Saab 2000-06

Removal & Installation

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2.0L And 2.3L Engines



  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Loosen the expansion tank pressure cap.
  4.  
  5. Drain the coolant.
  6.  
  7. Remove or disconnect the following:

    Negative battery cable
     
    Center air deflector
     
    Right front wheel
     
    Front section of the inner fender panel
     
    Expansion tank, with its hoses and electrical connector
     

  8.  
  9. Pull hard on the drive belt and lock the tensioner.

    Water pump and A/C compressor belt
     

  10.  
  11. Place protective covers on the engine oil cooler and upper radiator crossmember.
    WARNING
    Use care not to damage the O 2 S sensor.



    A/C compressor electrical connector
     
    A/C compressor with the lines attached and position it to the side
     
    A/C compressor bracket
     
    Coolant hoses to water pump
     
    Oxygen O 2 S sensor wire from the clips
     
    Coolant pipe from the turbocharger
     
    Coolant pipe from water pump
     
    Three bolts attaching the water pump to the timing cover
     
    Water pump by prying first at the sleeve in the cylinder block, then around the rest of the pump
     



    Water pump pulley then take the pump out of its housing
     

  12.  

To install:

  1. Clean the sealing surfaces and use a new gasket.
  2.  
  3. Install or connect the following:

    Water pump in the housing
     
    Water pump pulley and torque the bolts to 72 inch lbs. (8 Nm)
     
    Water pump to cylinder head sleeve and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Coolant pipe to the water pump
     
    Coolant pipe to the turbocharger
     
    O 2 S sensor wire in the clips
     
    Coolant hoses to water pump
     
    A/C compressor bracket
     
    A/C compressor
     
    Compressor electrical connector
     

  4.  
  5. Protective covers from the engine oil cooler and the upper radiator crossmember may now be removed.

    Water pump belt. Pull on it firmly and remove the locking pin from the tensioner. Check for proper belt alignment and tension.
     
    Coolant hoses and electrical connector to expansion tank
     
    The expansion tank
     
    Center air deflector
     
    Front section of the inner fender panel
     
    Right front wheel
     
    Negative battery cable
     

  6.  
  7. Properly fill the cooling system.
  8.  
  9. Start the engine, check for leaks and repair if necessary.
  10.  

3.0L Engines



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

    Negative battery cable
     
    Lower center air deflector
     
    Top engine covers
     
    Power steering reservoir
     
    Connection on the torque arm engine mount
     
    The torque arm
     
    Power steering line clamp from the torque arm engine mount
     
    The engine mount
     
    Upper coolant hose
     
    Coolant expansion tank hose
     
    Upper alternator air intake
     
    Power steering pump pulley and water pump pulley bolts, loosen only
     
    Drive belt and tensioner
     
    Power steering pump pulley
     
    Water pump pulley
     
    Timing cover
     
    Water pump bolts and pump
     

  6.  
  7. Check the timing belt for damage and replace if necessary.
  8.  

To install:

  1. Clean water pump mounting surface. Coat the water pump O-ring and sealing surface with acid-free petroleum jelly.
  2.  
  3. Install or connect the following:

    Water pump with new O-ring and torque the bolts to 18 ft. lbs. (25 Nm)
     
    Timing cover
     
    Water pump pulley and torque the water pump pulley bolts to 72 inch lbs. (8 Nm)
     
    Power steering pump pulley
     
    Drive belt tensioner and belt
     
    Upper alternator air intake
     
    Torque arm engine mount
     
    Power steering line clamp
     
    Torque arm
     
    The connection to the torque arm engine mount
     
    Upper coolant hose
     
    Coolant expansion tank to upper coolant hose
     
    Power steering reservoir
     
    Upper engine covers
     
    Lower center air deflector
     
    Negative battery cable
     

  4.  
  5. Fill the radiator with coolant and check for leaks.
  6.  

9-3



2.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Take the cap off the expansion tank to release any pressure.
  6.  
  7. Raise and safely support the vehicle.
  8.  
  9. Undo the right-hand side of the spoiler shield. 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.
  10.  
  11. Remove the chassis reinforcement from the front subframe (convertible model).
  12.  
  13. Fit 83 96 145 Centering tool, subframe - engine and 83 96 152 Centering tool, power train with 32 025 059 Support. First remove the two long supports. Relieve the load on the engine.
  14.  
  15. Lower the vehicle.
  16.  
  17. Disconnect the turbocharger intake hose.
  18.  
  19. Remove the air cleaner casing cover.
  20.  
  21. Remove the air cleaner. Detach the intake hose and remove the air cleaner casing.
  22.  
  23. Remove the engine pad from the body and bracket.
  24.  
  25. Remove the engine bracket. The lower hole is slotted.
  26.  
  27. Loosen the bolts of the water pump pulley slightly.
  28.  
  29. Unload the drive belt tensioner using a ½ inch puller and remove the belt from the water pump pulley.
  30.  
  31. Remove the pulley.
  32.  
  33. Remove the water pump.
  34.  

To install:

  1. Clean the sealing surfaces.
  2.  
  3. Install the water pump and tighten the bolts to 7 ft. lbs. (10 Nm).
  4.  
  5. Install the pulley.
  6.  
  7. Install the drive belt.
  8.  
  9. Tighten the bolts on the pulley to 9 ft. lbs. (12 Nm).
  10.  
  11. Install the engine bracket. Tighten the M10 size bolts to 31 ft. lbs. (42 Nm), and the M12 size bolts to 69 ft. lbs. (93 Nm).
  12.  
  13. Install the engine pad to the body and bracket using 32 025 063 Special box spanner. Tighten the bolts to the body to 37 ft. lbs. (50 Nm), plus an additional 180°. Tighten the bolts to the engine mounting to 33 ft. lbs. (45 Nm), plus an additional 90°.
  14.  
  15. Install the air cleaner casing and connect the intake hose. Install the air cleaner.
  16.  
  17. Install the air cleaner casing cover.
  18.  
  19. Install the turbocharger inlet hose.
  20.  
  21. Raise and safely support the vehicle.
  22.  
  23. Remove 83 96 145 Centering tool, subframe - engine and 83 96 152 Centering tool, power train with 32 025 059 Support.
  24.  
  25. Install the chassis reinforcement to the front subframe (convertible model).
  26.  
  27. Install the spoiler shield.
  28.  
  29. Lower the vehicle.
  30.  
  31. Connect the negative battery cable.
  32.  
  33. Fill cooling system and bleed system by starting and running the engine at varying speeds until the cooling fan comes on.
  34.  
  35. Stop the engine and top off the coolant.
  36.  
  37. Install remaining components and check for any signs of leaks.
  38.  

