Saab 2000-06

Timing Chain, Cover, Sprockets, & Seal

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Removal & Installation



9-3
2.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the battery cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Open the cap to the expansion tank, release any overpressure.
  8.  
  9. Raise and safely support the vehicle.
  10.  
  11. Undo the right-hand side of the spoiler shield.
  12.  
  13. Place a suitable receptacle under the radiator. Connect a hose to the radiator and drain the coolant. Close the cock and refit the spoiler shield.
  14.  
  15. Lower the vehicle.
  16.  
  17. Remove the upper section of the air cleaner. When removing the air cleaner casing cover, be careful not to damage the brake vacuum pump sensor.
  18.  
  19. Remove the lower section of the air filter.
  20.  
  21. Unplug the mass air flow sensor connector. Detach the secondary air pipe, the delivery hose from the turbocharger intake manifold and the crankcase ventilation pipes. Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins.
  22.  
  23. Detach the turbocharger intake manifold from the air filter housing cover and the turbocharger.
  24.  
  25. Remove the upper engine cover.
  26.  
  27. Remove the charge air pipe by first removing the clamps and the charge pressure sensor connectors. Detach the power steering line.
  28.  
  29. Remove the coolant return line by first removing the wiring harnesses.
  30.  
  31. Remove the connector and the ground connection to the engine control module.
  32.  
  33. Remove the engine control module bolts.
  34.  
  35. Remove the wiring harnesses holders by removing the cable duct, the connectors and the nut. Unplug the connector to the intake manifold pressure sensor. Remove the bolt, cable tie and connector.
  36.  
  37. Undo the quick coupling and remove the vacuum line from the upper section of the intake manifold.
  38.  
  39. Remove the crankcase ventilation lines by removing the bolt and removing the holder.
  40.  
  41. Remove the holder to the injector's connector.
  42.  
  43. Remove the throttle body connector and remove the upper section of the intake manifold.
  44.  
  45. Undo the quick couplings and remove the bleeder valve plus lines.
  46.  
  47. Place a collecting pan under the vehicle.
  48.  
  49. Detach the fuel line, wiping up any fuel spill with a cloth.
  50.  
  51. Remove the power steering reservoir by removing the bolt, return hose and clamp. Seal the hose and reservoir. Turn the reservoir to the side.
  52.  
  53. Unplug the connectors to the fuel pressure sensor.
  54.  
  55. Remove the wiring harnesses from the cylinder head for cylinders 1-3-5. Unplug the camshaft position sensor connector, the connector to the camshaft setting valve and the holder.
  56.  
  57. Remove the wiring harnesses from the cylinder head for cylinders 2-4-6. Unplug the camshaft position sensor connector, the connector to the camshaft setting valve and the holder.
  58.  
  59. Remove the wiring harness for the injectors by first unplugging the injectors' connectors.
  60.  
  61. Remove the fuel rail with injectors.
  62.  
  63. Remove the lower section of the intake manifold. Seal the inlet ducts to the cylinder head with lintless rags.
  64.  
  65. Remove the ignition coils for cylinders 2-4-6 by first unplugging the connectors.
  66.  
  67. Remove the wiring harness holder from the camshaft cover for cylinders 1-3-5.
  68.  
  69. Remove the ignition coils for cylinders 1-3-5 by first unplugging the connectors.
  70.  
  71. Remove the ground cable from the wiring harnesses by carefully cutting open the tape strip (arrows). Place the ground cable to one side.
  72.  
  73. Remove the wiring harnesses plus connectors. Remove the cable tie.
  74.  
  75. Remove the battery cover bottom section.
  76.  
  77. Loosen the expansion tank from the mounting.
  78.  
  79. Remove the turbocharger heat shield panel.
  80.  
  81. Remove the crankcase ventilation line from the turbocharger.
  82.  
  83. Remove the crankcase ventilation check valve from the camshaft cover for cylinders 1-3-5.
  84.  
  85. Undo the quick coupling and remove the secondary air system's valve for cylinders 2-4-6.
  86.  
  87. Undo the upper quick coupling by removing the bolt and removing the secondary air system's delivery line.
  88.  
  89. Remove the turbocharger diaphragm unit by undoing the bolt and pressing it out.
  90.  
  91. Remove the secondary air system's delivery line for cylinders 1-3-5.
  92.  
  93. Remove the secondary air system's delivery line for cylinders 2-4-6.
  94.  
  95. Remove the ventilation line to the oil dipstick's guide tube by undoing the quick coupling.
  96.  
  97. Remove the engine's wiring harness from cylinders 2-4-6 by unplugging the connectors, and by removing the head shield and the ground cable from the cylinder head. Fold the wiring harnesses to the side.
  98.  
  99. Remove the engine's transport lug by removing the bolts.
  100.  
  101. Remove the camshaft cover for cylinders 2-4-6 by removing the bolts.
  102.  
  103. Remove the camshaft cover for cylinders 1-3-5 by removing the bolts.
  104.  
  105. Raise the car to half height.
  106.  
  107. Remove the front wheels.
  108.  
  109. Remove the right wing liner.
  110.  
  111. Remove the power steering hydraulic line from the holder on the front axle beam.
  112.  
  113. Remove the right engine mounting.
  114.  
  115. Relieve the load on the belt tensioner. Use a ¼ inch puller handle and remove the driver belt from the A/C compressor pulley.
  116.  
  117. Remove the bolt holding the crankshaft pulley using 83 95 360 Holding tool, crankshaft pulley (handle only) and EN-47981 Holding tool, pulley.
  118.  
  119. Remove the pulley using EN-47982 Puller and EN-47981 Holding tool, pulley.
  120.  
  121. Remove the transaxle housing at the bottom by removing the bolts.
  122.  
  123. Remove the wiring harness holder from the bottom of the transaxle housing by removing the bolt.
  124.  
  125. Lower the vehicle.
  126.  
  127. Remove the coolant line from the coolant outlet pipe by removing the bolt.
  128.  
  129. Remove the coolant outlet pipe by removing the coolant hose, remove the clamp and remove the bolts.
  130.  
  131. Remove the coolant pump pulley by removing the bolts. Hold firm with a screwdriver.
  132.  
  133. Remove the coolant pump by removing the bolts.
  134.  
  135. Remove the power steering pump at the top by removing the bolted joint.
  136.  
  137. Raise and safely support the vehicle.
  138.  
  139. Remove the power steering pump at the bottom by removing the bolt. Move the power steering pump towards the front of the car
  140.  
  141. Lower the vehicle.
  142.  
  143. Remove the drive belt tensioner by removing the bolt.
  144.  
  145. Remove the camshaft setting valve for cylinders 1-3-5 by removing the bolt.
  146.  
  147. Remove the camshaft setting valve for cylinders 2-4-6 by removing the bolt.
  148.  
  149. Remove the upper bolts of the transaxle housing.
  150.  
  151. Remove the timing cover. Carefully pry the cover loose with a pry bar and a screw that is carefully screwed in (to press the cover loose).
  152.  
  153. Remove the starter motor's wiring harness holder from the wiring harnesses.
    NOTE
    There is no marking to check valve timing on the camshafts and cylinder heads. The timing chains have silver links that are to align with the marks on the sprockets. The links of the primary chain are marked with yellow.

  154.  
  155. Turn the crankshaft so that the cams of cylinder 1 point upward and inward at an angle, thus aligning the installation marks on the crankshaft sprocket and the oil pump. When the engine is approx. 15 degrees ATDC, use EN-46111 Sleeve to turn the engine.
  156.  
  157. Remove the timing chain tensioner of the rear cylinder bank.
  158.  
  159. Remove the chain tensioner gasket.
    NOTE
    The exhaust camshaft turns somewhat when tension is relieved from the chain.

  160.  
  161. Remove the guides and lift off the chain.
  162.  
  163. Remove the chain tensioner of the primary circuit and remove the gasket.
  164.  
  165. Remove the guides and lift off the chain.
  166.  
  167. Remove the rear primary sprocket.
  168.  
  169. Remove the timing chain tensioner of the front cylinder bank and remove the gasket.
  170.  
  171. Remove the guides and lift off the front primary sprocket. Lift off the chain.
  172.  
  173. Remove the crankshaft sprocket, counter holding with a spanner on the camshaft flats.
  174.  
  175. Remove the crankshaft sprocket, counter holding with a fixed wrench on the camshaft flats.
    CAUTION
    The camshafts must not be rotated as the valves may collide with the pistons or other valves and be damaged.

  176.  

