(210-2230) Faulty camshaft gear 9-3
Symptom: The faulty camshaft gears may cause engine breakdown.
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MODIFICATION INSTRUCTION
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Bulletin Nbr:
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210-2230
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Date:
...........
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mars 2000
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Market:
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all
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Customer satisfaction campaign 107 21
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Cars in stock must be remedied before delivery.
A personal communication must be sent to the owners of cars already delivered requesting them to get in touch with the nearest Saab garage as soon as possible to have the fault rectified.
Saab 9-3 M00 4-cyl petrol with VIN
Y2030053 - Y2034207
Y7010845 - Y7012022
Y3055761 - Y3060850
A material fault has occurred in a limited number of camshaft gears. They have been fitted to cars within the VIN intervals given above. The service life of the camshaft gears concerned is considerably impaired and they must therefore be changed.
Symptom description
The faulty camshaft gears may cause engine breakdown.
91 15 205 Camshaft gear (2x)
Before taking any action, check box C2 on the modification identity plate. Proceed as follows if the box has not been marked
9-3 with engine variant B204i/E
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1.
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Fit wing protectors and undo the negative battery cable. Ensure the radio code is available where applicable.
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2.
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Remove the engine cover or, alternatively, the resonator.
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3.
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Detach the crankcase ventilation pipe and any cables for the solenoid valve and move them aside.
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4.
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Remove the dipstick holder.
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5.
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Remove the cover, ignition cables and distributor cap (B204i) or ignition discharge module (B204E).
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6.
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Remove the camshaft cover.
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7.
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Raise the car and remove the belt circuit cover.
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8.
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Turn the belt pulley so the sprocket setting marks are pointing straight up.
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9.
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Mark the chain according to the sprocket setting marks. Use a felt tip pen or similar.
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10.
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Remove the chain tensioner.
Start by removing the plug, pin and spring. Then use a 27 mm socket to undo the chain tensioner.
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11.
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Change the camshaft gear on the exhaust side. Do the same with the camshaft gear on the intake side. Restrain the camshaft with a spanner on the rear edge.
Tightening torque 63 Nm (47 lbf ft)
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12.
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Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.
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13.
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Fit the chain tensioner with a 27 mm socket.
Tightening torque 63 Nm (47 lbf ft)
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14.
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Fit the chain tensioner plug with push rod and spring
Tightening torque 22 Nm (16 lbf ft)
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15.
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Make sure the chain is lying with the markings towards the sprocket setting marks.
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16.
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Clean the sealing surface of the camshaft cover with benzine.
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17.
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Fit the cover starting at the recess. Tighten the bolt at the front on the timing gear end and then tighten all the inner and outer bolts as shown in the illustration.
Tightening torque 15 Nm (11 lbf ft)
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18.
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Apply Krytox, part no. 30 19 312, to the rubber seal on the ignition discharge module and fit the ignition discharge module (B204E) or fit the ignition cables and then the cover (B204i).
Tightening torque ignition discharge module: 11 Nm (8 lbf ft)
Cover: 4 Nm (3 lbf ft)
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19.
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Attach the crankcase ventilation hose and vacuum hose to the camshaft cover. Fit the dipstick holder.
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20.
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Fit the crankcase ventilation pipe.
Tightening torque 24 Nm (18 lbf ft)
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21.
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Fit the belt circuit cover.
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22.
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Fit the engine cover or resonator as applicable. Apply petroleum jelly to the resonator O-ring.
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23.
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Remove the protective covers from the wings and check that the engine bay is clean.
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24.
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Connect the negative battery cable.
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25.
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Start the engine, check all functions and inspect for leaks.
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26.
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Set the clock and radio code where applicable. Calibrate the ACC.
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9-3 with engine variants B205L/R and B235R
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1.
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Fit wing protectors and undo the negative battery cable. Ensure the radio code is available where applicable.
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2.
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Remove the engine cover.
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3.
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Remove the crankcase ventilation pipe and the cable to the solenoid valve and move them to one side.
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4.
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Remove the ignition discharge module with connector.
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5.
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Detach the crankcase ventilation hose and the vacuum hose from the camshaft cover. Cut the cable ties to the camshaft cover at the non-return valve.
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6.
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Remove the camshaft cover.
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7.
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Raise the car and remove the belt circuit cover.
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8.
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Turn the crankshaft in its direction of rotation until the camshaft gear setting marks are pointing straight up.
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9.
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Mark the chain according to the sprocket setting marks. Use a felt tip pen or similar.
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10.
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Undo the bolts on the camshaft sprockets. Take up the strain on the rear end of the camshaft with a spanner.
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11.
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Undo the bolt on the idler sprocket in order to gain access to the chain tensioner using a socket wrench.
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12.
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Remove the chain tensioner.
Start by removing the plug, pin and spring. Then use a 27 mm socket to undo the chain tensioner.
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13.
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Change the camshaft gear on the exhaust side. Do the same with the camshaft gear on the intake side. Restrain the camshaft with a spanner on the rear edge.
Tightening torque 63 Nm (47 lbf ft)
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14.
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Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.
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15.
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Fit the chain tensioner with a 27 mm socket. If necessary, change the gasket on the chain tensioner
Tightening torque 63 Nm (47 lbf ft)
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16.
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Fit the chain tensioner plug with push rod and spring.
Tightening torque 22 Nm (16 lbf ft).
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17.
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Make sure the chain mark coincides with the camshaft gear setting marks.
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18.
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Clean the sealing surface of the camshaft cover with benzine.
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19.
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Fit the camshaft cover starting at the recess. Tighten the bolt at the front on the timing gear end and then tighten all the inner and outer bolts as shown in the illustration.
Tightening torque 15 Nm (11 lbf ft)
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20.
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Apply Krytox, part no. 30 19 312, to the rubber seal on the ignition discharge module and fit the ignition discharge module.
Tightening torque 11 Nm (8 lbf ft)
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21.
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Connect the hose for the crankcase ventilation and the vacuum hose for the camshaft cover. Refit the cable tie to the camshaft cover by the non-return valve.
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22.
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Fit the pipe for the crankcase ventilation with the banjo screw. Use new copper gaskets.
Tightening torque 24 Nm (18 lbf ft)
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23.
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Plug in the connector to the solenoid valve.
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24.
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Raise the car and fit the belt circuit cover.
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25.
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Connect the negative battery cable and fit the engine cover.
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26.
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Start the engine. Turn off the engine, inspect for leaks and rectify if necessary.
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27.
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Set the clock and radio code where applicable. Calibrate the ACC.
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Marking the modification identity plate
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Box C2 on the modification identity plate must be marked after completing the procedure. Mark with the number "7" if the procedure was carried out by the importer or with the number "8" if carried out by the dealer.
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Warranty/Time information
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See separate information.