2000-2002 Model
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Loosen the expansion tank pressure cap.
  4.  
  5. Raise the car and remove the lower front cover.
  6.  
  7. Drain the coolant.
  8.  
  9. Detach the coolant pipe from the turbocharger.
  10.  
  11. Lower the car.
  12.  
  13. Disconnect the negative battery cable.
  14.  
  15. For the turbocharger, remove or disconnect the following:
    NOTE
    Keep pipe seals and washers in a safe place.



    Air hose between air collector casing and turbocharger intake pipe
     
    Tie securing main engine harnesses
     
    Tension from auxiliary drive belt tensioner
     
    Auxiliary drive belt from power steering pump and water pump pulleys
     
    Engine top cover
     
    Crankcase vent pipe from turbocharger inlet pipe and camshaft cover (bend aside)
     



    Solenoid valve connector and hoses
     
    Engine lifting eye
     
    Bypass pipe with valve from turbocharger intake pipe
     
    Exhaust manifold heat shield
     
    Vent hose from T-connection
     
    Turbocharger intake pipe; plug openings in turbocharger
     

  16.  
  17. Remove the power steering pump bolt on right side behind the belt pulley.
  18.  
  19. Remove the upper power steering pump bolt.
  20.  
  21. Lift up the pump and remove the lower bolt and 2 upper bolts on the bracket.
  22.  
  23. Move the power steering pump and bracket aside and secure with a cable tie.
  24.  
  25. Remove hose clips and detach hoses from water pump inlet.
  26.  
  27. Detach the 2 longitudinal coolant pipes from cylinder block.
  28.  
  29. Disconnect coolant pipes from water pump. Keep the O-rings and move pipes aside.
  30.  
  31. Loosen water pump slightly.
  32.  
  33. Detach the coolant pipe from the water pump. Retain the seals.
  34.  
  35. Remove the 3 water pump bolts.
  36.  
  37. Carefully wiggle the water pump away from its mounting and connecting piece in cylinder block.
  38.  
  39. Remove the connecting piece from the cylinder block.
  40.  

To install:

  1. Clean the sealing surfaces and use a new gasket.
  2.  
  3. Install or connect the following:

    Connecting piece to cylinder block
     
    Coat seals with sealant Gleitmo 805 30-06 442.
     
    Water pump loosely to mounting
     
    Coolant pipe between water pump and turbocharger with new washers and seals
     
    Coolant pipe to water pump to 15 ft. lbs. (20 Nm)
     
    2 longitudinal pipes to water pump with new O-rings coated with non-acidic Vaseline
     
    3 water pump bolts to 16 ft. lbs. (22 Nm)
     
    2 longitudinal pipes to 7 ft. lbs. (10 Nm)
     
    Power steering pump and bracket, tightening bolts to 18 ft. lbs. (24 Nm)
     
    Hoses and clips on water pump inlet
     
    Turbocharger inlet pipe, but do not tighten (coat O-ring with non-acidic Vaseline)
     
    Engine lifting eye
     
    Solenoid valve and hoses
     
    Turbocharger intake pipe V-clamp
     
    Vent hose to T-connection
     
    Exhaust manifold heat shield
     
    Bypass pipe and valve, with new O-ring, to turbocharger inlet pipe
     
    Solenoid valve connector
     
    Crankcase ventilation pipe to turbocharger inlet pipe, with new copper seals, to 18 ft. lbs. (24 Nm)
     
    Crankcase vent pipe to camshaft cover clip
     
    Throttle body cover
     
    Coolant line to turbocharger to 18 ft. lbs. (24 Nm) from under the car
     
    Auxiliary drive belt in all pulleys
     
    Release tension from drive belt tensioner
     
    Main wiring harness secured with cable ties
     
    Air hose between air collector casing and turbocharger inlet pipe
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Bleed the cooling system as follows:
    1. Ensure A/C is off.
    2.  
    3. Fill system to MAX level. Fit pressure cap.
    4.  
    5. Start engine and warm to normal operating temperature, varying engine speeds until cooling fan starts.
    6.  
    7. Switch off engine and top coolant up to MAX, if necessary.
    8.  

  8.  
  9. Check for any leaks.
  10.  

2001-02
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Loosen the expansion tank pressure cap.
  4.  
  5. Raise the car and remove the lower front cover.
  6.  
  7. Drain the coolant.
  8.  
  9. Detach the coolant pipe from the turbocharger.
  10.  
  11. Lower the car.
  12.  
  13. Disconnect the negative battery cable.
  14.  
  15. For the turbocharger, remove or disconnect the following: Air hose between air collector casing and turbocharger intake pipeTie securing main engine harnessesTension from auxiliary drive belt tensionerAuxiliary drive belt from power steering pump and water pump pulleysEngine top coverCrankcase vent pipe from turbocharger inlet pipe and camshaft cover (bend aside)

    Air hose between air collector casing and turbocharger intake pipe
     
    Tie securing main engine harnesses
     
    Tension from auxiliary drive belt tensioner
     
    Auxiliary drive belt from power steering pump and water pump pulleys
     
    Engine top cover
     
    Crankcase vent pipe from turbocharger inlet pipe and camshaft cover (bend aside)
     

  16.  


