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Engine - Repair (2.0L & 2.3L): Removal & Installation Saab 9-3 I

Mechanical 29 illustrations ~4256 words

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses, and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Removal (9-3)

  1. Disconnect windshield washer hoses. Remove hood. Install Spacer (83 93 209) between upper control arm and body. Remove battery. Disconnect exhaust pipe at manifold. Loosen right front wheel lug bolts. Drain power steering reservoir. Raise and support vehicle.
  2. Disconnect shifter rod from transmission linkage. Remove exhaust pipe bracket at transaxle. Disconnect CV joint boots at transaxle. Remove right front wheel. Lower control arm and anti-roll bar from ball joint.
  3. Separate right axle shaft from transmission. Disconnect pressure line from power steering pump. Remove A/C compressor drive belt. Drain engine coolant. Disconnect oil filler tube. Disconnect coolant hoses at intercooler, expansion tank, and thermostat housing.
  4. Unplug all wiring connectors. Lift wiring harness from engine compartment and place it on A/C condenser. Remove turbo discharge duct (if equipped). Remove mass airflow meter and air cleaner. On turbo models, remove intercooler and air duct as an assembly. Cap turbocharger inlet. Remove top cover and baffle plate from side of intercooler (turbo models).
  5. On all models, remove ignition coil and cooling fan. Disconnect coolant hose from bottom of radiator. Disconnect throttle cable. Disconnect all remaining wiring and vacuum hoses. Disconnect and plug end of line to clutch release cylinder (if equipped).
  6. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-8773-S16567716432000092200000) . Disconnect fuel lines at fuel pressure regulator and fuel injection manifold. Remove A/C compressor and place it on A/C condenser. DO NOT disconnect A/C hoses. Remove engine mount bolts. Attach engine hoist and lifting sling.
  7. Lift engine slightly. Disconnect remaining inboard axle joint. Remove return line from power steering pump. Remove oil pressure sensor and oil cooler lines at oil filter. Ensure all wiring, hoses, and other attachments have been removed from engine. Lift engine and transaxle from vehicle as an assembly. Cover CV joints at transaxle.

Installation (9-3)

Pack CV joint cups with grease. Tilt engine forward slightly while lowering into position. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Bleed clutch (if equipped).

Removal (9-5)

  1. Raise and support vehicle. Remove front wheels, inner panel from right front fender, and center panel under spoiler. Drain coolant. Remove battery. Disconnect ABS brace. Unplug wiring, and disconnect battery cable from terminal block on battery tray. Remove battery tray.
  2. Unplug connectors for ignition system and knock sensor. Disconnect upper radiator hose. Remove mass airflow meter, resonator, and elbow as an assembly. Remove washer fluid reservoir. Disconnect throttle cable.
  3. Release fuel pressure. See «FUEL PRESSURE RELEASE»(ref-8773-S16567716432000092200000) . Disconnect fuel return line at fuel pressure regulator, and fuel supply line at fuel rail. Remove cover over space between firewall and panel. Remove panel. Unplug engine wiring connector. Disconnect speedometer sensor wire at transaxle.
  4. Disconnect heater hoses at cylinder head. Unplug connector at brake fluid reservoir. Apply sufficient upward tension to accessory drive belt to install Lock (83 94 488) to tensioner. Protect oil cooler and radiator crossmember. Remove A/C compressor, and wire to radiator crossmember. DO NOT disconnect hoses.
  5. On models with A/T, disconnect cooler lines at transmission. Plug lines and transmission fittings. Disconnect kickdown cable clip at power steering pump. Remove nut from A/T shifter linkage. Pry shifter cable from clip.
  6. On models with M/T, disconnect line from clutch release cylinder. Cap hose and release cylinder openings. Position gear selector in 4th gear. Separate rubber joint in shift linkage.
  7. On all models, disconnect hoses from expansion tank. Disconnect radiator hoses at water pump. Unplug connector at HO2S sensor. Remove torque strut. Disconnect exhaust pipe at manifold. Unplug connector at oil level sensor. Secure oil cooler to engine with wire.
  8. Remove power steering reservoir retaining bolt. Lower reservoir. Siphon fluid from reservoir. Disconnect return hose. Place reservoir on firewall. Disconnect pressure line at power steering pump. Plug hose and pump openings. Remove clip from rear engine mount.
  9. Remove right engine mount nuts. Remove clips from inboard drive axle joints. Remove upper and loosen lower shock absorber bolts. Pull steering knuckles outward to separate CV joints at transmission. Cover both halves of each joint.
  10. Disconnect hood struts. Install Extensions (83 94 439) onto struts. Ensure all wiring, hoses, or other attachments have been removed from engine. Attach engine hoist and lifting sling. Carefully lift engine and transmission assembly from vehicle.

