SAAB WIS ONLINE

Camshaft

Camshaft

(In car)

To remove



1. Place the car on a lift, put covers over the wings and detach the negative cable from the battery.

2. Remove the air cleaner with mass air flow sensor and hoses from the turbocharger and camshaft cover.

3. Remove the engine cover.

4. Remove the turbo delivery pipe (2 bolts under the wiring harness) and seal the hoses.


5. Remove both the wiring harness channels from the cylinder head, cut the securing points and detach the fuel line holder from the camshaft cover.

6. Separate the fuel hoses with tool 83 95 261 and seal them.

7. Remove the camshaft cover.

8. Detach the vacuum hose to the brake servo and the vacuum hose connected to the bottom of the vacuum pump.


9. Remove the four vacuum pump retaining bolts and carefully lift away the vacuum pump and its adapter.

Important

Note the position of the vacuum pump.


10. Remove the rear nut from the front exhaust pipe connection to the turbocharger.

11. Raise the car and remove the lower engine cover, the right-hand air shield, the cover in the right-hand wheel housing and the front right wheel.


12. Turn the crankshaft with the centre bolt on the pulley two revolutions until it reaches the mark for top dead centre in cylinder 1. Make sure both cams for cylinder 1 are point up.


13. Remove the crankshaft position sensor with O-ring and position inspection gauge 83 95 352 in the hole. Press the tool slightly inwards while turning the crankshaft to the zero mark. The tool will then fit into a recess in the crankshaft and lock it.

14. Relieve the tension on the belt tensioner by turning it anticlockwise (towards the rear of the car) with a 19 mm spanner and lift off the belt.


15. Remove the belt tensioner.

16. Remove the front part of the exhaust pipe and lower the car.


17. Place a jack with a wood block under the oil sump, raise the engine until the strain is off the right-hand engine mounting and dismantle the right-hand engine mounting.


18. Remove the engine anchorage (the lower bolt need not be removed completely) and refit the rear bolt. Undo the nut on the rear engine mounting.

19. Place lifting beam 83 94 850 on the front wings, hook on the extension hook from holder 83 95 287 and lift the engine.


Important

Make sure nothing is damaged when the engine is moved.


20. Remove the bolts on the cover, carefully insert a spatula behind the cover and prise it off.


Important

Take care, otherwise the cover can be distorted, which result in leaks.


21. Make sure the marks on the crankshaft pulley and the timing cover are aligned. Also, the arrow on the single cam chain sprocket on the fuel distribution pump must be aligned with the recess in the pump. Position inspection gauge 83 95 337 inside the hole.

22. Remove all the inspection gauges.

23. Dismantle the upper timing chain tensioner.


24. Fasten the camshaft chain to the gear.


25. Dismantle the camshaft gear using an open spanner in the hexagonal recess on the camshaft as a backstop.

26. Carefully place the chain on one side.

27. Undo the camshaft bearing cap bolts in stages, 0.5-1 turn in a spiral formation starting with cap number 1.

Important

Camshaft bearing cap markings.


28. Lift off the camshaft bearing caps and remove the camshaft.

Important

The camshaft must be detached evenly from the bearing seats.


29. If the camshaft is to be changed, the valve bridges must also be replaced.

Important

Note how the valve bridges are fitted. The markings are on the side of the valve bridges facing the fuel bridges.



To fit



1. Clean off any gasket remains from the sealing surfaces.

2. Check the camshaft and bearing seats for signs of wear and replace as necessary.

3. If the camshaft has been changed, the valve bridges must also be replaced.

Important

Note how the valve bridges are fitted. The markings are on the side of the valve bridges facing the fuel bridges.


4. Apply sealing compound 87 81 841 on the 5th camshaft bearing cap sealing surfaces, see illustration.

5. Lubricate the sliding surfaces on the camshaft and valve bridges.

6. Position the camshaft with both cams for cylinder 1 pointing up and lay the camshaft bearing caps in their respective positions.


7. Tighten the camshaft bearing cap bolts in stages, 0.5-1 turn in a spiral formation starting with cap number 3.

Tightening torque: 20 Nm (15 lbf ft).

8. Lift up the timing chain and position the camshaft gear so that it runs freely on the camshaft, and fit it with a new bolt. Tighten by hand.


9. Position inspection gauge 83 95 352 in the hole for the crankshaft position sensor.

10. Position inspection gauge 83 95 337 in the recess in the fuel distribution pump.

11. Position inspection gauge 83 95 386 on the camshaft and the cylinder head.

12. Fit the adapter for the timing chain adjuster 83 95 394 on the camshaft gear and the timing chain adjuster on the cylinder head.


13. Secure the position of the adapter on the camshaft gear by turning it slightly anticlockwise with a ratchet handle. Tighten the adjuster screw on the tool.