NOTE
Keep pipe seals and washers in a safe place.



Solenoid valve connector and hoses
 
Engine lifting eye
 
Bypass pipe with valve from turbocharger intake pipe
 
Exhaust manifold heat shield
 
Vent hose from T-connection
 
Turbocharger intake pipe; plug openings in turbocharger
 

  1. Remove the power steering pump bolt on right side behind the belt pulley.
  2.  
  3. Remove the upper power steering pump bolt.
  4.  
  5. Lift up the pump and remove the lower bolt and 2 upper bolts on the bracket.
  6.  
  7. Move the power steering pump and bracket aside and secure with a cable tie.
  8.  
  9. Remove hose clips and detach hoses from water pump inlet.
  10.  
  11. Detach the 2 longitudinal coolant pipes from cylinder block.
  12.  
  13. Disconnect coolant pipes from water pump. Keep the O-rings and move pipes aside.
  14.  
  15. Loosen water pump slightly.
  16.  
  17. Detach the coolant pipe from the water pump. Retain the seals.
  18.  
  19. Remove the 3 water pump bolts.
  20.  
  21. Carefully wiggle the water pump away from its mounting and connecting piece in cylinder block.
  22.  
  23. Remove the connecting piece from the cylinder block.
  24.  

To install:

  1. Clean the sealing surfaces and use a new gasket.
  2.  
  3. Install or connect the following: Connecting piece to cylinder blockCoat seals with sealant Gleitmo 805, 30-06 442.Water pump loosely to mountingCoolant pipe between water pump and turbocharger with new washers and sealsCoolant pipe to water pump to 15 ft. lbs. (20 Nm)2 longitudinal pipes to water pump with new O-rings coated with non-acidic Vaseline3 water pump bolts to 16 ft. lbs. (22 Nm)2 longitudinal pipes to 7 ft. lbs. (10 Nm)Power steering pump and bracket, tightening bolts to 18 ft. lbs. (24 Nm)Hoses and clips on water pump inletTurbocharger inlet pipe, but do not tighten (coat O-ring with non-acidic Vaseline)Engine lifting eyeSolenoid valve and hosesTurbocharger intake pipe V-clampVent hose to T-connectionExhaust manifold heat shieldBypass pipe and valve, with new O-ring, to turbocharger inlet pipeSolenoid valve connectorCrankcase ventilation pipe to turbocharger inlet pipe, with new copper seals, to 18 ft. lbs. (24 Nm)Crankcase vent pipe to camshaft cover clipThrottle body coverCoolant line to turbocharger to 18 ft. lbs. (24 Nm) from under the carAuxiliary drive belt in all pulleysRelease tension from drive belt tensionerMain wiring harness secured with cable tiesAir hose between air collector casing and turbocharger inlet pipe

    Connecting piece to cylinder block
     
    Coat seals with sealant Gleitmo 805, 30-06 442.
     
    Water pump loosely to mounting
     
    Coolant pipe between water pump and turbocharger with new washers and seals
     
    Coolant pipe to water pump to 15 ft. lbs. (20 Nm)
     
    2 longitudinal pipes to water pump with new O-rings coated with non-acidic Vaseline
     
    3 water pump bolts to 16 ft. lbs. (22 Nm)
     
    2 longitudinal pipes to 7 ft. lbs. (10 Nm)
     
    Power steering pump and bracket, tightening bolts to 18 ft. lbs. (24 Nm)
     
    Hoses and clips on water pump inlet
     
    Turbocharger inlet pipe, but do not tighten (coat O-ring with non-acidic Vaseline)
     
    Engine lifting eye
     
    Solenoid valve and hoses
     
    Turbocharger intake pipe V-clamp
     
    Vent hose to T-connection
     
    Exhaust manifold heat shield
     
    Bypass pipe and valve, with new O-ring, to turbocharger inlet pipe
     
    Solenoid valve connector
     
    Crankcase ventilation pipe to turbocharger inlet pipe, with new copper seals, to 18 ft. lbs. (24 Nm)
     
    Crankcase vent pipe to camshaft cover clip
     
    Throttle body cover
     
    Coolant line to turbocharger to 18 ft. lbs. (24 Nm) from under the car
     
    Auxiliary drive belt in all pulleys
     
    Release tension from drive belt tensioner
     
    Main wiring harness secured with cable ties
     
    Air hose between air collector casing and turbocharger inlet pipe
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Bleed the cooling system as follows: Ensure A/C is off.Fill system to MAX level. Fit pressure cap.Start engine and warm to normal operating temperature, varying engine speeds until cooling fan starts.Switch off engine and top coolant up to MAX, if necessary.
    1. Ensure A/C is off.
    2.  
    3. Fill system to MAX level. Fit pressure cap.
    4.  
    5. Start engine and warm to normal operating temperature, varying engine speeds until cooling fan starts.
    6.  
    7. Switch off engine and top coolant up to MAX, if necessary.
    8.  

  8.  
  9. Check for any leaks.
  10.  

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Loosen the expansion tank pressure cap.
  4.  
  5. Raise the car and remove the lower front cover.
  6.  
  7. Drain the coolant.
  8.  
  9. Detach the coolant pipe from the turbocharger.
  10.  
  11. Lower the car.
  12.  
  13. Disconnect the negative battery cable.
  14.  
  15. For the turbocharger, remove or disconnect the following: Air hose between air collector casing and turbocharger intake pipeTie securing main engine harnessesTension from auxiliary drive belt tensionerAuxiliary drive belt from power steering pump and water pump pulleysEngine top coverCrankcase vent pipe from turbocharger inlet pipe and camshaft cover (bend aside)

    Air hose between air collector casing and turbocharger intake pipe
     
    Tie securing main engine harnesses
     
    Tension from auxiliary drive belt tensioner
     
    Auxiliary drive belt from power steering pump and water pump pulleys
     
    Engine top cover
     
    Crankcase vent pipe from turbocharger inlet pipe and camshaft cover (bend aside)
     

  16.  