Installation (9-5)

Pack CV joint cups with grease. Insert bolt through left engine mount. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Bleed clutch (if equipped).

Removal & Installation (9-3)

  1. Relieve fuel pressure. See «FUEL PRESSURE RELEASE»(ref-8773-S16567716432000092200000) . Disconnect fuel lines at fuel pressure regulator and fuel injection manifold. Drain coolant. Disconnect coolant hose at thermostat housing. Remove fuel pressure regulator. Remove ground connections as necessary.
  2. Remove auxiliary air valve (if equipped). Unbolt A/C bracket from cylinder head. Remove intake manifold, fuel injectors and fuel rail as an assembly. To install, reverse removal procedure.

Removal & Installation (9-5)

  1. Drain coolant. Disconnect battery negative cable. Remove rubber elbow from between throttle body and mass airflow meter. Unplug connector from throttle position sensor. Disconnect hoses from throttle body. Remove throttle body retaining bolts. Move throttle body aside.
  2. Unplug connector from Automatic Idle Control (AIC) valve. Move AIC valve aside. Disconnect fuel lines at fuel pressure regulator and rail. See «FUEL PRESSURE RELEASE»(ref-8773-S16567716432000092200000) . Disconnect wiring from fuel injectors. Remove fuel rail and injectors as an assembly.
  3. Disconnect temperature sensor and ground points on intake manifold. Remove harness from clips under manifold. Disconnect EGR tube and Red-marked hose (if equipped). Remove retaining bolts and intake manifold. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8773-S14160002402000092200000) .

Removal

Remove A/C compressor (if equipped). Remove pulse air unit and EGR tube. Remove exhaust manifold retaining nuts. Disconnect exhaust pipe from manifold. Remove manifold.

Installation

Always install NEW pulse air nozzles and ferrules. Ensure nozzles are perpendicular to flanges, and extend .60-.70" (15-18 mm) beyond face of flange. To complete installation, reverse removal procedure. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

  1. Remove intake manifold. See «INTAKE MANIFOLD»(ref-8773-S08786819362000092200000). Remove turbocharger (if equipped) and exhaust manifold. See «EXHAUST MANIFOLD»(ref-8773-S06299737352000092200000). Remove 2 timing cover-to-cylinder head bolts. Remove engine mount bolts from cylinder head.
  2. Disconnect lead from temperature sender. Remove inspection panel from valve cover. Remove distributor cap and spark plug leads as an assembly. Remove valve cover. Disconnect crankcase ventilation hose. Remove split rubber plugs from cylinder head.
  3. Align timing mark on flywheel with "0" mark on flywheel cover. Remove camshaft chain tensioner, camshaft chain and sprockets. Raise engine to permit removal of cylinder head from engine brace. Remove cylinder head bolts in reverse order of tightening sequence. (Scheme 1)