Important

Inspection gauge 83 95 337 must be easy to remove and fit the whole time. If this is not the case, the tool's adjuster screw can be loosened slightly.


14. Tighten the bolt for the camshaft gear using an open spanner as backstop in the hexagonal recess on the camshaft.

Tightening torque: 90 Nm (66.5 lbf ft) + 60°.

15. Fit the chain tensioner for the upper timing chain with a new gasket.

Tightening torque: 60 Nm (44 lbf ft).

16. Remove all tools and gauges.

17. Turn the crankshaft with the centre bolt on the pulley two revolutions until it reaches the mark for top dead centre in cylinder 1. Make sure both cams for cylinder 1 are point up.


18. Position inspection gauge 83 95 352 in the hole for the crankshaft position sensor. Press the tool inwards slightly while rotating the crankshaft to the zero mark. The tool will then fit into a recess in the crankshaft and lock it.

19. Make sure the marks on the crankshaft pulley and the timing cover are aligned. The arrow on the single cam chain sprocket on the fuel distribution pump must also be aligned with the recess in the pump.

20. Position inspection gauge 83 95 337 in the recess in the fuel distribution pump.

21. Position inspection gauge 83 95 386 to the camshaft and cylinder head. If the gauge does not fit, the engine valve timing must be adjusted. See .

22. Remove all the inspection gauges.

23. Cover the opening in the timing cover with a lint-free cloth and remove any remains from the old gasket from the sealing surface. Clean also the sealing surface on the cap.

24. Apply a string of sealing compound 87 81 841 about 2 mm thick on the cap, remove the cloth from the timing cover and fit the cap.

Tightening torque: 6 Nm (4.5 lbf ft).

25. Place a jack with wood block under the oil sump. Lift the engine and remove the lifting beam.

26. Fit the right-hand engine mounting bracket on the engine.


Tightening torque: 47 Nm (35 lbf ft).

27. Lower the engine and tighten the right-hand engine mounting.

Tightening torque: 47 Nm (35 lbf ft).

28. Tighten the nut on the rear engine mounting.


Tightening torque: 47 Nm (35 lbf ft).

29. Put back the wiring harness and fuel pipe mounting on the engine mounting bracket.

30. Apply Molycote 1000 on the turbocharger studs.

31. Raise the car and fit the crankshaft position sensor with a new O-ring.

Tightening torque: 8 Nm (6 lbf ft).

32. Position the front part of the exhaust pipe with a new gasket and fit new nuts.


Tighten the front exhaust pipe to the turbocharger.

Tightening torque: 25 Nm (18.5 lbf ft).

33. Tighten the front exhaust pipe to the middle exhaust pipe.

Tightening torque: 30 Nm (22 lbf ft).

34. Fit the belt tensioner, tightening the top bolt first.


Tightening torque: 42 Nm (31 lbf ft).

Tighten the bottom bolt.

Tightening torque: 23 Nm (17 lbf ft).

35. Fit the multigroove V-belt on all the pulleys. Relieve the tension on the belt tensioner by turning it anticlockwise (towards the rear of the car) with a 19 mm spanner and fit the belt on its pulley. Make sure the belt is positioned correctly on all the pulleys.

36. Refit the lower engine cover and the wheel.


Tightening torque, wheel 110 Nm (81 lbf ft).

Lower the car to the floor.

37. Tighten the remaining nuts on the front exhaust pipe and turbocharger.


Tightening torque: 25 Nm (18.5 lbf ft).

38. Fit a new gasket on the vacuum pump and fit the pump together with the adapter.

Important

The vacuum pump must be fitted in the same position as it was previously.


Tightening torque: 8 Nm (6 lbf ft).

39. Connect the vacuum hose for the brake servo to the vacuum pump.

Tightening torque: 18 Nm (13 lbf ft).

Connect the hose on the bottom of the vacuum pump.

40. Clean any gasket remains from the sealing surfaces on the camshaft cover.


41. Position a new gasket on the camshaft cover. There are sleeves on the bolts on which the gasket fits.

42. Apply sealing compound 87 81 841 to the sealing surface, see illustration.

43. Position the transmission cover on the cylinder head and tighten the bolts.

Tightening torque: 8 Nm (6 lbf ft).

44. Press the fuel lines into their fastenings on the cylinder head and fit the wiring harness channel to the cylinder head.


45. Refit the turbo delivery pipe.

46. Refit the air cleaner with mass air flow sensor and hoses.


47. Connect the crankcase ventilation hose to the camshaft cover.

48. Connect the fuel lines.

49. Connect the negative cable to the battery.


50. Restore the engine bay to its original condition.

51. Refit the engine cover.

52. Adjust the clock in the car and press 5 times on the remote control lock/unlock button.