NOTE
Keep pipe seals and washers in a safe place.



Solenoid valve connector and hoses
 
Engine lifting eye
 
Bypass pipe with valve from turbocharger intake pipe
 
Exhaust manifold heat shield
 
Vent hose from T-connection
 
Turbocharger intake pipe; plug openings in turbocharger
 

  1. Remove the power steering pump bolt on right side behind the belt pulley.
  2.  
  3. Remove the upper power steering pump bolt.
  4.  
  5. Lift up the pump and remove the lower bolt and 2 upper bolts on the bracket.
  6.  
  7. Move the power steering pump and bracket aside and secure with a cable tie.
  8.  
  9. Remove hose clips and detach hoses from water pump inlet.
  10.  
  11. Detach the 2 longitudinal coolant pipes from cylinder block.
  12.  
  13. Disconnect coolant pipes from water pump. Keep the O-rings and move pipes aside.
  14.  
  15. Loosen water pump slightly.
  16.  
  17. Detach the coolant pipe from the water pump. Retain the seals.
  18.  
  19. Remove the 3 water pump bolts.
  20.  
  21. Carefully wiggle the water pump away from its mounting and connecting piece in cylinder block.
  22.  
  23. Remove the connecting piece from the cylinder block.
  24.  

To install:

  1. Clean the sealing surfaces and use a new gasket.
  2.  
  3. Install or connect the following: Connecting piece to cylinder blockCoat seals with sealant Gleitmo 805 30-06 442.Water pump loosely to mountingCoolant pipe between water pump and turbocharger with new washers and sealsCoolant pipe to water pump to 15 ft. lbs. (20 Nm)2 longitudinal pipes to water pump with new O-rings coated with non-acidic Vaseline3 water pump bolts to 16 ft. lbs. (22 Nm)2 longitudinal pipes to 7 ft. lbs. (10 Nm)Power steering pump and bracket, tightening bolts to 18 ft. lbs. (24 Nm)Hoses and clips on water pump inletTurbocharger inlet pipe, but do not tighten (coat O-ring with non-acidic Vaseline)Engine lifting eyeSolenoid valve and hosesTurbocharger intake pipe V-clampVent hose to T-connectionExhaust manifold heat shieldBypass pipe and valve, with new O-ring, to turbocharger inlet pipeSolenoid valve connectorCrankcase ventilation pipe to turbocharger inlet pipe, with new copper seals, to 18 ft. lbs. (24 Nm)Crankcase vent pipe to camshaft cover clipThrottle body coverCoolant line to turbocharger to 18 ft. lbs. (24 Nm) from under the carAuxiliary drive belt in all pulleysRelease tension from drive belt tensionerMain wiring harness secured with cable tiesAir hose between air collector casing and turbocharger inlet pipe

    Connecting piece to cylinder block
     
    Coat seals with sealant Gleitmo 805 30-06 442.
     
    Water pump loosely to mounting
     
    Coolant pipe between water pump and turbocharger with new washers and seals
     
    Coolant pipe to water pump to 15 ft. lbs. (20 Nm)
     
    2 longitudinal pipes to water pump with new O-rings coated with non-acidic Vaseline
     
    3 water pump bolts to 16 ft. lbs. (22 Nm)
     
    2 longitudinal pipes to 7 ft. lbs. (10 Nm)
     
    Power steering pump and bracket, tightening bolts to 18 ft. lbs. (24 Nm)
     
    Hoses and clips on water pump inlet
     
    Turbocharger inlet pipe, but do not tighten (coat O-ring with non-acidic Vaseline)
     
    Engine lifting eye
     
    Solenoid valve and hoses
     
    Turbocharger intake pipe V-clamp
     
    Vent hose to T-connection
     
    Exhaust manifold heat shield
     
    Bypass pipe and valve, with new O-ring, to turbocharger inlet pipe
     
    Solenoid valve connector
     
    Crankcase ventilation pipe to turbocharger inlet pipe, with new copper seals, to 18 ft. lbs. (24 Nm)
     
    Crankcase vent pipe to camshaft cover clip
     
    Throttle body cover
     
    Coolant line to turbocharger to 18 ft. lbs. (24 Nm) from under the car
     
    Auxiliary drive belt in all pulleys
     
    Release tension from drive belt tensioner
     
    Main wiring harness secured with cable ties
     
    Air hose between air collector casing and turbocharger inlet pipe
     

  4.  
  5. Refill the cooling system.
  6.  
  7. Bleed the cooling system as follows: Ensure A/C is off.Fill system to MAX level. Fit pressure cap.Start engine and warm to normal operating temperature, varying engine speeds until cooling fan starts.Switch off engine and top coolant up to MAX, if necessary.
    1. Ensure A/C is off.
    2.  
    3. Fill system to MAX level. Fit pressure cap.
    4.  
    5. Start engine and warm to normal operating temperature, varying engine speeds until cooling fan starts.
    6.  
    7. Switch off engine and top coolant up to MAX, if necessary.
    8.  

  8.  
  9. Check for any leaks.
  10.  

2003-04
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Loosen the expansion tank pressure cap.
  4.  
  5. Remove or disconnect the following: Connector for oxygen sensors and temperature sensorConnector from MAF sensorCover on air cleaner housingAir filterAir cleaner housing

    Connector for oxygen sensors and temperature sensor
     
    Connector from MAF sensor
     
    Cover on air cleaner housing
     
    Air filter
     
    Air cleaner housing
     

  6.  


CAUTION
Use caution when removing air cleaner housing to ensure A/C pressure sensor is not damaged.