Scheme 1

Scheme 1
Scheme 1
  1. Install guide pin into one bolt hole. Remove cylinder head. Ensure pivoting timing chain guide is not damaged.
  2. Lubricate cylinder head bolts and washers before installation. Tighten cylinder head bolts, using several steps, in sequence shown. (Scheme 1) Tighten bolts to an initial torque of 44 ft. lbs. (60 N.m). Next, tighten bolts to 59 ft. lbs. (80 N.m). Finally, tighten each bolt an additional 90 degrees.
  3. Install 2 timing cover-to-cylinder head bolts. Install timing chain and camshaft sprockets, starting with exhaust valve camshaft. Keep chain taut between sprockets. Lightly tighten sprocket bolts.
  4. Adjust chain tensioner by pressing piston and rotating tensioner into locked position. Install tensioner with piston under tension. Tighten bolt. Release tensioner by pressing pivoting guide firmly. Press pivoting guide against chain to release tension. Press pivoting guide to check tensioner operation.
  5. Rotate crankshaft 2 complete turns clockwise. Check timing marks on crankshaft and camshafts. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8773-S14160002402000092200000).
  1. Remove turbocharger (if equipped) and exhaust manifold as an assembly. See «EXHAUST MANIFOLD»(ref-8773-S06299737352000092200000) . Disconnect lead from temperature sender. Remove intake manifold. See «INTAKE MANIFOLD»(ref-8773-S08786819362000092200000) . Remove engine mount bolts from cylinder head.
  2. Disconnect hoses from valve cover. Remove ignition cartridge and valve cover. Rotate crankshaft to align "0" mark on flywheel with timing mark on flywheel cover. Remove camshaft sprockets and chain tensioner. Remove 2 timing cover-to-cylinder head bolts.
  3. Detach starter lead from clip on thermostat housing. Remove cylinder head bolts. Install guide pin into top right corner of cylinder head. Ensure timing chain is positioned so that pivoting chain guide does not obstruct cylinder head. Lift cylinder head from engine.
  1. Place NEW gasket on cylinder block. Rotate crankshaft to TDC position of No. 1 piston. Align camshafts with their respective timing marks. Position timing chain in pivot guide.
  2. Install guide pin into top right corner of cylinder head. Lubricate cylinder head bolts and washers before installation. Tighten cylinder head bolts in sequence. (Scheme 1) Tighten bolts to an initial torque of 44 ft. lbs. (60 N.m). Then tighten bolts to 59 ft. lbs. (80 N.m). Finally, tighten each bolt an additional 90 degrees.
  3. Install sprocket for intake camshaft first, then remaining sprocket. Ensure timing chain is positioned correctly between guides. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8773-S14160002402000092200000).

Remove drive belt. Remove drive pulley and vibration damper. Remove A/C pulley. Pry out old seal.

Grease sealing surface of new seal. Press seal into position with Seal Installer (83 93 349). Reverse removal procedure to complete installation. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

  1. Remove engine/transaxle from vehicle. See «ENGINE»(ref-8773-S30389586912000092200000) . Rotate crankshaft until "0" mark on flywheel aligns with timing mark on flywheel cover. Remove inspection panel from valve cover. Disconnect ignition leads and vacuum hose (if equipped) from distributor. Remove distributor cap and valve cover.
  2. Remove center bolts from camshaft sprockets. Ensure camshafts remain at correct timing settings. Remove chain tensioner and camshaft sprockets. Remove crankshaft pulley and oil pump. Remove water pump pulley and water pump. Remove cylinder head-to-timing cover bolts.
  3. Remove timing cover bolts and cover. Note lengths and locations of retaining bolts. Remove timing chain and crankshaft sprocket.
  1. Disconnect battery negative cable. Using Locking Attachment (83 93 993), prevent flywheel from turning. Raise and support vehicle. Drain engine oil and coolant. Remove right front wheel and inner fender panel. Remove drive belt and belt tensioner.
  2. Remove power steering pump retaining bolts. Lower pump onto subframe. Remove generator mounting bolts. Place generator inboard of rear engine mount. Remove power steering pump bracket. Remove lower bolts from upper engine mount. Remove torque strut. Remove remaining upper engine mount bolts.
  3. Remove bolt from coolant pipe clip next to knock detector. Remove upper belt tensioner bracket. Remove A/C compressor, and wire to radiator crossmember. DO NOT disconnect hoses. Remove A/C compressor bracket. Remove water pump.
  4. Remove crankshaft pulley. Move Hall Effect sensor aside. Disconnect coolant tube clip. Move coolant tube aside. Remove oil pan. See «OIL PAN»(ref-8773-S27608104092000092200000) . Remove 2 timing cover-to-cylinder head bolts. Remove timing cover retaining bolts and timing cover. Note lengths and locations of retaining bolts.
  5. Rotate crankshaft until "0" mark on flywheel aligns with timing mark on flywheel cover. Remove ignition cartridge. Remove inspection panel from valve cover. Remove camshaft sprocket retaining bolts.
  6. Ensure camshafts remain at correct timing settings. Remove balance shaft chain. See «BALANCE SHAFTS»(ref-8773-S05312494582000092200000) . Remove chain tensioner and camshaft sprockets. Remove timing chain and crankshaft sprocket.