To install:

  1. Fit the crankshaft sprocket, counter holding with a fixed wrench on the camshaft flats. Tighten the bolt to 48 ft. lbs. (65 Nm).
  2.  
  3. Install the sprocket on the crankshaft. The marking should be visible. The intake sprocket is variable.
  4.  
  5. Check that the installation marks on the crankshaft sprocket and the oil pump are aligned. Use EN-46111 Sleeve to adjust the position of the crankshaft. The crankshaft must not be rotated. Otherwise the pistons could damage the valves.
  6.  
  7. Install the camshaft drive of the front cylinder bank. Position the chain on the camshaft sprockets so that the silver links align with the marks on the sprockets. The front cylinder bank sprockets are marked with an L.
  8.  
  9. Install the primary sprocket so that the lower silver link is visible through the hole in the primary sprocket and tighten the bolt to 48 ft. lbs. (65 Nm).
  10.  
  11. Install the chain guides and tighten the fasteners to 18 ft. lbs. (25 Nm).
  12.  
  13. Restore the chain tensioner to its previous position by removing the piston and turning the spring clockwise until it engages in the inner position. Use a screwdriver. Refit the piston in the tensioner and check that the groove in the piston is vertical so that is fits with the tensioner guide.
  14.  
  15. Install the chain tensioner using a new gasket and tighten the fasteners to 18 ft. lbs. (25 Nm).
  16.  
  17. Trigger/activate the chain tensioner by carefully pressing on the timing chain or guide.
  18.  
  19. Install the rear primary sprocket. Tighten the bolt to 48 ft. lbs. (65 Nm).
  20.  
  21. Install the primary chain so that the yellow links align with the marks on the primary sprockets and crankshaft sprocket.
  22.  
  23. Install the front chain guide and tighten the fasteners to 7 ft. lbs. (10 Nm).
  24.  
  25. Install the upper guide and tighten the fasteners to 18 ft. lbs. (25 Nm).
  26.  
  27. Restore the chain tensioner to its previous position by removing the piston and turning the spring clockwise until it engages in the inner position. Use a screwdriver. Refit the piston in the tensioner. Check that the groove in the piston is vertical so that is fits with the tensioner guide.
  28.  
  29. Install the chain tensioner using a new gasket and tighten the fasteners to 18 ft. lbs. (25 Nm).
  30.  
  31. Trigger/activate the chain tensioner by carefully pressing on the timing chain or guide.
  32.  
  33. Position the chain on the camshaft sprockets so that the silver links align with the marks on the sprockets. The rear cylinder bank sprockets are marked with an R.
  34.  
  35. Rotate the crankshaft approx. ¼ turn approx. 100° ATDC so that the lower silver link aligns with the marking on the primary sprocket.
  36.  
  37. Install the chain guides and tighten the fasteners to 18 ft. lbs. (25 Nm).
  38.  
  39. Restore the chain tensioner to its previous position by removing the piston and turning the spring clockwise until it engages in the inner position. Use a screwdriver. Refit the piston in the tensioner. Check that the groove in the piston is vertical so that is fits with the tensioner guide.
  40.  
  41. Install the chain tensioner using a new gasket and tighten the fasteners to 18 ft. lbs. (25 Nm). Trigger/activate the chain tensioner by carefully pressing on the timing chain or guide.
  42.  
  43. Rotate the crankshaft one turn to check and ensure that all chain tensioners have been triggered and that the chain is correctly seated in the guide.
  44.  
  45. Clean the sealing surfaces.
  46.  
  47. Fit EN-46109-2 Centering tool in the engine block and cylinder head.
  48.  
  49. Apply 93 165 267 Flange sealant. Apply an approx. 3mm thick bead on the sealing surfaces of the transaxle housing.
  50.  
  51. Install the transaxle housing with help from an assistant. Check that the sealing bead remains undamaged during the alignment of the transaxle housing.
  52.  
  53. Install the upper bolts for the transmission housing and tighten to 17 ft. lbs. (23 Nm). Remove the centering tools.
  54.  
  55. Secure the starter motor's wiring harness holder on the wiring harnesses.
  56.  
  57. Raise and safely support the vehicle.
  58.  
  59. Fit the lower bolts of the transaxle housing and tighten to 17 ft. lbs. (23 Nm).
  60.  
  61. Install the lower bolt to the power steering pump and tighten to 16 ft. lbs. (22 Nm).
  62.  
  63. Install the pulley to the crankshaft using J-41998 Fitting tool to press on the pulley.
  64.  
  65. Install the pulley bolt using 83 95 360 Holding tool, crankshaft pulley (handle only) and EN-47981 Pulley holding tool. Tighten the pulley bolt to 74 ft. lbs. (100 Nm), plus an additional 150°.
  66.  
  67. Secure the starter motor's wiring harness holder at the bottom. Tighten the bolt.
  68.  
  69. Lower the vehicle.
  70.  
  71. Install the camshaft setting solenoid valves Tighten to 8 ft. lbs. (10 Nm).
  72.  
  73. Install the belt tensioner and the bolt. Tighten the bolt to 16 ft. lbs. (22 Nm).
  74.  
  75. Secure the starter motor's wiring harness holder at the top. Tighten the bolt.
  76.  
  77. Secure the power steering pump at the top. Tighten the fasteners to 16 ft. lbs. (22 Nm).
  78.  
  79. Install the mounting bolts to the engine pad's attaching plate and tighten to 32 ft. lbs. (44 Nm).
  80.  
  81. Install the coolant pump. Use a new gasket and tighten the bolts to 8 ft. lbs. (10 Nm).
  82.  
  83. Install the coolant pump's belt pulley. Counterhold with a screwdriver. Tighten the bolts to 9 ft. lbs. (12 Nm).
  84.  
  85. Install the coolant outlet pipe. Use a new gasket and tighten the bolts to 9 ft. lbs. (12 Nm).
  86.  
  87. Install the coolant hose and secure the clamp.
  88.  
  89. Unload the belt tensioner. Use a 1/4 inch puller and fit the drive belt.
  90.  
  91. Install the right engine mounting.
  92.  
  93. Install the holder to the power steering line and tighten the bolt to 6 ft. lbs. (8 Nm).
  94.  
  95. Fit the coolant line to the coolant outlet pipe. Use a new sealing ring. Tighten to 6 ft. lbs. (8 Nm).
  96.  
  97. Raise and safely support the vehicle.
  98.  
  99. Secure the power steering hydraulic line in the holder on the front axle beam.
  100.  
  101. Lower the vehicle to half height.
  102.  
  103. Install the right-hand wing liner.
  104.  
  105. Install the wheels.
  106.  
  107. Clean the camshaft cover sealing surfaces.
  108.  
  109. Replace the camshaft cover gasket for cylinders 2-4-6.
  110.  
  111. Apply an approx. 3mm thick bead of sealing compound on the separating points of the cylinder head and transmission housing.
  112.  
  113. Install the camshaft cover for cylinders 2-4-6 and tighten the bolts to 8 ft. lbs. (10 Nm).
  114.  
  115. Install the engine's transport lug and tighten the bolt to 48 ft. lbs. (65 Nm).
  116.  
  117. Clean the camshaft cover sealing surfaces.
  118.  
  119. Replace the camshaft cover gasket for cylinders 1-3-5. Use new gaskets.
  120.  
  121. Apply an approx. 3mm thick bead of sealing compound on the separating points of the cylinder head and transmission housing.
  122.  
  123. Install the camshaft cover for cylinders 1-3-5 and tighten the bolts to 8 ft. lbs. (10 Nm).
  124.  
  125. Install the engine wiring harnesses to the cylinder head for cylinders 2-4-6 by plugging in the connectors on the cylinder head for cylinders 2-4-6. Fit the heat shield and fit the ground cable on the cylinder head for cylinders 2-4-6. Fit the bolts. Secure the wiring harnesses. Secure the engine control module's ground cable in the wiring harnesses. Fit the cable ties.
  126.  
  127. Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector.
  128.  
  129. Install the secondary air system line for cylinders 2-4-6. Fit the exhaust pipe and tighten the bolts to 8 ft. lbs. (10 Nm).
  130.  
  131. Install the ventilation line to the oil dipstick's guide tube. Connect the quick coupling.
  132.  
  133. Install the turbocharger diaphragm unit by fitting the bolts.
  134.  
  135. Install the secondary air system's delivery line. Connect the quick couplings.
  136.  
  137. Install the secondary air system's check valve for cylinders 2-4-6. Use a new gasket. Tighten the bolts and connect the quick coupling.
  138.  
  139. Install the secondary air system's delivery line and bolt.
  140.  
  141. Install the check valve to the crankcase ventilation on the camshaft cover for cylinders 1-3-5.
  142.  
  143. Install the crankcase ventilation line on the turbocharger and tighten the bolt to 8 ft. lbs. (10 Nm).
  144.  
  145. Install the turbocharger's upper heat shield panel. Fit the nut and tighten to 8 ft. lbs. (10 Nm).
  146.  
  147. Install the expansion tank in the holder.
  148.  
  149. Install the battery cover bottom section.
  150.  
  151. Install the charge pressure regulator's wiring harness. Plug in the connector. Fit the cable tie.
  152.  
  153. Install the ignition coils for cylinders 2-4-6. Plug in the connectors and fit the bolts. Tighten the bolts to 8 ft. lbs. (10 Nm).
  154.  
  155. Install the wiring harness holder on the camshaft cover for cylinders 1-3-5. Secure in the holder.
  156.  
  157. Install the ignition coils for cylinders 1-3-5. Plug in the connectors and fit the bolts. Tighten the bolts to 8 ft. lbs. (10 Nm).
  158.  
  159. Install the lower section of the intake manifold with a new seal. Remove the rags from the inlet ducts.
  160.  
  161. Install the fuel rail with injectors and tighten the bolts to 8 ft. lbs. (10 Nm).
  162.  
  163. Install the injectors' wiring harness. Plug in the connectors.
  164.  
  165. Plug in the connectors to the fuel pressure sensor.
  166.  
  167. Install the wiring harness to the camshaft guide for cylinders 2-4-6. Plug in the connectors and secure in the holder.
  168.  
  169. Connect the wiring harness to the camshaft guide for cylinders 1-3-5. Plug in the connectors and secure in the holder.
  170.  
  171. Install the power steering reservoir. Fit the return hose. Secure the clamp and tighten to 7 ft. lbs. (9 Nm).
  172.  
  173. Connect the fuel delivery line.
  174.  
  175. Fit the bleeder valve plus lines. Connect the quick couplings. Plug in the connectors to the bleeder valve.
  176.  
  177. Fit the upper section of the intake manifold. Plug in the throttle body's connector. Use new gaskets and tighten the fasteners to 17 ft. lbs. (23 Nm).
  178.  
  179. Fit the holder to the injector's connector.
  180.  
  181. Fit the lines for the crankcase ventilation.
  182.  
  183. Fit the vacuum line on the upper section of the intake manifold. Connect the quick coupling.
  184.  
  185. Fit the wiring harnesses' holders. Fit the bolt. Plug in the connectors for the intake manifold's pressure sensor. Fit the cable cables. Secure the connectors. Fit the cable duct. Plug in the connectors. Fit the nut.
  186.  
  187. Install the engine control module. Fit the bolts and tighten to 8 ft. lbs. (10 Nm).
  188.  
  189. Fit the ground connection.
  190.  
  191. Plug in the engine control module connector.
  192.  
  193. Install the coolant return line. Fit the clamps and tighten the bolts to 8 ft. lbs. (10 Nm).
  194.  
  195. Install the charge air pipe. Install the clamp.
  196.  
  197. Plug in the charge pressure sensor connector. Secure the power steering line with clips.
  198.  
  199. Install the air intake pipe.
  200.  
  201. Install the air filter housing with the mass air flow sensor as follows:


