  
  53. Connect the negative battery cable.
  54.  
  55. Connect the negative battery cable.
  56.  

Rear Cover
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the heat shield between the engine and turbo.
  6.  
  7. Remove the bleeder pipe.
  8.  
  9. Release the quick-coupling of the secondary air pipe and put the pipe aside.
  10.  
  11. Remove the power steering fluid reservoir's bolt.
  12.  
  13. Unplug the connectors from ignition coils 2, 4 and 6.
  14.  
  15. Remove the left grounding point.
  16.  
  17. Raise the heat shield and unplug the coolant temperature sensor connector.
  18.  
  19. Release the right ground cable from the wiring harness.
  20.  
  21. Remove the wiring harness from the camshaft cover.
  22.  
  23. Unplug the connectors from the camshaft position sensor and the camshaft solenoid valve.
  24.  
  25. Raise the wiring harness slightly.
  26.  
  27. Remove the ground cable of the engine control module.
  28.  
  29. Unplug the engine control module connectors (608A and 608B).
  30.  
  31. Detach the cable duct from the intake manifold.
  32.  
  33. Unplug the atmospheric pressure sensor connectors.
  34.  
  35. Detach the corner bracket and move it aside.
  36.  
  37. Remove the bolt holding the injector bracket in place and unplug the connector.
  38.  
  39. Detach the brake vacuum hose from the intake manifold.
  40.  
  41. Detach the crankcase ventilation from the intake manifold.
  42.  
  43. Unplug the fuel pressure sensor connector.
  44.  
  45. Detach the fuel line, wiping up any fuel spill with a cloth.
  46.  
  47. Remove the intake manifold.
  48.  
  49. Unplug the connectors from the camshaft position sensor and the camshaft solenoid valve.
  50.  
  51. Raise the wiring harness slightly.
  52.  
  53. Remove the connector and pipe from the fuel bleeder valve. Lift away the valve.
  54.  
  55. Detach the vacuum pipe from the venturi valve.
  56.  
  57. Unplug the 7-pin contact connector.
  58.  
  59. Unplug the lower oxygen sensor connector and the connectors of ignition coils 1, 3 and 5.
  60.  
  61. Remove ignition coils 1, 3 and 5.
  62.  
  63. Remove the rear cable duct from the camshaft cover. Use an angled screwdriver to release the 3 clips from the cable duct. Press the cable duct back toward the bulkhead.
  64.  
  65. Remove the camshaft cover bolts.
  66.  
  67. Raise the wiring harness and servo reservoir. Remove the camshaft cover.
  68.  
  69. Remove the camshaft cover gasket and seals around the spark plug holes.
  70.  

To install:

  1. Fit new seals on the camshaft cover.
  2.  
  3. Add a spot of sealant to each mating surface between the cylinder head and timing cover.
  4.  
  5. Position the camshaft cover.
  6.  
  7. Install the bolts using new seals and tighten to 7 ft. lbs. (10 Nm).
  8.  
  9. Fit the cable duct on the camshaft cover.
  10.  
  11. Fit ignition coils 1, 3 and 5.
  12.  
  13. Fit the connectors of the lower oxygen sensor and ignition coils 1, 3 and 5.
  14.  
  15. Plug in the 7-pin contact connector.
  16.  
  17. Fit the vacuum pipe to the venturi valve.
  18.  
  19. Fit the connector and pipe to the fuel bleeder valve.
  20.  
  21. Fit the wiring harness to the camshaft cover.
  22.  
  23. Plug in the connectors of the camshaft position sensor and the camshaft solenoid valve.
  24.  
  25. Install the intake manifold.
  26.  
  27. Fit the fuel line.
  28.  
  29. Fit the fuel pressure sensor connector.
  30.  
  31. Fit the crankcase ventilation to the intake manifold.
  32.  
  33. Fit the brake vacuum hose to the intake manifold.
  34.  
  35. Plug in the injector connectors and fit the bracket.
  36.  
  37. Reposition the corner bracket and fit the bolts.
  38.  
  39. Plug in the atmospheric pressure sensor connector.
  40.  
  41. Fit the cable duct to the intake manifold.
  42.  
  43. Plug in the engine control module connectors (608A and 608B).
  44.  
  45. Fit the ground cable of the engine control module.
  46.  
  47. Plug in the connectors of the camshaft position sensor and the camshaft solenoid valve.
  48.  
  49. Fit the wiring harness to the camshaft cover using new cable ties.
  50.  
  51. Secure the ground cable to the wiring harness.
  52.  
  53. Plug in the coolant temperature sensor connector and press down the heat shield.
  54.  
  55. Fit ignition coils 2, 4 and 6. Plug in the connectors.
  56.  
  57. Fit the left grounding point.
  58.  
  59. Fit the power steering fluid reservoir's bolt and tighten to 7 ft. lbs. (10 Nm).
  60.  
  61. Fit the secondary air pipe and check that the quick-coupling engages.
  62.  
  63. Fit the bleeder pipe and tighten fasteners to 7 ft. lbs. (10 Nm).
  64.  
  65. Install the heat shield between the engine and turbo.
  66.  
  67. Connect the negative battery cable.
  68.  

3.0L Engines
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: Negative battery cableCrankcase breather hose and vacuum control unitTemperature sensor wiringRocker arm (camshaft) cover and discard the gasket

    Negative battery cable
     
    Crankcase breather hose and vacuum control unit
     
    Temperature sensor wiring
     
    Rocker arm (camshaft) cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following: Rocker arm (camshaft) cover with a new gasket and torque the bolts to 16 ft. lbs. (22 Nm)Temperature sensor wiringCrankcase breather hose and vacuum control unitNegative battery cable

    Rocker arm (camshaft) cover with a new gasket and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Temperature sensor wiring
     
    Crankcase breather hose and vacuum control unit
     
    Negative battery cable
     

  2.  

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

    Negative battery cable
     
    Crankcase breather hose and vacuum control unit
     
    Temperature sensor wiring
     
    Rocker arm (camshaft) cover and discard the gasket
     

  4.  
  5. Clean all mating surfaces of any residual gasket material.
  6.  

To install:

  1. Install or connect the following:

    Rocker arm (camshaft) cover with a new gasket and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Temperature sensor wiring
     
    Crankcase breather hose and vacuum control unit
     
    Negative battery cable
     

  2.  

 
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