Installation (All Models)

  1. Ensure No. 1 piston is in TDC position and camshafts are aligned with their respective timing marks. (Scheme 2) Position timing chain around crankshaft sprocket and through pivoting guide.
  2. Install timing chain and camshaft sprockets, starting with exhaust valve camshaft. Keep chain taut between sprockets. Lightly tighten sprocket bolts. Adjust chain tensioner by fully bottoming and then rotating piston to locked position.
  3. Install tensioner with piston under tension. Release tensioner by pressing pivoting guide firmly. Press pivoting guide to check tensioner operation.
  4. Rotate crankshaft 2 complete turns clockwise. Check timing marks on crankshaft and camshafts. Tighten camshaft sprocket bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8773-S14160002402000092200000). Apply anaerobic sealant to timing cover sealing surface. Reverse removal procedure to complete installation.

See VALVE SPRINGS under CYLINDER HEAD under OVERHAUL.

  1. Rotate crankshaft until "0" mark on flywheel aligns with timing mark on flywheel cover. Remove inspection panel from valve cover. On 9-3, disconnect ignition leads and vacuum hose from distributor. Remove distributor (if equipped). On 9-5, remove ignition cartridge.
  2. On all models, remove valve cover. Remove camshaft sprocket retaining bolts. Remove chain tensioner, camshaft sprockets, and timing chain. Remove oil line and camshaft bearing caps. Remove camshafts.
  1. Ensure "0" mark on flywheel aligns with timing mark on flywheel cover. Install intake camshaft with bearing caps No. 1-5, and exhaust camshaft with bearing caps No. 6-10.
  2. Tighten bearing cap bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8773-S14160002402000092200000). Rotate camshafts until they are aligned with their respective timing marks. (Scheme 2) Reverse removal procedure to complete installation.

Scheme 2

Scheme 2
Scheme 2

Remove timing chain cover. See TIMING CHAIN . Remove upper chain guide, chain tensioner, and pivoting guide. Remove idler sprocket and balance shaft chain. Pull oil pump drive and balance chain drive sprocket from crankshaft. Carefully pull balance shafts from engine block.

  1. Ensure "0" mark on flywheel aligns with timing mark on flywheel cover. Lubricate balance shaft journals and bearing housings. Carefully insert balance shafts into their respective bores. Shaft marked INL goes into intake side of engine. Ensure timing marks on balance shaft bearing housings and sprockets are aligned.
  2. Install balance shaft chain and idler sprocket, leaving some slack in area of tensioner. Keep chain reasonably taut with upper chain guide. Press plunger on chain tensioner. Maintain plunger in position by inserting paper clip into hole in housing. Ensure plunger is turned to position in which spring acts fully upon it.
  3. Install chain guides and tensioner. Remove paper clip to set tensioner. Rotate crankshaft several times. Ensure timing marks align. To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8773-S14160002402000092200000) .

Removal (9-3 A/T)

Remove engine. See ENGINE . Separate engine and transaxle. Remove torque converter and flexplate. Pry out old seal.

Removal (9-3 M/T)

Remove clutch. See appropriate article in CLUTCHES. Remove flywheel. Pry out old seal.

Removal (9-5 A/T)

Remove transaxle and flexplate. See TRANSMISSION REMOVAL & INSTALLATION article in TRANSMISSION SERVICING. Pry out old seal.

Removal (9-5 M/T)

Remove clutch. See appropriate article in CLUTCHES. Remove flywheel. Pry out old seal.