    1. Plug in the mass air flow sensor connector.
    2.  
    3. Secure the cable ties.
    4.  
    5. Fit the secondary air system's intake manifold. Secure the line.
    6.  
    7. Connect the quick coupling.
    8.  

  202.  
  203. Install the upper engine cover. Remove the oil filler opening's screw cap. Fit the protective cover. Fit the oil filler opening's screw cap.
  204.  
  205. Fill and bleed the cooling system.
  206.  
  207. Connect the negative battery cable and install the battery cover.
  208.  

2000-2002 Model


Click image to see an enlarged view

Fig. Installed view of the timing chains-2.0L and 2.3L engine 2002 shown



Click image to see an enlarged view

Fig. Be sure to align the crankshaft and camshaft timing marks, as shown-2.0L and 2.3L engines 2002 shown



Click image to see an enlarged view

Fig. Secure the engine in position using a flywheel locking tool-2.0L and 2.3L engines



Click image to see an enlarged view

Fig. Loosen the bolts from the timing chain front cover, starting with the last bolt and working in reverse. To tighten, start with the bolt hole in the opening of the cover and work around in sequence -2.0L and 2.3L engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil, disconnect the cables to the starter motor, generator and engine oil pressure sensor.
  4.  
  5. Remove or disconnect the following:

    Oil filler pipe
     
    Intake manifold stay
     
    Crankcase ventilation pipe with intake manifold and nuts on turbocharger
     
    Loosen the bolts on turbocharger stay slightly
     
    Water pipe for turbocharger from thermostat housing
     
    Hose for throttle body preheating and unscrew thermostat housing cover
     
    Ignition discharge module electrical connection
     
    Crankcase ventilation and vacuum hoses from camshaft cover
     
    Ignition discharge module (place module aside)
     
    Spark plugs
     
    Camshaft cover
     
    Zero engine and make sure camshafts are aligned with their setting markings
     
    Chain tensioner
     
    Camshaft sprockets (place chain so cylinder head can be removed without interference)
     
    Cylinder head
     

  6.  
  7. Start with the bolts in the timing cover and continue in reverse order to assembly. Use the protective sleeve, 75 19 531, to retrieve the bolts.
  8.  
  9. Make sure that the timing chain dies not obstruct removal and then lift off the cylinder head.
  10.  
  11. Remove the protective plate and oil sump. Leave the guide sleeve in the cylinder block.
  12.  
  13. Remove or disconnect the following:
  14.  
  15. Remove the crankshaft pulley. Use the flywheel locking attachment, part no. 83 94 868.
  16.  
  17. Remove the water pump and the sleeve with O-rings.
  18.  
  19. Remove the belt tensioner, generator and the bolt for the support bearing bracket in the timing cover.
  20.  
  21. Remove all the bolts on the timing cover, carefully tap the cover off and remove it.
  22.  

To install:

  1. Thoroughly remove all remains of sealant on all surfaces. Wash clean with benzene.
  2.  
  3. Apply a bead of flange sealant, 93 21 795, about 0.04 inch (1 mm) wide on the center of the sealing surfaces.
  4.  
  5. Fit the timing cover and torque to 16 ft. lbs. (22 Nm).
  6.  
  7. Install the bolt for support bearing bracket in the timing cover and fit the generator and belt tensioner.
  8.  
  9. Install water pump. Use new O-rings if needed.
  10.  
  11. Fit the crankshaft belt pulley. Use the flywheel locking attachment, part no. 83 94 868. Torque pulley bolt to 130 ft. lbs. (175 Nm).
  12.  
  13. Verify that oil pan is clean. Clean mating surfaces. Apply an even bead of flange sealant, 93 21 795, to the sealing surface of the oil sump and fit the oil pan. Torque pan bolts to 16 ft. lbs. (22 Nm).
  14.  
  15. Install the oil pan protective plate.
  16.  
  17. Rotate the crankshaft 45 degrees and fit the cylinder head with a new gasket. Make sure it is correctly seated on the guide sleeves and that the chain runs freely.
  18.  
  19. Install and tighten the cylinder head bolts according to bolt tightening sequence and to specified torque.
  20.  
  21. Install the 2 bolts between the timing cover and cylinder head. Tighten to 18 ft. lbs. (24 Nm).
  22.  
  23. Make sure the camshafts are aligned with their setting marks and rotate the crankshaft back to its 0-marking.
  24.  
  25. Starting with the intake camshaft, install the camshaft sprockets and chain.
    NOTE
    Do not tighten the bolts at this time.

  26.  
  27. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner. Install the chain tensioner, with a 27mm socket, and torque to 47 ft. lbs. (63 Nm).
  28.  
  29. Install the chain tensioner plug with push rod and spring. Torque the plug to 17 ft. lbs. (23 Nm).
  30.  
  31. Be sure the chain is positioned correctly on the chain guards. Turn the crankshaft 2 revolutions and check the setting of the flywheel and camshafts.
  32.  
  33. Tighten the camshaft sprocket bolts to 47 ft. lbs. (63 Nm).
  34.  
  35. Clean the sealing surface of the camshaft cover with benzene.
  36.  
  37. Apply soap to the opening in the camshaft cover and fit the cover, starting at the opening. Then, tighten the bolt located furthest to the front at the timing chain end. Continue all the way round the outside and inside. Torque the bolts to 11 ft. lbs. (15 Nm).
  38.  
  39. Install the spark plugs to 21 ft. lbs. (28 Nm). Install the ignition discharge module. Tighten to 8 ft. lbs. (11 Nm).
  40.  
  41. Connect the ignition discharge module electrical connection and the crankcase ventilation and vacuum hoses.
  42.  
  43. Install the thermostat housing cover and connect the hose for the throttle body preheating.
  44.  
  45. Tighten the lock nuts on the turbocharger to 19 ft. lbs. (25 Nm).
  46.  
  47. Tighten the bolts on the turbocharger stay. Start with the one in the cylinder block. Torque to 16 ft. lbs. (22 Nm).
  48.  
  49. Fit the water pipe to the thermostat housing and tighten bolts to 19 ft. lbs. (25 Nm).
  50.  
  51. Fit the crankcase ventilation pipe together with the intake manifold (turbo). Tighten the turbo/intake manifold bolts to 6 ft. lbs. (8 Nm) and the crankcase vent pip to 18 ft. lbs. (24 Nm).
  52.  
  53. Tighten the bolts on the intake manifold stay, starting with the one in the cylinder block and fit the oil filler pipe. Tighten stay-to-block bolts to 18 ft. lbs. (24 Nm). Tighten the upper mounting bolts to 7 ft. lbs. (10 Nm). Tighten the lower mounting bolts to 16 ft. lbs. (22 Nm).
  54.  
  55. Be sure the oil plug is tight and connect the cables to the engine oil pressure sensor, generator and starter motor.
  56.  