Turbocharger inlet hose (plug turbocharger opening)
 
Upper bolt for water pump in timing cover and engine block
 
Turbocharger heat shield
 
Upper oxygen sensor
 
Catalytic converter-to-turbocharger nuts
 
Turbocharger oil delivery pipe bolt
 

  1. Raise the car and remove the right front wheel.
  2.  
  3. Remove the front spoiler shield.
  4.  
  5. Remove the right fender well liner.
  6.  
  7. Drain the cooling system.
  8.  
  9. Remove the lower water pump bolt in the timing cover and engine block.
  10.  
  11. Remove plug from water pump and drain coolant.
  12.  
  13. Mark direction of rotation of the auxiliary drive belt.
  14.  
  15. Relieve belt tension and remove the belt.
  16.  
  17. Remove or disconnect the following: Turbocharger lower pressure pipeFront exhaust pipeSteering gear heat shieldCatalytic converter heat shieldTemperature sensorLower oxygen sensorCatalytic converter and bracket from engine blockTurbocharger coolant pipe from thermostat housing and turbochargerThermostat housing bolts

    Turbocharger lower pressure pipe
     
    Front exhaust pipe
     
    Steering gear heat shield
     
    Catalytic converter heat shield
     
    Temperature sensor
     
    Lower oxygen sensor
     
    Catalytic converter and bracket from engine block
     
    Turbocharger coolant pipe from thermostat housing and turbocharger
     
    Thermostat housing bolts
     

  18.  
  19. Remove the water pump cover from the timing cover (34).
  20.  
  21. Install water pump holder tool, B207, to secure the balancer shaft pinion (35).
  22.  
  23. Remove the pinion bolts (36). Use a magnetic socket to remove the bolts from the holder tool.
  24.  
  25. Remove the bolts on the back of the water pump.
  26.  
  27. Move aside the thermostat housing, with the pipe, and remove the water pump.
  28.  
  29. Remove the water pipe from the thermostat housing.
  30.  


    Click image to see an enlarged view

    Fig. Showing water pump holding tool for securing balancer shaft pinion-2.0L and 2.3L engines


To install:

  1. Clean water pipe fittings. Install new O-rings, lightly coated with Vaseline.
  2.  
  3. Clean the thermostat housing connections, fit a new seal and install the water pipe.
  4.  
  5. Install the stud to the water pump driver using a holding tool, 83 96 103.
  6.  
  7. Install the water pump, with a new seal coated lightly with Vaseline. Guide the stud through one of the holes in the balancer shaft pinion.
  8.  
  9. Install the 2 rear water pump bolts and the lower bolt through the timing cover.
  10.  
  11. Lower the car.
  12.  
  13. Torque the water pump bolts to 15 ft. lbs. (20 Nm) for short bolts and 18 ft. lbs. (25 Nm) for the long bolts.
  14.  
  15. Install the coolant pipe to the water pump and install the thermostat.
  16.  
  17. Fit the coolant pipe between the turbocharger and thermostat with a new seal. Tighten pipe to 15 ft. lbs. (20 Nm).
  18.  
  19. Lift catalytic converter and position its bracket to studs on the engine block. Position the catalytic converter to the turbocharger connection.
  20.  
  21. Insert the catalytic converter bracket bolts into the engine block and new nuts on the studs.
  22.  
  23. Lower the car. Lubricate the turbocharger studs with screw thread paste 30 20 971.
  24.  
  25. Install the new nuts so they are firmly against the turbocharger, then torque to 7 ft. lbs. (10 Nm).
  26.  
  27. Raise the car.
  28.  
  29. Tighten the catalytic converter nut and bolts one last time to 19 ft. lbs. (25 Nm).
  30.  
  31. Lubricate the lower oxygen sensor threads with screw thread paste and install the sensor and tighten to 30 ft. lbs. (40 Nm).
  32.  


CAUTION
Be sure oxygen sensor cables are not twisted or damaged.

  1. Lubricate the temperature sensor threads with screw thread paste and install the sensor and tighten to 33 ft. lbs. (45 Nm).
  2.  
  3. Lift the oxygen sensor and temperature sensor cables to check for proper routing.
  4.  
  5. Install the heat shields on the catalytic converter and steering gear.
  6.  
  7. Clean the catalytic converter joint at pipe connection with front muffler. Install clamp and position front pipe, with new gasket, mounting nuts and rubber mountings. Apply thread paste to studs.
  8.  
  9. Position joint clamp so pipe ends are in middle of the clamp. Torque joint at catalytic converter to 19 ft. lbs. (25 Nm) and clamp nuts to 30 ft. lbs. (40 Nm).
  10.  
  11. Remove the stud and install bolts to the balancer shaft pinion, using a 10mm magnetic socket.
  12.  


NOTE
It may be necessary to remove the fixing tool for access before finally tightening the bolts.

  1. Install the timing cover with a new gasket.
  2.  
  3. Install the auxiliary drive belt over the pulleys, making sure it is in proper direction of rotation.
  4.  
  5. Install the lower turbocharger delivery pipe.
  6.  
  7. Close the radiator drain and lower the car.
  8.  
  9. Apply thread paste and install upper oxygen sensor. Tighten it to 30 ft. lbs. (40 Nm).
  10.  
  11. Plug in and secure the oxygen sensor and temperature sensor connectors.
  12.  
  13. Install the turbocharger heat shield. Tighten bolts to 15 ft. lbs. (20 Nm).
  14.  
  15. Install the air cleaner assembly and hoses, including to the turbocharger.
  16.  
  17. Plug in the MAF sensor.
  18.  
  19. Fill cooling system and bleed system by starting and running the engine at varying speeds until the cooling fan comes on. Then, check and top off the coolant.
  20.  
  21. Install remaining components and check for any signs of leaks.
  22.  