Lubricate sealing surface of NEW seal with engine oil. Install into position with Seal Installer (83 92 540). Reverse removal procedure to complete installation. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Scheme 3

Scheme 3: To Remove
Scheme 3: To Remove

Scheme 4

Scheme 4
Scheme 4

Scheme 5

Scheme 5
Scheme 5

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9
  1. Open the expansion tank pressure cap to release system pressure. (Scheme 3): Illustration For Steps 1-3
  2. Raise the car.
  3. Connect a hose to the system drain plug and drain the coolant into a suitable receptacle.
  4. Detach the coolant pipe from the turbocharger. (Scheme 4): Illustration For Steps 4-6
  5. Close the system drain plug and lower the car.
  6. Remove the air hose between the air collector casing and the turbocharger intake pipe.
  7. Cut the 2 cable ties securing the main engine cables. Relieve the strain on the belt tensioner with a ratchet handle and secure the belt tensioner with a 3.5 mm drill or similar. (Scheme 5): Illustration For Steps 7-8
  8. Lift the belt off the power steering pump and coolant pump pulleys. (Scheme 6): Illustration For Steps 9-10-11-12-2-13-15-16-17
  9. Remove the top engine cover.
  10. Detach the crankcase ventilation pipe from the turbo inlet pipe and camshaft cover. Bend the pipe to one side. Keep seals and washers safe.
  11. Unplug the solenoid valve's connector.
  12. Detach the solenoid valve hoses.
  13. Remove the engine lifting eye.
  14. Remove the bypass pipe with valve. Keep the O-ring from the connection to the turbocharger intake pipe.
  15. Remove the heat shield over the exhaust manifold.
  16. Detach the venting hose from the T-connection.
  17. Remove the turbocharger's intake pipe, plug the turbo.
  18. Remove the power steering servo pump bolt on the right-hand side behind the belt pulley. (Scheme 7): Illustration For Steps 18-19-20-21
  19. Undo the upper power steering servo pump bolt.
  20. Lift up the power steering servo pump and remove the lower bolt and the 2 upper bolts on the bracket.
  21. Move the power steering pump and bracket aside and secure with a cable tie or similar.
  22. Undo the hose clips and detach the hoses from the coolant pump inlet. (Scheme 8): Illustration For Steps 22-23-24
  23. Detach the two longitudinal coolant pipes from the cylinder block.
  24. Disconnect the coolant pipes from the coolant pump, keep the O-rings and move the pipes aside.
  25. Loosen the coolant pump slightly.
  26. Detach the coolant pipe from the coolant pump. keep the seals. (Scheme 9): Illustration For Steps 26-27-29
  27. Undo the coolant pump's 3 retaining bolts.
  28. Carefully wiggle the coolant pump away from the mounting and from its connecting piece in the cylinder block.
  29. Remove the connecting piece from the cylinder block, check its seals and change as necessary.