2001-02


Click image to see an enlarged view

Fig. Installed view of the timing chains-2.0L and 2.3L engine (2001-02)



Click image to see an enlarged view

Fig. Be sure to align the crankshaft and camshaft timing marks, as shown-2.0L and 2.3L engines (2001-02)



Click image to see an enlarged view

Fig. Secure the engine in position using a flywheel locking tool-2.0L and 2.3L engines



Click image to see an enlarged view

Fig. Loosen the bolts from the timing chain front cover, starting with the last bolt and working in reverse. To tighten, start with the bolt hole in the opening of the cover and work around in sequence -2.0L and 2.3L engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil, disconnect the cables to the starter motor, generator and engine oil pressure sensor.
  4.  
  5. Remove or disconnect the following: Oil filler pipeIntake manifold stayCrankcase ventilation pipe with intake manifold and nuts on turbochargerLoosen the bolts on turbocharger stay slightlyWater pipe for turbocharger from thermostat housingHose for throttle body preheating and unscrew thermostat housing coverIgnition discharge module electrical connectionCrankcase ventilation and vacuum hoses from camshaft coverIgnition discharge module (place module aside)Spark plugsCamshaft coverZero engine and make sure camshafts are aligned with their setting markingsChain tensionerCamshaft sprockets (place chain so cylinder head can be removed without interference)Cylinder head

    Oil filler pipe
     
    Intake manifold stay
     
    Crankcase ventilation pipe with intake manifold and nuts on turbocharger
     
    Loosen the bolts on turbocharger stay slightly
     
    Water pipe for turbocharger from thermostat housing
     
    Hose for throttle body preheating and unscrew thermostat housing cover
     
    Ignition discharge module electrical connection
     
    Crankcase ventilation and vacuum hoses from camshaft cover
     
    Ignition discharge module (place module aside)
     
    Spark plugs
     
    Camshaft cover
     
    Zero engine and make sure camshafts are aligned with their setting markings
     
    Chain tensioner
     
    Camshaft sprockets (place chain so cylinder head can be removed without interference)
     
    Cylinder head
     

  6.  
  7. Start with the bolts in the timing cover and continue in reverse order to assembly. Use the protective sleeve, 75 19 531, to retrieve the bolts.
  8.  
  9. Make sure that the timing chain dies not obstruct removal and then lift off the cylinder head.
  10.  
  11. Remove the protective plate and oil sump. Leave the guide sleeve in the cylinder block.
  12.  
  13. Remove or disconnect the following:
  14.  
  15. Remove the crankshaft pulley. Use the flywheel locking attachment, part no. 83 94 868.
  16.  
  17. Remove the water pump and the sleeve with O-rings.
  18.  
  19. Remove the belt tensioner, generator and the bolt for the support bearing bracket in the timing cover.
  20.  
  21. Remove all the bolts on the timing cover, carefully tap the cover off and remove it.
  22.  

To install:

  1. Thoroughly remove all remains of sealant on all surfaces. Wash clean with benzene.
  2.  
  3. Apply a bead of flange sealant, 93 21 795, about 0.04 inch (1 mm) wide on the center of the sealing surfaces.
  4.  
  5. Fit the timing cover and torque to 16 ft. lbs. (22 Nm).
  6.  
  7. Install the bolt for support bearing bracket in the timing cover and fit the generator and belt tensioner.
  8.  
  9. Install water pump. Use new O-rings if needed.
  10.  
  11. Fit the crankshaft belt pulley. Use the flywheel locking attachment, part no. 83 94 868. Torque pulley bolt to 130 ft. lbs. (175 Nm).
  12.  
  13. Verify that oil pan is clean. Clean mating surfaces. Apply an even bead of flange sealant, 93 21 795, to the sealing surface of the oil sump and fit the oil pan. Torque pan bolts to 16 ft. lbs. (22 Nm).
  14.  
  15. Install the oil pan protective plate.
  16.  
  17. Rotate the crankshaft 45 degrees and fit the cylinder head with a new gasket. Make sure it is correctly seated on the guide sleeves and that the chain runs freely.
  18.  
  19. Install and tighten the cylinder head bolts according to bolt tightening sequence and to specified torque.
  20.  
  21. Install the 2 bolts between the timing cover and cylinder head. Tighten to 18 ft. lbs. (24 Nm).
  22.  
  23. Make sure the camshafts are aligned with their setting marks and rotate the crankshaft back to its 0-marking.
  24.  
  25. Starting with the intake camshaft, install the camshaft sprockets and chain.
  26.  


NOTE
Do not tighten the bolts at this time.

  1. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner. Install the chain tensioner, with a 27mm socket, and torque to 47 ft. lbs. (63 Nm).
  2.  
  3. Install the chain tensioner plug with push rod and spring. Torque the plug to 17 ft. lbs. (23 Nm).
  4.  
  5. Be sure the chain is positioned correctly on the chain guards. Turn the crankshaft 2 revolutions and check the setting of the flywheel and camshafts.
  6.  
  7. Tighten the camshaft sprocket bolts to 47 ft. lbs. (63 Nm).
  8.  
  9. Clean the sealing surface of the camshaft cover with benzene.
  10.  
  11. Apply soap to the opening in the camshaft cover and fit the cover, starting at the opening. Then, tighten the bolt located furthest to the front at the timing chain end. Continue all the way round the outside and inside. Torque the bolts to 11 ft. lbs. (15 Nm).
  12.  
  13. Install the spark plugs to 21 ft. lbs. (28 Nm). Install the ignition discharge module. Tighten to 8 ft. lbs. (11 Nm).
  14.  
  15. Connect the ignition discharge module electrical connection and the crankcase ventilation and vacuum hoses.
  16.  
  17. Install the thermostat housing cover and connect the hose for the throttle body preheating.
  18.  
  19. Tighten the lock nuts on the turbocharger to 19 ft. lbs. (25 Nm).
  20.  
  21. Tighten the bolts on the turbocharger stay. Start with the one in the cylinder block. Torque to 16 ft. lbs. (22 Nm).
  22.  
  23. Fit the water pipe to the thermostat housing and tighten bolts to 19 ft. lbs. (25 Nm).
  24.  
  25. Fit the crankcase ventilation pipe together with the intake manifold (turbo). Tighten the turbo/intake manifold bolts to 6 ft. lbs. (8 Nm) and the crankcase vent pip to 18 ft. lbs. (24 Nm).
  26.  
  27. Tighten the bolts on the intake manifold stay, starting with the one in the cylinder block and fit the oil filler pipe. Tighten stay-to-block bolts to 18 ft. lbs. (24 Nm). Tighten the upper mounting bolts to 7 ft. lbs. (10 Nm). Tighten the lower mounting bolts to 16 ft. lbs. (22 Nm).
  28.  
  29. Be sure the oil plug is tight and connect the cables to the engine oil pressure sensor, generator and starter motor.
  30.  