2003-06 Model (Except 2.8L Engine)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Loosen the expansion tank pressure cap.
  4.  
  5. Remove or disconnect the following:
    CAUTION
    Use caution when removing air cleaner housing to ensure A/C pressure sensor is not damaged.



    Connector for oxygen sensors and temperature sensor
     
    Connector from MAF sensor
     
    Cover on air cleaner housing
     
    Air filter
     
    Air cleaner housing
     



    Turbocharger inlet hose (plug turbocharger opening)
     
    Upper bolt for water pump in timing cover and engine block
     
    Turbocharger heat shield
     
    Upper oxygen sensor
     
    Catalytic converter-to-turbocharger nuts
     
    Turbocharger oil delivery pipe bolt
     

  6.  
  7. Raise the car and remove the right front wheel.
  8.  
  9. Remove the front spoiler shield.
  10.  
  11. Remove the right fender well liner.
  12.  
  13. Drain the cooling system.
  14.  
  15. Remove the lower water pump bolt in the timing cover and engine block.
  16.  
  17. Remove plug from water pump and drain coolant.
  18.  
  19. Mark direction of rotation of the auxiliary drive belt.
  20.  
  21. Relieve belt tension and remove the belt.
  22.  
  23. Remove or disconnect the following:

    Turbocharger lower pressure pipe
     
    Front exhaust pipe
     
    Steering gear heat shield
     
    Catalytic converter heat shield
     
    Temperature sensor
     
    Lower oxygen sensor
     
    Catalytic converter and bracket from engine block
     
    Turbocharger coolant pipe from thermostat housing and turbocharger
     
    Thermostat housing bolts
     

  24.  
  25. Remove the water pump cover from the timing cover (34).
  26.  
  27. Install water pump holder tool, B207, to secure the balancer shaft pinion (35).
  28.  
  29. Remove the pinion bolts (36). Use a magnetic socket to remove the bolts from the holder tool.
  30.  
  31. Remove the bolts on the back of the water pump.
  32.  
  33. Move aside the thermostat housing, with the pipe, and remove the water pump.
  34.  
  35. Remove the water pipe from the thermostat housing.

    Click image to see an enlarged view

    Fig. Showing water pump holding tool for securing balancer shaft pinion-2.0L and 2.3L engines

  36.  

To install:

  1. Clean water pipe fittings. Install new O-rings, lightly coated with Vaseline.
  2.  
  3. Clean the thermostat housing connections, fit a new seal and install the water pipe.
  4.  
  5. Install the stud to the water pump driver using a holding tool, 83 96 103.
  6.  
  7. Install the water pump, with a new seal coated lightly with Vaseline. Guide the stud through one of the holes in the balancer shaft pinion.
  8.  
  9. Install the 2 rear water pump bolts and the lower bolt through the timing cover.
  10.  
  11. Lower the car.
  12.  
  13. Torque the water pump bolts to 15 ft. lbs. (20 Nm) for short bolts and 18 ft. lbs. (25 Nm) for the long bolts.
  14.  
  15. Install the coolant pipe to the water pump and install the thermostat.
  16.  
  17. Fit the coolant pipe between the turbocharger and thermostat with a new seal. Tighten pipe to 15 ft. lbs. (20 Nm).
  18.  
  19. Lift catalytic converter and position its bracket to studs on the engine block. Position the catalytic converter to the turbocharger connection.
  20.  
  21. Insert the catalytic converter bracket bolts into the engine block and new nuts on the studs.
  22.  
  23. Lower the car. Lubricate the turbocharger studs with screw thread paste 30 20 971.
  24.  
  25. Install the new nuts so they are firmly against the turbocharger, then torque to 7 ft. lbs. (10 Nm).
  26.  
  27. Raise the car.
  28.  
  29. Tighten the catalytic converter nut and bolts one last time to 19 ft. lbs. (25 Nm).
  30.  
  31. Lubricate the lower oxygen sensor threads with screw thread paste and install the sensor and tighten to 30 ft. lbs. (40 Nm).
    CAUTION
    Be sure oxygen sensor cables are not twisted or damaged.

  32.  
  33. Lubricate the temperature sensor threads with screw thread paste and install the sensor and tighten to 33 ft. lbs. (45 Nm).
  34.  
  35. Lift the oxygen sensor and temperature sensor cables to check for proper routing.
  36.  
  37. Install the heat shields on the catalytic converter and steering gear.
  38.  
  39. Clean the catalytic converter joint at pipe connection with front muffler. Install clamp and position front pipe, with new gasket, mounting nuts and rubber mountings. Apply thread paste to studs.
  40.  
  41. Position joint clamp so pipe ends are in middle of the clamp. Torque joint at catalytic converter to 19 ft. lbs. (25 Nm) and clamp nuts to 30 ft. lbs. (40 Nm).
  42.  
  43. Remove the stud and install bolts to the balancer shaft pinion, using a 10mm magnetic socket.
    NOTE
    It may be necessary to remove the fixing tool for access before finally tightening the bolts.

  44.  
  45. Install the timing cover with a new gasket.
  46.  
  47. Install the auxiliary drive belt over the pulleys, making sure it is in proper direction of rotation.
  48.  
  49. Install the lower turbocharger delivery pipe.
  50.  
  51. Close the radiator drain and lower the car.
  52.  
  53. Apply thread paste and install upper oxygen sensor. Tighten it to 30 ft. lbs. (40 Nm).
  54.  
  55. Plug in and secure the oxygen sensor and temperature sensor connectors.
  56.  
  57. Install the turbocharger heat shield. Tighten bolts to 15 ft. lbs. (20 Nm).
  58.  
  59. Install the air cleaner assembly and hoses, including to the turbocharger.
  60.  
  61. Plug in the MAF sensor.
  62.  
  63. Fill cooling system and bleed system by starting and running the engine at varying speeds until the cooling fan comes on. Then, check and top off the coolant.
  64.  
  65. Install remaining components and check for any signs of leaks.
  66.  