Scheme 10

Scheme 10: To Fit
Scheme 10: To Fit

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17
  1. Fit the connecting piece to the cylinder block. Coat the seals with Gleitmo 805, part no. 30 06 442. (Scheme 10): Illustration For Steps 1-4-6
  2. Fit the coolant pump in place but do not tighten it.
  3. Position the coolant pipe between the coolant pump and turbocharger. Use new washers and seals.
  4. Tighten the coolant pipe to the coolant pump. Tightening torque: 20 N.m
  5. Bring the two transverse coolant pipes up to the coolant pump, use new O-rings coated with non-acidic vaseline, part no. 30 06 665 or the like. (Scheme 11): Illustration For Steps 5,7-7
  6. Tighten the coolant pump, 3 bolts. Tightening torque: 22 N.m (16.2 lbf ft)
  7. Tighten the two transverse coolant pipes. Tightening torque: 10 N.m (7.4 lbf ft)
  8. Fit the power steering pump and bracket. Tightening torque: 24 N.m (17.7 lbf ft) (Scheme 12): Illustration For Steps 8
  9. Fit hoses and hose clips on the coolant pump inlet.
  10. Remove the plug from the turbocharger air intake. Inspect the O-ring and coat it with non-acidic vaseline, part no. 30 06 665, or the equivalent.
  11. Fit the turbocharger inlet pipe but do not tighten the V-clamp. (Scheme 13): Illustration For Steps 9-12-13-14,11-15
  12. Fit the solenoid valve on the engine lifting eye. Connect the hoses to the solenoid valve. Note the markings on the hoses and the connection.
  13. Fit the engine lifting eye.
  14. Tighten the turbocharger's intake pipe, V-clamp. Tightening torque: 3 N.m (2.2 lbf ft)
  15. Connect the venting hose to the T-connection.
  16. Fit the heat shield over the exhaust manifold. (Scheme 14): Illustration For Steps 16-18-19-20
  17. Fit the bypass pipe and valve, use a new O-ring for the connection to the turbocharger inlet pipe. Tightening torque: 8 N.m (5.9 lbf ft)
  18. Spray the solenoid valve connector with Kontakt 61, part no. 30 04 520, and plug it in.
  19. Fit the crankcase ventilation pipe to the turbocharger intake pipe. Use new copper seals. Tightening torque: 24 N.m (17.7 lbf ft) Fasten the crankcase ventilation pipe to the camshaft cover, clip.
  20. Fit the throttle body's cover.
  21. Raise the car and fit the coolant line to the turbocharger. Tightening torque: 25 N.m (18.4 lbf ft) (Scheme 15): Illustration For Steps 21
  22. From underneath, check that the multigroove V-belt is correctly fitted round all pulleys. (Scheme 16): Illustration For Steps 22-24
  23. Check that the cooling system's drain plug is closed. Lower the car to the floor.
  24. Relieve the tension on the belt tensioner with a ratchet handle and remove the catch. Make sure the belt is positioned correctly and carefully release the ratchet handle.
  25. Secure the engine's main wiring harness with cable ties. (Scheme 17): Illustration For Steps 25-26
  26. Fit the air hose between the air collector casing and the turbocharger intake pipe.
  27. Fill up with coolant. Close the filler cap.
  28. Fill up and bleed the system as follows: NOTE: A/C and ACC must be OFF. Fill the system to MAX level, fit the pressure cap, start the engine and warm it up, preferably at varying engine speeds, until the radiator fan starts. Switch off the engine and top up as necessary to the MAX level.
  29. Raise the car to check for oil or coolant leakage.
  30. Lower the car and top up the coolant and/or oil as necessary.
  1. Open the cap (1) on the expansion tank and release the pressure. (Scheme 18)
  2. Raise the car.
  3. Remove the lower front cover (3).
  4. Drain off the coolant (4).
  5. Lower the car to the floor.
  6. Unplug the mass air flow sensor connector (6). (Scheme 19)
  7. Remove the air hose and mass air flow sensor (7).
  8. Off-load the multigroove V-belt (8) using the Pull Bar (83 95 254). (Scheme 20)
  9. Remove the belt from the power steering pump and water pump (9).
  10. Remove the crankcase breather pipe (10), fastened to the turbo intake pipe, and the camshaft cover. (Scheme 21)
  11. Unplug the boost pressure control valve connector (11).
  12. Remove the engine lifting eyelet (12).
  13. Loosen the hoses (13) to the turbo's wastegate valve.
  14. Remove the by-pass pipe (14) with valve. NOTE: There is an "O" ring at the by-pass pipe's attachment to the turbo intake pipe.
  15. Remove the exhaust manifold heat shield (15). The heat shield is attached with a nut and two clips on the underside. (Scheme 22)
  16. Undo the quick-release coupling on the vent hose (16), using Tool (83 95 261).
  17. Remove the turbo intake pipe (17).
  18. Remove the intake pipe (18).
  19. Plug the turbo inlet using a plastic plug or the like.
  20. Undo the power steering pump (20). (Scheme 23)
  21. Move the power steering pump (21) aside.
  22. Remove the hose clips and hoses (22) on the coolant pump inlet.
  23. Detach the two longitudinal coolant pipes (23) from the engine block.
  24. Detach the two longitudinal coolant pipes from the coolant pump (24).
  25. Slacken the bolt (by the turbo) securing the coolant pipe from the coolant pump (25).
  26. Remove the coolant pipe from the coolant pump (26).
  27. Undo the coolant pump retaining bolts (27). (Scheme 24)
  28. Carefully work the pump free from the bracket and from the pump's connecting piece on the engine block.
  29. Remove the connecting piece (29) from the engine block and inspect its seals, change the seals as necessary.