Click image to see an enlarged view

Fig. Installed view of the timing chains-2.0L and 2.3L engine 2001-02



Click image to see an enlarged view

Fig. Be sure to align the crankshaft and camshaft timing marks, as shown-2.0L and 2.3L engines 2001-02



Click image to see an enlarged view

Fig. Secure the engine in position using a flywheel locking tool-2.0L and 2.3L engines



Click image to see an enlarged view

Fig. Loosen the bolts from the timing chain front cover, starting with the last bolt and working in reverse. To tighten, start with the bolt hole in the opening of the cover and work around in sequence -2.0L and 2.3L engines

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Drain the engine oil, disconnect the cables to the starter motor, generator and engine oil pressure sensor.
  4.  
  5. Remove or disconnect the following: Oil filler pipeIntake manifold stayCrankcase ventilation pipe with intake manifold and nuts on turbochargerLoosen the bolts on turbocharger stay slightlyWater pipe for turbocharger from thermostat housingHose for throttle body preheating and unscrew thermostat housing coverIgnition discharge module electrical connectionCrankcase ventilation and vacuum hoses from camshaft coverIgnition discharge module (place module aside)Spark plugsCamshaft coverZero engine and make sure camshafts are aligned with their setting markingsChain tensionerCamshaft sprockets (place chain so cylinder head can be removed without interference)Cylinder head

    Oil filler pipe
     
    Intake manifold stay
     
    Crankcase ventilation pipe with intake manifold and nuts on turbocharger
     
    Loosen the bolts on turbocharger stay slightly
     
    Water pipe for turbocharger from thermostat housing
     
    Hose for throttle body preheating and unscrew thermostat housing cover
     
    Ignition discharge module electrical connection
     
    Crankcase ventilation and vacuum hoses from camshaft cover
     
    Ignition discharge module (place module aside)
     
    Spark plugs
     
    Camshaft cover
     
    Zero engine and make sure camshafts are aligned with their setting markings
     
    Chain tensioner
     
    Camshaft sprockets (place chain so cylinder head can be removed without interference)
     
    Cylinder head
     

  6.  
  7. Start with the bolts in the timing cover and continue in reverse order to assembly. Use the protective sleeve, 75 19 531, to retrieve the bolts.
  8.  
  9. Make sure that the timing chain dies not obstruct removal and then lift off the cylinder head.
  10.  
  11. Remove the protective plate and oil sump. Leave the guide sleeve in the cylinder block.
  12.  
  13. Remove or disconnect the following:
  14.  
  15. Remove the crankshaft pulley. Use the flywheel locking attachment, part no. 83 94 868.
  16.  
  17. Remove the water pump and the sleeve with O-rings.
  18.  
  19. Remove the belt tensioner, generator and the bolt for the support bearing bracket in the timing cover.
  20.  
  21. Remove all the bolts on the timing cover, carefully tap the cover off and remove it.
  22.  

To install:

  1. Thoroughly remove all remains of sealant on all surfaces. Wash clean with benzene.
  2.  
  3. Apply a bead of flange sealant, 93 21 795, about 0.04 inch (1 mm) wide on the center of the sealing surfaces.
  4.  
  5. Fit the timing cover and torque to 16 ft. lbs. (22 Nm).
  6.  
  7. Install the bolt for support bearing bracket in the timing cover and fit the generator and belt tensioner.
  8.  
  9. Install water pump. Use new O-rings if needed.
  10.  
  11. Fit the crankshaft belt pulley. Use the flywheel locking attachment, part no. 83 94 868. Torque pulley bolt to 130 ft. lbs. (175 Nm).
  12.  
  13. Verify that oil pan is clean. Clean mating surfaces. Apply an even bead of flange sealant, 93 21 795, to the sealing surface of the oil sump and fit the oil pan. Torque pan bolts to 16 ft. lbs. (22 Nm).
  14.  
  15. Install the oil pan protective plate.
  16.  
  17. Rotate the crankshaft 45 degrees and fit the cylinder head with a new gasket. Make sure it is correctly seated on the guide sleeves and that the chain runs freely.
  18.  
  19. Install and tighten the cylinder head bolts according to bolt tightening sequence and to specified torque.
  20.  
  21. Install the 2 bolts between the timing cover and cylinder head. Tighten to 18 ft. lbs. (24 Nm).
  22.  
  23. Make sure the camshafts are aligned with their setting marks and rotate the crankshaft back to its 0-marking.
  24.  
  25. Starting with the intake camshaft, install the camshaft sprockets and chain.
  26.  


NOTE
Do not tighten the bolts at this time.

  1. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner. Install the chain tensioner, with a 27mm socket, and torque to 47 ft. lbs. (63 Nm).
  2.  
  3. Install the chain tensioner plug with push rod and spring. Torque the plug to 17 ft. lbs. (23 Nm).
  4.  
  5. Be sure the chain is positioned correctly on the chain guards. Turn the crankshaft 2 revolutions and check the setting of the flywheel and camshafts.
  6.  
  7. Tighten the camshaft sprocket bolts to 47 ft. lbs. (63 Nm).
  8.  
  9. Clean the sealing surface of the camshaft cover with benzene.
  10.  
  11. Apply soap to the opening in the camshaft cover and fit the cover, starting at the opening. Then, tighten the bolt located furthest to the front at the timing chain end. Continue all the way round the outside and inside. Torque the bolts to 11 ft. lbs. (15 Nm).
  12.  
  13. Install the spark plugs to 21 ft. lbs. (28 Nm). Install the ignition discharge module. Tighten to 8 ft. lbs. (11 Nm).
  14.  
  15. Connect the ignition discharge module electrical connection and the crankcase ventilation and vacuum hoses.
  16.  
  17. Install the thermostat housing cover and connect the hose for the throttle body preheating.
  18.  
  19. Tighten the lock nuts on the turbocharger to 19 ft. lbs. (25 Nm).
  20.  
  21. Tighten the bolts on the turbocharger stay. Start with the one in the cylinder block. Torque to 16 ft. lbs. (22 Nm).
  22.  
  23. Fit the water pipe to the thermostat housing and tighten bolts to 19 ft. lbs. (25 Nm).
  24.  
  25. Fit the crankcase ventilation pipe together with the intake manifold (turbo). Tighten the turbo/intake manifold bolts to 6 ft. lbs. (8 Nm) and the crankcase vent pip to 18 ft. lbs. (24 Nm).
  26.  
  27. Tighten the bolts on the intake manifold stay, starting with the one in the cylinder block and fit the oil filler pipe. Tighten stay-to-block bolts to 18 ft. lbs. (24 Nm). Tighten the upper mounting bolts to 7 ft. lbs. (10 Nm). Tighten the lower mounting bolts to 16 ft. lbs. (22 Nm).
  28.  
  29. Be sure the oil plug is tight and connect the cables to the engine oil pressure sensor, generator and starter motor.
  30.  

2003-04
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Raise the car and remove the front right wheel.
  4.  
  5. Remove the right wing liner.
  6.  
  7. Relieve the belt tensioner, using 83 96 095, and remove the belt. Mark the direction of rotation of the belt.
  8.  
  9. Remove the belt tensioner.
  10.  
  11. Lower the car and remove the upper engine cover.
  12.  
  13. Unplug the mass air flow sensor connector and detach the inlet hose from the air cleaner casing cover. Remove the cover and the air filter. Remove the SAI hose.
  14.  
  15. Detach the inlet hose and remove the air cleaner casing. Unplug the connector for the A/C pressure sensor.
  16.  
  17. Remove the turbocharger heat shield.
  18.  
  19. Install the lifting eye kit 83 96 178.
  20.  
  21. Fit the lifting beam, 83 94 850, and holder, 83 95 287. Take the weight off the engine and remove the bolts in the engine bracket.
  22.  
  23. Lower the engine slightly.
  24.  
  25. Raise the car and remove the crankshaft pulley using a holding tool.
  26.  
  27. Carefully remove the timing cover.
  28.  
  29. Cut away the timing cover gasket around the engine mounting and remove the gasket.
  30.  
  31. Remove the crankshaft seal. To install:
  32.  
  33. Clean all the sealing surfaces.
  34.  
  35. Cut off the part of the gasket that is around the engine mounting and position the new timing cover gasket.
  36.  
  37. Install the timing cover and tighten bolts to 15 ft. lbs. (20 Nm).
  38.  
  39. Position the crankshaft seal protective sleeve, 83 96 202, on the crankshaft. Lubricate the new seal with non-acidic Vaseline and position it on the tool.
  40.  
  41. Position the tool on the crankshaft. Screw in the seal, using the crankshaft pulley bolt so that it is flush with the timing cover. Remove the tool.
  42.  
  43. Install the crankshaft pulley with a new bolt, while using a holding tool to prevent crankshaft rotation. Torque pulley bolt to 74 ft. lbs. (100 Nm), plus an additional 75 degrees.
  44.  
  45. Lower the car and raise the engine with the lifting beam until it rests against the engine mount.
  46.  
  47. Fit the bolts to the engine bracket. Remove the lifting beam with holder. Tighten the bolts to 52 ft. lbs. (70 Nm), plus an additional 60 degrees.
  48.  
  49. Remove the lifting eye kit.
  50.  
  51. Install the turbocharger heat shield.
  52.  
  53. Install the air cleaner casing and connect the intake hose. Plug in the A/C pressure sensor connector.
  54.  
  55. Install the filter element and the air cleaner casing cover. Connect the intake hose and the MAF sensor connector. Fit the SAI hose.
  56.  
  57. Install the upper engine cover.
  58.  
  59. Raise the car and fit the belt tensioner, tightening the bolt to 37 ft. lbs. (50 Nm).
  60.  
  61. Relieve the belt tensioner with the belt circuit relieving tool, 83 96 095 and install the belt in the marked direction of rotation. Make sure the belt is located correctly on all the pulleys.
  62.  
  63. Install the right fender liner and the front wheel.
  64.  
  65. Check the engine oil level. Top up as necessary.
  66.  