9-5



2.3L Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Open cap of expansion tank and release any pressure.
  4.  
  5. Raise the car and remove the lower front cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Lower the car and remove or disconnect the following: Negative battery cableMass Air Flow (MAF) sensor electrical connectorMAF sensor and air hoseV-belt tension with tool 83 95 254V-belt from the power steering pump and water pumpCrankcase breather pipeCamshaft coverBoost pressure control valve connectorEngine lifting eyeTurbocharger wastegate valve hoses, loosen onlyBypass valve and pipeExhaust manifold heat shieldQuick release coupling on the vent hose with tool 83 9-5 261Turbocharger intake pipe (plug turbocharger opening)Power steering pump and move it asideWater pump inlet hoses2 longitudinal coolant pipes from the engine block and water pumpWater pump and connecting piece

    Negative battery cable
     
    Mass Air Flow (MAF) sensor electrical connector
     
    MAF sensor and air hose
     
    V-belt tension with tool 83 95 254
     
    V-belt from the power steering pump and water pump
     
    Crankcase breather pipe
     
    Camshaft cover
     
    Boost pressure control valve connector
     
    Engine lifting eye
     
    Turbocharger wastegate valve hoses, loosen only
     
    Bypass valve and pipe
     
    Exhaust manifold heat shield
     
    Quick release coupling on the vent hose with tool 83 9-5 261
     
    Turbocharger intake pipe (plug turbocharger opening)
     
    Power steering pump and move it aside
     
    Water pump inlet hoses
     
    2 longitudinal coolant pipes from the engine block and water pump
     
    Water pump and connecting piece
     

  10.  


    Click image to see an enlarged view

    Fig. Remove the water pump and engine block connecting piece


To install:

  1. Clean all mating surfaces and connecting piece seals. Replace the seals if necessary
  2.  
  3. Install or connect the following: Connecting piece to the engine blockWater pump and torque the bolts to 16 ft. lbs. (22 Nm)Coolant pipe to the water pump and turbocharger. Torque the water pump bolt to 15 ft. lbs. (20 Nm) and the turbocharger bolt to 18 ft. lbs. (24 Nm)Longitudinal pipes to the water pump and torque the bolts to 7 ft. lbs. (10 Nm)Water pump inlet hosesPower steering pump and torque the bolts to 18 ft. lbs. (24 Nm)Turbocharger intake pipeTurbocharger vent hoseExhaust manifold heat shield and torque the bolts to 15 ft. lbs. (20 Nm)Bypass pipe and valve and torque the bolts to 6 ft. lbs. (8 Nm)Turbocharger wastegate valve hosesEngine lifting eyeBoost pressure control valve connectorCrankcase breather pipe fastened to turbocharger inlet pipe and camshaft cover, torque to 18 ft. lbs. (24 Nm)V-beltMAF sensor and air hoseNegative battery cable

    Connecting piece to the engine block
     
    Water pump and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Coolant pipe to the water pump and turbocharger. Torque the water pump bolt to 15 ft. lbs. (20 Nm) and the turbocharger bolt to 18 ft. lbs. (24 Nm)
     
    Longitudinal pipes to the water pump and torque the bolts to 7 ft. lbs. (10 Nm)
     
    Water pump inlet hoses
     
    Power steering pump and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Turbocharger intake pipe
     
    Turbocharger vent hose
     
    Exhaust manifold heat shield and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Bypass pipe and valve and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Turbocharger wastegate valve hoses
     
    Engine lifting eye
     
    Boost pressure control valve connector
     
    Crankcase breather pipe fastened to turbocharger inlet pipe and camshaft cover, torque to 18 ft. lbs. (24 Nm)
     
    V-belt
     
    MAF sensor and air hose
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  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. Open cap of expansion tank and release any pressure.
  4.  
  5. Raise the car and remove the lower front cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Lower the car and remove or disconnect the following:

    Negative battery cable
     
    Mass Air Flow (MAF) sensor electrical connector
     
    MAF sensor and air hose
     
    V-belt tension with tool 83 95 254
     
    V-belt from the power steering pump and water pump
     
    Crankcase breather pipe
     
    Camshaft cover
     
    Boost pressure control valve connector
     
    Engine lifting eye
     
    Turbocharger wastegate valve hoses, loosen only
     
    Bypass valve and pipe
     
    Exhaust manifold heat shield
     
    Quick release coupling on the vent hose with tool 83 95 261
     
    Turbocharger intake pipe (plug turbocharger opening)
     
    Power steering pump and move it aside
     
    Water pump inlet hoses
     
    2 longitudinal coolant pipes from the engine block and water pump
     
    Water pump and connecting piece

    Click image to see an enlarged view

    Fig. Remove the water pump and engine block connecting piece

     

  10.  

To install:

  1. Clean all mating surfaces and connecting piece seals. Replace the seals if necessary
  2.  
  3. Install or connect the following:

    Connecting piece to the engine block
     
    Water pump and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Coolant pipe to the water pump and turbocharger. Torque the water pump bolt to 15 ft. lbs. (20 Nm) and the turbocharger bolt to 18 ft. lbs. (24 Nm)
     
    Longitudinal pipes to the water pump and torque the bolts to 7 ft. lbs. (10 Nm)
     
    Water pump inlet hoses
     
    Power steering pump and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Turbocharger intake pipe
     
    Turbocharger vent hose
     
    Exhaust manifold heat shield and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Bypass pipe and valve and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Turbocharger wastegate valve hoses
     
    Engine lifting eye
     
    Boost pressure control valve connector
     
    Crankcase breather pipe fastened to turbocharger inlet pipe and camshaft cover, torque to 18 ft. lbs. (24 Nm)
     
    V-belt
     
    MAF sensor and air hose
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Open cap on expansion tank and drain off any pressure.
  4.  
  5. Raise the car and remove the lower front cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Lower the car and remove or disconnect the following: Negative battery cableLower front cover and raise the engine until the right front mount is unloadedMass Air Flow (MAF) sensor and hosePower steering hose from the holderRight side engine mount and bracketWater pump and power steering pump pulley bolts and loosen the V-beltWater pump and power steering pump pulleysBelt tensionerTiming coverWater pump

    Negative battery cable
     
    Lower front cover and raise the engine until the right front mount is unloaded
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Water pump and power steering pump pulley bolts and loosen the V-belt
     
    Water pump and power steering pump pulleys
     
    Belt tensioner
     
    Timing cover
     
    Water pump
     

  10.  