Scheme 18

Scheme 18
Scheme 18

Scheme 19

Scheme 19
Scheme 19

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Note. Spray the connectors with Kontakt 61 contact cleaner.

  1. Fit the connecting piece to the engine block. Coat seals with Gleitmo 805.
  2. Fit the coolant pump (2). (Scheme 25) Tighten to specifications, see «TORQUE SPECIFICATIONS»(ref-8773-S14160002402000092200000).
  3. Fit and tighten the coolant pipe to the coolant pump and by the turbo (3). (Scheme 26) Tighten to specifications.
  4. Fit the two longitudinal coolant pipes (4) to the coolant pump. Tighten to specifications.
  5. Fit the two longitudinal coolant pipes to the engine block (5).
  6. Fit the hose clips and hoses to the coolant pump inlet (6).
  7. Fit the power steering pump (7). Tighten to specifications.
  8. Extract the plug from the turbo inlet (8) and then fit the intake pipe. (Scheme 27) Tighten to specifications.
  9. Reconnect the vent hose (9).
  10. Fit the exhaust manifold heat shield (10). Tighten to specifications.
  11. Fit the by-pass pipe (11) and valve. (Scheme 28) Tighten to specifications. NOTE: Fit a new "O" ring at the by-pass pipe mounting to the turbo intake pipe.
  12. Fit the hoses to the turbo's wastegate valve (12).
  13. Fit the engine lifting eye (13).
  14. Plug in the boost pressure control valve connector (14).
  15. Fit the crankcase breather pipe (15), fastened to the turbo intake pipe, and the camshaft cover. Tighten to specifications.
  16. Fit the multigroove V-belt (16) and tension it with the belt tensioner. Use the Pull Bar (83 95 254). (Scheme 29)
  17. Fit the air hose and mass air flow sensor (17). see scheme 30
  18. Plug in the mass air flow sensor connector (18).
  19. Switch off the A/C or ACC. Fill with coolant to the MAX level. Do not forget to close the drain plug on the radiator first. Close the expansion tank lid.
  20. Start the engine and run unloaded until warm at varying engine speeds until the radiator fan starts.
  21. Turn off the engine and top up to MAX level.
  22. Inspect the system for possible leaks.
  23. Raise the car.
  24. Fit the lower front cover.
  25. Lower the car to the floor.

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29
  1. Remove dipstick. Stuff rag into opening. Raise and support front of vehicle. Drain engine oil. Remove right front wheel and inner fender panel. Remove front and rear engine mount nuts, HO2S sensor, and front section of exhaust pipe. Remove torque strut through-bolt. Lift engine slightly. Remove lower oil pan-to-transaxle bolt.
  2. Disconnect wiring from oil level sensor. Remove turbocharger brace and oil return line (if equipped). Fold down splash plate. Remove rubber plugs from transaxle housing to gain access to rear oil pan bolts. Remove oil pan retaining bolts. Tap guide sleeve into engine block. Remove oil pan. Remove guide sleeve.

Clean gasket surfaces. Apply silicone sealant to gasket surfaces. Install rubber seal for oil strainer into groove in oil pan. Reverse removal procedure to complete installation. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

Clean area around pump. Attach Locking Device (83 92 987) to flywheel ring gear. Remove crankshaft pulley retaining bolt and pulley. Remove oil pump retaining bolts and pump.

Coat gears with oil. Ensure ring gear is installed with mark on visible face. Position NEW sealing ring into groove in pump body. Prime pump with oil and install on engine. Remove oil filter adapter casting and fill passage with oil. Install casting.

Note. It may be necessary to pull pump gear out slightly to position gear on driving plate.

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