    Click image to see an enlarged view

    Fig. Showing the location of timing cover bolts (start loosening or tightening with the bolt shown with the number)-9-3 2.0L engine (2003-04)


  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Raise the car and remove the front right wheel.
  4.  
  5. Remove the right wing liner.
  6.  
  7. Relieve the belt tensioner, using 83 96 095, and remove the belt. Mark the direction of rotation of the belt.
  8.  
  9. Remove the belt tensioner.
  10.  
  11. Lower the car and remove the upper engine cover.
  12.  
  13. Unplug the mass air flow sensor connector and detach the inlet hose from the air cleaner casing cover. Remove the cover and the air filter. Remove the SAI hose.
  14.  
  15. Detach the inlet hose and remove the air cleaner casing. Unplug the connector for the A/C pressure sensor.
  16.  
  17. Remove the turbocharger heat shield.
  18.  
  19. Install the lifting eye kit 83 96 178.
  20.  
  21. Fit the lifting beam, 83 94 850, and holder, 83 95 287. Take the weight off the engine and remove the bolts in the engine bracket.
  22.  
  23. Lower the engine slightly.
  24.  
  25. Raise the car and remove the crankshaft pulley using a holding tool.
  26.  
  27. Carefully remove the timing cover.
  28.  
  29. Cut away the timing cover gasket around the engine mounting and remove the gasket.
  30.  
  31. Remove the crankshaft seal.
  32.  

To install:

  1. Clean all the sealing surfaces.
  2.  
  3. Cut off the part of the gasket that is around the engine mounting and position the new timing cover gasket.
  4.  
  5. Install the timing cover and tighten bolts to 15 ft. lbs. (20 Nm).
  6.  
  7. Position the crankshaft seal protective sleeve, 83 96 202, on the crankshaft. Lubricate the new seal with non-acidic Vaseline and position it on the tool.
  8.  
  9. Position the tool on the crankshaft. Screw in the seal, using the crankshaft pulley bolt so that it is flush with the timing cover. Remove the tool.
  10.  
  11. Install the crankshaft pulley with a new bolt, while using a holding tool to prevent crankshaft rotation. Torque pulley bolt to 74 ft. lbs. (100 Nm), plus an additional 75 degrees.
  12.  
  13. Lower the car and raise the engine with the lifting beam until it rests against the engine mount.
  14.  
  15. Fit the bolts to the engine bracket. Remove the lifting beam with holder. Tighten the bolts to 52 ft. lbs. (70 Nm), plus an additional 60 degrees.
  16.  
  17. Remove the lifting eye kit.
  18.  
  19. Install the turbocharger heat shield.
  20.  
  21. Install the air cleaner casing and connect the intake hose. Plug in the A/C pressure sensor connector.
  22.  
  23. Install the filter element and the air cleaner casing cover. Connect the intake hose and the MAF sensor connector. Fit the SAI hose.
  24.  
  25. Install the upper engine cover.
  26.  
  27. Raise the car and fit the belt tensioner, tightening the bolt to 37 ft. lbs. (50 Nm).
  28.  
  29. Relieve the belt tensioner with the belt circuit relieving tool, 83 96 095 and install the belt in the marked direction of rotation. Make sure the belt is located correctly on all the pulleys.
  30.  
  31. Install the right fender liner and the front wheel.
  32.  
  33. Check the engine oil level. Top up as necessary.
  34.  


    Click image to see an enlarged view

    Fig. Showing the location of timing cover bolts (start loosening or tightening with the bolt shown with the number)-9-3 2.0L engine 2003-04


2003-06 Models (Except 2.8L Engine)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Raise the car and remove the front right wheel.
  4.  
  5. Remove the right wing liner.
  6.  
  7. Relieve the belt tensioner, using 83 96 095, and remove the belt. Mark the direction of rotation of the belt.
  8.  
  9. Remove the belt tensioner.
  10.  
  11. Lower the car and remove the upper engine cover.
  12.  
  13. Unplug the mass air flow sensor connector and detach the inlet hose from the air cleaner casing cover. Remove the cover and the air filter. Remove the SAI hose.
  14.  
  15. Detach the inlet hose and remove the air cleaner casing. Unplug the connector for the A/C pressure sensor.
  16.  
  17. Remove the turbocharger heat shield.
  18.  
  19. Install the lifting eye kit 83 96 178.
  20.  
  21. Fit the lifting beam, 83 94 850, and holder, 83 95 287. Take the weight off the engine and remove the bolts in the engine bracket.
  22.  
  23. Lower the engine slightly.
  24.  
  25. Raise the car and remove the crankshaft pulley using a holding tool.
  26.  
  27. Carefully remove the timing cover.
  28.  
  29. Cut away the timing cover gasket around the engine mounting and remove the gasket.
  30.  
  31. Remove the crankshaft seal.
  32.  

To install:

  1. Clean all the sealing surfaces.
  2.  
  3. Cut off the part of the gasket that is around the engine mounting and position the new timing cover gasket.
  4.  
  5. Install the timing cover and tighten bolts to 15 ft. lbs. (20 Nm).
  6.  
  7. Position the crankshaft seal protective sleeve, 83 96 202, on the crankshaft. Lubricate the new seal with non-acidic Vaseline and position it on the tool.
  8.  
  9. Position the tool on the crankshaft. Screw in the seal, using the crankshaft pulley bolt so that it is flush with the timing cover. Remove the tool.
  10.  
  11. Install the crankshaft pulley with a new bolt, while using a holding tool to prevent crankshaft rotation. Torque pulley bolt to 74 ft. lbs. (100 Nm), plus an additional 75 degrees.
  12.  
  13. Lower the car and raise the engine with the lifting beam until it rests against the engine mount.
  14.  
  15. Fit the bolts to the engine bracket. Remove the lifting beam with holder. Tighten the bolts to 52 ft. lbs. (70 Nm), plus an additional 60 degrees.
  16.  
  17. Remove the lifting eye kit.
  18.  
  19. Install the turbocharger heat shield.
  20.  
  21. Install the air cleaner casing and connect the intake hose. Plug in the A/C pressure sensor connector.
  22.  
  23. Install the filter element and the air cleaner casing cover. Connect the intake hose and the MAF sensor connector. Fit the SAI hose.
  24.  
  25. Install the upper engine cover.
  26.  
  27. Raise the car and fit the belt tensioner, tightening the bolt to 37 ft. lbs. (50 Nm).
  28.  
  29. Relieve the belt tensioner with the belt circuit relieving tool, 83 96 095 and install the belt in the marked direction of rotation. Make sure the belt is located correctly on all the pulleys.
  30.  
  31. Install the right fender liner and the front wheel.
  32.  
  33. Check the engine oil level. Top up as necessary.

    Click image to see an enlarged view

    Fig. Showing the location of timing cover bolts (start loosening or tightening with the bolt shown with the number)-9-3 2.0L engine 2003-06

  34.  

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: DipstickIdler pulleyPower steering pump and bracket with the lifting eyeWater pump and the sleeve with O-ringsProtective plate and oil pan (leave guide sleeve in cylinder block)Crankshaft pulley (use locking segment 83 94 868 on flywheel)Crankcase breather hose from the oil panLocating pins in the timing cover by cutting an internal thread in them using a 3/8- UNC thread tap and withdraw them with sliding hammer 83 90 270.Timing cover retaining bolts

    Dipstick
     
    Idler pulley
     
    Power steering pump and bracket with the lifting eye
     
    Water pump and the sleeve with O-rings
     
    Protective plate and oil pan (leave guide sleeve in cylinder block)
     
    Crankshaft pulley (use locking segment 83 94 868 on flywheel)
     
    Crankcase breather hose from the oil pan
     
    Locating pins in the timing cover by cutting an internal thread in them using a 3/8- UNC thread tap and withdraw them with sliding hammer 83 90 270.
     
    Timing cover retaining bolts
     

  4.  
  5. Pull the timing cover away, starting at the bottom, then lift the cover outwards/downwards to avoid damaging the gasket at the cylinder head.
  6.  