To install:

  1. Clean all mating surfaces.
  2.  
  3. Install or connect the following: Water pump with a new O-ring and torque the bolts to 18 ft. lbs. (24 Nm)Timing coverBelt tensioner and torque the bolts to 30 ft. lbs. (40 Nm)Water pump and power steering pump pulleys. Do not tighten the boltsV-belt and torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm)Right side engine mount and bracketPower steering hose to the holderMAF sensorLower front coverNegative battery cable

    Water pump with a new O-ring and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Timing cover
     
    Belt tensioner and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Water pump and power steering pump pulleys. Do not tighten the bolts
     
    V-belt and torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket
     
    Power steering hose to the holder
     
    MAF sensor
     
    Lower front cover
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle, run at varying speeds until cooling fan comes on. Top up the coolant. Let the engine run until the cooling fan comes on 3 more times.
  8.  
  9. Stop the engine and top up the coolant.
  10.  
  11. Check for leaks and repair if necessary.
  12.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Open cap on expansion tank and drain off any pressure.
  4.  
  5. Raise the car and remove the lower front cover.
  6.  
  7. Drain the cooling system.
  8.  
  9. Lower the car and remove or disconnect the following:

    Negative battery cable
     
    Lower front cover and raise the engine until the right front mount is unloaded
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Water pump and power steering pump pulley bolts and loosen the V-belt
     
    Water pump and power steering pump pulleys
     
    Belt tensioner
     
    Timing cover
     
    Water pump
     

  10.  

To install:

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

    Water pump with a new O-ring and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Timing cover
     
    Belt tensioner and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Water pump and power steering pump pulleys. Do not tighten the bolts
     
    V-belt and torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket
     
    Power steering hose to the holder
     
    MAF sensor
     
    Lower front cover
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle, run at varying speeds until cooling fan comes on. Top up the coolant. Let the engine run until the cooling fan comes on 3 more times.
  8.  
  9. Stop the engine and top up the coolant.
  10.  
  11. Check for leaks and repair if necessary.
  12.  

9-5 Models



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

    Negative battery cable
     
    Front lower cover
     
    Mass Air Flow (MAF) sensor electrical connector
     
    MAF sensor and air hose
     
    V-belt tension with Tool 83-95-254
     
    V-belt from the power steering pump and water pump
     
    Crankcase breather pipe
     
    Camshaft cover
     
    Boost pressure control valve connector
     
    Engine lifting eye
     
    Turbocharger wastegate valve hoses, loosen only
     
    Bypass valve and pipe
     
    Exhaust manifold heat shield
     
    Quick release coupling on the vent hose with Tool 83-95-261
     
    Turbocharger intake pipe
     
    Power steering pump and move it aside
     
    Water pump inlet hoses
     
    2 longitudinal coolant pipes from the engine block and water pump
     
    Water pump and connecting piece

    Click image to see an enlarged view

    Fig. Remove the water pump and engine block connecting piece-2.3L Engine

     

  6.  

To install:

  1. Clean all mating surfaces and connecting piece seals. Replace the seals if necessary.
  2.  
  3. Install or connect the following:

    Connecting piece to the engine block
     
    Water pump and torque the bolts to 16 ft. lbs. (22 Nm)
     
    Coolant pipe to the water pump and turbocharger. Torque the water pump bolt to 15 ft. lbs. (20 Nm) and the turbocharger bolt to 18 ft. lbs. (24 Nm).
     
    Longitudinal pipes to the water pump and torque the bolts to 89 inch lbs. (10 Nm)
     
    Water pump inlet hoses
     
    Power steering pump and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Turbocharger intake pipe
     
    Turbocharger vent hose
     
    Exhaust manifold heat shield and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Bypass pipe and valve and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Turbocharger wastegate valve hoses
     
    Engine lifting eye
     
    Boost pressure control valve connector
     
    Crankcase breather pipe and camshaft cover and torque the pipe to 18 ft. lbs. (24 Nm)
     
    V-belt
     
    MAF sensor and air hose
     
    Front lower cover
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

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

    Negative battery cable
     
    Lower front cover and raise the engine until the right front mount is unloaded
     
    Mass Air Flow (MAF) sensor and hose
     
    Power steering hose from the holder
     
    Right side engine mount and bracket
     
    Water pump and power steering pump pulley bolts and loosen the V-belt
     
    Water pump and power steering pump pulleys
     
    Belt tensioner
     
    Timing cover
     
    Water pump bolts and pump
     

  6.  

To install:

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

    Water pump with a new O-ring and torque the bolts to 18 ft. lbs. (24 Nm)
     
    Timing cover
     
    Belt tensioner and torque the bolts to 30 ft. lbs. (40 Nm)
     
    Water pump and power steering pump pulleys. Do not tighten the bolts
     
    V-belt and torque the water pump pulley bolts to 6 ft. lbs. (8 Nm) and the power steering pump pulley bolts to 15 ft. lbs. (20 Nm)
     
    Right side engine mount and bracket
     
    Power steering hose to the holder
     
    MAF sensor
     
    Lower front cover
     
    Negative battery cable
     

  4.  
  5. Fill the cooling system.
  6.  
  7. Start the vehicle, check for leaks and repair if necessary.
  8.  

 
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