To install:

  1. Thoroughly remove all remains of sealant on all surfaces.
  2.  
  3. Apply a bead of Loctite 518 about 0.40 inch (1mm) thick along the middle of the sealing surfaces.
  4.  
  5. Position the timing cover, carefully turning it into position. Fit the retaining bolts, but do not tighten them. Tap the locating pins in place.
  6.  
  7. Now, tighten the timing cover bolts to 16 ft. lbs. (22 Nm).
  8.  
  9. Install new water pump O-rings
  10.  
  11. Clean the hole in the block and tighten the sleeve until its large wing is pointing horizontally towards the flywheel end.
  12.  
  13. Lubricate the O-rings and fit the water pump.
  14.  
  15. Install the crankshaft pulley, using a locking segment, 83 94 868, on the flywheel. Tighten to 130 ft. lbs. (175 Nm).
  16.  
  17. Be sure oil pan is clean. Also clean mating surfaces.
  18.  
  19. Apply an even bead of Loctite 518 on the oil pan sealing surface and position the pan in place. Tighten bolts to 16 ft. lbs. (22 Nm).
  20.  
  21. Install the oil pan protective plate.
  22.  
  23. Plug in the oil level sensor connector and press the cable back into its clamps.
  24.  
  25. Check that the oil plug is properly tightened and connect the cables to the oil pressure sensor, generator, and starter motor. Tighten to 19 ft. lbs. (25 Nm).
  26.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Remove or disconnect the following: DipstickIdler pulleyPower steering pump and bracket with the lifting eyeWater pump and the sleeve with O-ringsProtective plate and oil pan (leave guide sleeve in cylinder block)Crankshaft pulley (use locking segment 83 94 868 on flywheel)Crankcase breather hose from the oil panLocating pins in the timing cover by cutting an internal thread in them using a 3/8 inch UNC thread tap and withdraw them with sliding hammer 83 90 270.Timing cover retaining bolts

    Dipstick
     
    Idler pulley
     
    Power steering pump and bracket with the lifting eye
     
    Water pump and the sleeve with O-rings
     
    Protective plate and oil pan (leave guide sleeve in cylinder block)
     
    Crankshaft pulley (use locking segment 83 94 868 on flywheel)
     
    Crankcase breather hose from the oil pan
     
    Locating pins in the timing cover by cutting an internal thread in them using a 3/8 inch UNC thread tap and withdraw them with sliding hammer 83 90 270.38
     
    Timing cover retaining bolts
     

  4.  
  5. Pull the timing cover away, starting at the bottom, then lift the cover outwards/downwards to avoid damaging the gasket at the cylinder head.
  6.  

To install:

  1. Thoroughly remove all remains of sealant on all surfaces.
  2.  
  3. Apply a bead of Loctite 518 about 0.40 inch (1mm) thick along the middle of the sealing surfaces.
  4.  
  5. Position the timing cover, carefully turning it into position. Fit the retaining bolts, but do not tighten them. Tap the locating pins in place.
  6.  
  7. Now, tighten the timing cover bolts to 16 ft. lbs. (22 Nm).
  8.  
  9. Install new water pump O-rings
  10.  
  11. Clean the hole in the block and tighten the sleeve until its large wing is pointing horizontally towards the flywheel end.
  12.  
  13. Lubricate the O-rings and fit the water pump.
  14.  
  15. Install the crankshaft pulley, using a locking segment, 83 94 868, on the flywheel. Tighten to 130 ft. lbs. (175 Nm).
  16.  
  17. Be sure oil pan is clean. Also clean mating surfaces.
  18.  
  19. Apply an even bead of Loctite 518 on the oil pan sealing surface and position the pan in place. Tighten bolts to 16 ft. lbs. (22 Nm).
  20.  
  21. Install the oil pan protective plate.
  22.  
  23. Plug in the oil level sensor connector and press the cable back into its clamps.
  24.  
  25. Check that the oil plug is properly tightened and connect the cables to the oil pressure sensor, generator, and starter motor. Tighten to 19 ft. lbs. (25 Nm).
  26.  

  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:
    WARNING
    Throughout this procedure, keep the camshafts in their basic correct setting. If they are rotated out of position at any stage, especially without their sprockets and chain, the valves can be damaged.



    Negative battery cable
     
    Belt circuit cover
     
    Upper engine cover
     
    Lower spoiler section
     
    Ignition discharge module and spark plugs
     
    Crankcase ventilation pipe
     
    Camshaft cover and align the crankshaft and camshafts with the marks by turning the crankshaft clockwise
     
    Tension from the V-belt
     
    Idler sprocket so that the timing chain tensioner sleeve is free
     

  8.  
  9. The camshaft chain and crankshaft timing sprocket should both be visible. From above, release the timing chain tensioner by pressing the pivoting guide firmly against it. Remove the chain tensioner.
  10.  
  11. Remove or disconnect the following:

    Exhaust camshaft, using a wrench installed over the flats hold the camshaft and remove the center bolt securing the camshaft sprocket. Repeat this step for the intake camshaft.
     
    Timing chain from the sprockets
     

  12.  

To install:

  1. Install or connect the following:

    Timing chain and make certain that the chain lies over the camshaft sprockets on the intake side
     
    Connect the ends of the new chain together with a chain link and install a new chain lock
     
    Chain tensioner with a new washer. Torque the tensioner to 46 ft. lbs. (63 Nm). Turn the engine over 2 turns and check the O marks on the camshaft and crankshaft.
     
    Camshaft cover and torque the bolts to 10 ft. lbs. (15 Nm)
     
    Spark plugs and torque the plugs to 21 ft. lbs. (28 Nm)
     
    Ignition discharge module and torque the fastener to 8 ft. lbs. (11 Nm)
     
    Crankcase ventilation pipe
     
    Lower spoiler section
     
    Upper engine cover
     
    Negative battery cable
     

  2.  
  3. Fill the cooling system to the proper level.
  4.  
  5. Fill the engine with clean oil.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

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

    Dipstick
     
    Idler pulley
     
    Power steering pump and bracket with the lifting eye
     
    Water pump and the sleeve with O-rings
     
    Protective plate and oil pan (leave guide sleeve in cylinder block)
     
    Crankshaft pulley (use locking segment 83 94 868 on flywheel)
     
    Crankcase breather hose from the oil pan
     
    Locating pins in the timing cover by cutting an internal thread in them using a 3 / 8 inch UNC thread tap and withdraw them with sliding hammer 83 90 270.
     
    Timing cover retaining bolts
     

  4.  
  5. Pull the timing cover away, starting at the bottom, then lift the cover outwards/downwards to avoid damaging the gasket at the cylinder head.
  6.  

To install:

  1. Thoroughly remove all remains of sealant on all surfaces.
  2.  
  3. Apply a bead of Loctite 518 about 0.40 inch (1mm) thick along the middle of the sealing surfaces.
  4.  
  5. Position the timing cover, carefully turning it into position. Fit the retaining bolts, but do not tighten them. Tap the locating pins in place.
  6.  
  7. Now, tighten the timing cover bolts to 16 ft. lbs. (22 Nm).
  8.  
  9. Install new water pump O-rings
  10.  
  11. Clean the hole in the block and tighten the sleeve until its large wing is pointing horizontally towards the flywheel end.
  12.  
  13. Lubricate the O-rings and fit the water pump.
  14.  
  15. Install the crankshaft pulley, using a locking segment, 83 94 868, on the flywheel. Tighten to 130 ft. lbs. (175 Nm).
  16.  
  17. Be sure oil pan is clean. Also clean mating surfaces.
  18.  
  19. Apply an even bead of Loctite 518 on the oil pan sealing surface and position the pan in place. Tighten bolts to 16 ft. lbs. (22 Nm).
  20.  
  21. Install the oil pan protective plate.
  22.  
  23. Plug in the oil level sensor connector and press the cable back into its clamps.
  24.  
  25. Check that the oil plug is properly tightened and connect the cables to the oil pressure sensor, generator, and starter motor. Tighten to 19 ft. lbs. (25 Nm).
  26.  

900 And 9-3 Models


Click image to see an enlarged view

Fig. Exploded view of the timing chain front cover assembly-2.0L engine



Click image to see an enlarged view

Fig. Be sure to align the crankshaft timing mark, as shown-2.0L engine



Click image to see an enlarged view

Fig. Secure the engine in position using a flywheel locking tool-2.0L and 2.3L engines



Click image to see an enlarged view

Fig. Unthread the timing chain tensioner to remove it from the front cover-2.0L and 2.3L engines

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

    Negative battery cable
     
    Bracket for the steering servo pump, complete with the pump and alternator
     
    Belt tensioner and the water pump pipe
     
    Crankshaft pulley
     
    Oil pipes
     
    Water pump pulley
     
    Timing chain cover
     
    Oil seal
     

  8.  
  9. The cam chain and crankshaft timing sprocket should now both be visible. From above, release the timing chain tensioner by pressing the pivoting guide firmly against it. Remove the chain tensioner.
  10.  
  11. Using a wrench to hold the cast hex bolt on the camshafts, remove the center bolts securing the camshaft sprockets. Throughout this procedure, keep the camshafts in their basic correct setting. If they are rotated out of position at any stage, especially without their sprockets and chain, the valves can be damaged.
  12.  
  13. Disconnect the timing chain from the sprockets and remove the chain, clearing it from the crankshaft sprockets.
  14.  

To install:

  1. Using a suitable seal installer, tap the new seal into the front cover until it is flush with the casting.
  2.  
  3. To install the timing chain, place the chain around the crankshaft sprocket. Run the chain up through the opening in the cylinder head. Install the chain and sprocket on the exhaust cam first. Be sure the chain is taut between the crankshaft and camshaft sprockets. Install and snug the bolt but do not tighten.
  4.  
  5. Install the chain and sprocket to the intake cam. Keep the chain taut between the cam sprockets while it is being installed. Install and snug the bolt but do not tighten. Be sure the chain is seated in the guide tensioner grooves.
  6.  
  7. Tension the chain tensioner by fully depressing the piston, then rotating it to the locked position.
  8.  
  9. Install the chain tensioner with the piston under tension. Be sure the copper gasket is in good condition and that the sealing surface is clean and free from burrs. Torque the tensioner to 47 ft. lbs. (63 Nm).
  10.  
  11. Trigger the chain tensioner by pressing the pivoting chain guide against it, thereafter, press the pivoting guide against the chain to give the chain its basic tension. Check that the chain tensioner maintains tension on the chain when the pressure on the chain guide is released and that the basic setting stop for the tensioner holds the chain guide tight against the chain. A limited amount of play will be present until the hydraulic pressure takes over once the engine is running.
  12.  
  13. Check the setting by rotating the crankshaft 2 complete turns in its normal direction of rotation around to the timing mark. The basic setting of the cams should remain unaltered.
  14.  
  15. Lock the exhaust cam by using a wrench on the cast hex bolt and torque the sprocket bolt to 48 ft. lbs. (65 Nm). Repeat this on the intake cam.
  16.  
  17. Complete the procedure on the intake cam sprocket. When loosening or tightening the sprocket center bolts, hold the cam still using a wrench installed over the flats on the camshaft.
  18.  
  19. Install or connect the following:

    Timing cover and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Oil pump
     
    Oil supply pipes
     
    Water pump pulley
     
    Crankshaft pulley and torque the nut to 140 ft. lbs. (190 Nm)
     
    Belt tensioner
     
    Water pump pipe
     
    Power steering pump
     
    Alternator
     
    Drive belt
     
    Negative battery cable
     

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

    Click image to see an enlarged view

    Fig. Installing the front crankshaft seal-2.0L and 2.3L engines

  26.  

9000 Models


Click image to see an enlarged view

Fig. Timing and balance shaft chain assemblies' component identification-2.3L engines



Click image to see an enlarged view

Fig. Be sure to align the flywheel timing mark, as shown-2.3L engines



Click image to see an enlarged view

Fig. Exploded view of the timing chain tensioner-2.3L engines



Click image to see an enlarged view

Fig. Preparing the balance shaft's tensioner for installation-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. Drain the engine oil.
  6.  
  7. Remove or disconnect the following:
    NOTE
    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).


    WARNING
    Throughout this procedure, keep the camshafts in their basic correct setting. If they are rotated out of position at any stage, especially without their sprockets and chain, the valves can be damaged.



    Negative battery cable
     
    Right front wheel
     
    Inner wheel well
     
    Serpentine drive belt and belt tensioner
     
    Tie bar between the wheel arch and the subframe
     
    Power steering pump
     
    Power steering pump bracket
     
    Alternator
     
    Top engine mounting bracket. Note the location of the bolts as the bolts are of different lengths.
     
    Torque arm
     
    Top belt tensioner bracket
     
    A/C compressor and bracket. Do not disconnect any hoses.
     
    Coolant hoses
     
    Water pump
     
    Crankshaft pulley
     
    Crankshaft Position (CKP) sensor
     
    Oil pan. It may be necessary to move the coolant pipe aside.
     
    Timing cover bolts, including the bolts holding the cover to the cylinder head. Note the locations of all bolts as they are of different lengths
     
    Timing cover by tapping it off the guide pin
     
    Lid on the valve cover
     
    Ignition wires
     
    Valve cover
     



    Top chain guide and chain tensioner for the balance shaft chain
     
    Idler sprocket and balance shaft chain
     

  8.  
  9. The camshaft chain and crankshaft timing sprocket should both be visible. From above, release the timing chain tensioner by pressing the pivoting guide firmly against it. Remove the chain tensioner.
  10.  
  11. Remove or disconnect the following:

    Exhaust camshaft, using a wrench installed over the flats hold the camshaft and remove the center bolt securing the camshaft sprocket. Repeat this step for the intake camshaft.
     
    Timing chain from the sprockets
     

  12.  

To install:

  1. To install the timing chain, place the chain around the crankshaft sprocket. Run the chain up through the opening in the cylinder head. Install the chain and sprocket on the exhaust cam first. Be sure the chain is taut between the crankshaft and camshaft sprockets. Snug the bolt but do not tighten.
  2.  
  3. Install the chain and sprocket to the intake cam. Keep the chain taut between the cam sprockets while it is being installed. Snug the bolt but do not tighten. Be sure the chain is seated in the guide tensioner grooves.
  4.  
  5. Tension the chain tensioner by fully depressing the piston, then rotating it to the locked position.
  6.  
  7. Install the chain tensioner with the piston under tension. Be sure the copper gasket is in good condition and that the sealing surface is clean and free from burrs.
  8.  
  9. Trigger the chain tensioner by pressing the pivoting chain guide against it, thereafter, press the pivoting guide against the chain to give the chain its basic tension. Check that the chain tensioner maintains tension on the chain when the pressure on the chain guide is released and that the basic setting stop for the tensioner holds the chain guide tight against the chain. A limited amount of play will be present until the hydraulic pressure takes over once the engine is running.
  10.  
  11. Check the setting by rotating the crankshaft 2 complete turns in its normal direction of rotation around to the timing mark. The basic setting of the cams should remain unaltered.
  12.  
  13. Lock the exhaust cam by using a wrench installed over the flats on the camshaft and torque the sprocket bolt to 48 ft. lbs. (65 Nm). Repeat this step on the intake cam.
    NOTE
    The accuracy of the timing chain adjustment will depend on the condition of the chain.

  14.  
  15. Install the balance shaft chain and sprocket on the crankshaft.
  16.  
  17. Install or connect the following:
    NOTE
    There is an alternate way of installing the balance shaft chain. Install the top chain guide first, then adjust the run of the chain around the sprockets. Adjusting the chain is easier this way, although it will be more awkward to install the idler wheel sprocket.



    Oil pump drive dog
     
    Balance shaft chain and idler wheel sprocket. Ensure that the aligning marks on the bearing housing and sprocket are in line. When installing, leave some slack in the chain in line with the tensioner, and keep the chain reasonably taut by means of the top chain guide.
     

  18.  
  19. Cock the balance shaft chain tensioner and insert a paper clip through the hole in the cylinder to prevent the tensioner being triggered. Before installing the tensioner, be sure that the plunger is turned to the position in which the spring acts fully on it.
  20.  
  21. Install the balance shafts pivoting chain guide and tensioner. Torque the tensioner to 89 inch lbs. (10 Nm).
    WARNING
    It is extremely important for the correct torque to be applied when installing the tensioner.

  22.  
  23. Install the top chain guide and trigger the tensioner by removing the paper clip.
  24.  
  25. Rotate the crankshaft a few times to ensure the balance shafts chain is installed correctly.
  26.  
  27. Ensure that the timing cover flange is absolutely clean.
  28.  
  29. Remove all traces of old sealant from the cover. Apply a 0.04 in. (1mm) bead of 45-3028972 sealant to the flanges of the cover. Use sealant sparingly as excess sealant can get into the oil ways and damage the engine.
  30.  
  31. Install or connect the following:

    Timing cover and torque the bolts in their correct positions to 15 ft. lbs. (20 Nm)
     

  32.  
  33. Apply an even bead of Permatex® Ultra Blue sealant and fit the rubber seal for the oil strainer in the groove on the sump.

    Oil pan and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Crankshaft pulley and torque the retaining bolt to 140 ft. lbs. (190 Nm)
     
    Coolant pipe
     
    CKP sensor
     
    Engine mounts
     
    Water pump
     
    Coolant hoses
     
    A/C compressor
     
    Power steering pump and bracket
     
    Alternator
     
    Top engine mounting bracket
     
    Torque arm
     
    Serpentine drive belt
     
    Belt tensioner
     
    Tie bar between the wheel arch and the subframe
     
    Inner wheel well and wheel
     
    Negative battery cable
     

  34.  
  35. Fill the cooling system to the proper level.
  36.  
  37. Fill the engine with clean oil.
  38.  
  39. Start the engine and allow it to reach normal operating temperature and check for leaks.
  40.  

 
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