Basic Engine V6: Removal & Installation Saab 9-3 II

To remove

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1. Place the car on a lift and apply wing covers.
2. Open the cap on the expansion tank.
3. Remove the battery cover and disconnect the negative cable.
4. Raise the car slightly and remove the front wheels.
5. Remove the lower spoiler shield. Unplug and remove the connector.
6. Detach and plug the headlight washer hose.
7. Place a receptacle under the car, connect a hose to the radiator and drain the coolant.
8. Close the cock and remove the hose.
9. Remove the right wing liner and detach the front part of the left wing liner.
10. CV: Remove «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) . All: Relieve the load on the belt tensioner. Use a 1/4 " puller handle and remove the drive belt from the A/C compressor pulley.
11. Lower the car slightly and remove the bumper.
12. Remove the cover on the left-hand side.
13. Remove the charge air hose between the charge air pipe and the intercooler.
14. Remove the lower charge air pipe bracket from the fan cowling.
15. Remove the cover on the right-hand side.
16. Detach the hose from the charge air cooler.
17. Remove the dryer filter bolts from the radiator.
18. Detach the oil cooler's coolant hose from the radiator.
19. Remove the rear catalytic converter.
20. Place a receptacle under the car and remove the coolant connection. Move the hose aside.
21. Lower the car and remove the upper engine cover.
22. Remove the battery.
23. Undo the main fuse box in front of the battery tray and move it aside.
24. Remove the filler pipe of the washer fluid reservoir.
25. Detach the fuse holder from the battery tray.
26. Remove the cable duct from the battery tray.
27. Unplug the bonnet switch connector, undo the cable clip and remove the battery tray.
28. Detach the turbocharger intake manifold from the radiator member.
29. Undo the bonnet cable quick-release coupling by first undoing the clip in the body and then separating the quick-release coupling. Use a screwdriver.
30. Detach the right-hand headlight and pull it out slightly.
31. Detach the horn connector.
32. Remove the upper radiator member.
33. Unplug the connector from the mass air flow sensor.
34. Remove the dipstick tube's breather hose and the ventilation hose of the turbocharger.
35. Remove the secondary air pipe from the turbocharger intake manifold.
36. Remove the turbocharger intake manifold.
37. Remove the air cleaner cover and the air cleaner. Detach the inlet hose and remove the air cleaner casing.
38. Unplug the connector and undo the clips securing the cables on the fan cowling.
39. Remove the seal over the radiator assembly.
40. Remove the upper radiator brackets from the body.
41. Detach the upper radiator hose from the engine.
42. Remove the fan cowling retaining bolts.
43. Move the radiator assembly forward slightly and lift out the fan cowling.
44. Place a receptacle under the radiator and remove the lower radiator hose. Auto: Detach the oil pipes from the radiator using «87 92 806 REMOVAL TOOL, OIL PIPES, AUTOMATIC TRANSMISSION»(ref-275852-S07498375782007122900000) . Plug the pipes.
45. Detach the boost pressure sensor connector (688).
46. Remove the charge air pipe between the throttle body and charge air cooler.
47. Detach the breather hoses from the coolant reservoir.
48. Remove the cover on the main fuse box and undo the two retaining bolts.
49. Disconnect the positive cable from the battery.
50. Undo the retaining bolt on the engine harness connector in the main fuse box.
51. Remove the engine harness clamp from the body and detach the ground cables.
52. Unplug the two connectors on the structural member.
53. Move the engine harness up and secure it to the engine with a cable tie or the like.
54. Check and adjust the steering wheel and the steering assembly so that they are pointing straight ahead.
55. Raise the car.
56. Detach the steering shaft from the steering gear.
57. Detach the power steering pipes from the radiator assembly.
58. Unplug the A/C compressor connector and remove the A/C compressor retaining bolts.
59. Fit 83 96 152 Centering tool, power train and «32 025 059 SUPPORT»(ref-275854-S15940127642007122900000) on the subframe. Adjust the tool approx. 10 mm to relieve some pressure on the engine mounts.
60. Undo the drive shaft's center nuts. Detach the drive shafts from the hub. Use 89 96 951 Puller, drive shaft or a brass drift and mallet.
61. Undo the nuts and the outboard steering links from the steering swivel member with 87 91 287 Puller, 150 mm.
62. Remove the lower spindle joints' bolts on both sides.
63. Undo the lower anti-roll bar links while gripping the flats with a thin spanner.
64. Detach the angle sensor connector and detach the cable from the subframe.
65. Lower the car.
66. Detach the coolant hose and undo it from the holder on the engine.
67. Detach the brake servo vacuum pipe and move it aside.
68. Relieve excess pressure in the fuel system by carefully pressing on the needle of the service valve. Catch any fuel spill. Detach the fuel line from the fuel rail. Plug the fuel lines using «82 92 948 PLUGS, A/C SYSTEM, KIT»(ref-275855-S09721449632007122900000) .
69. Release the quick coupling of the breather line and move it aside.
70. Remove the right-hand engine mounting.
71. Remove the left-hand engine mounting.
72. Detach the shifter cables from the gearbox; carefully move them aside and secure them to a brake pipe with a cable tie. Auto: detach the breather hose of the automatic transmission.
73. Man: Fit 30 07 739 Hose pinch-off pliers to the clutch hose and disconnect the quick coupling from the clutch slave cylinder.
74. Place the radiator member back in position.
75. Fit 2 83 95 212 Strap in the radiator member in order to secure the radiator assembly. Insert one strap around the radiator assembly. Insert the other and wrap an extra loop around the A/C compressor in order to relieve the load. Place a cardboard disc or the like between the A/C compressor and the radiator as support.
76. Place 83 96 145 Centering tool, subframe - engine on the trolley lift. Make sure the adjuster screws on the height adjusters, part no. 83 95 170, are in their lowest position. See «CENTERING TOOL, ENGINE AND SUBFRAME»(ref-275839-S09940813002007122900000) .
77. Position the trolley lift; raise and insert the guide pins in the subframe reference holes. Adjust the lifting pillars with the height adjusters, part no. 83 95 170, so that they rest evenly on the subframe. Check with the body guide pins that the subframe is positioned correctly in relation to the body. See «CENTERING TOOL, ENGINE AND SUBFRAME»(ref-275839-S09940813002007122900000) .
78. Raise the trolley lift slightly to provide steady contact. Undo the rear bolts of the subframe stay and move the stay aside. Remove the subframe bolts from the body.
79. Carefully low the power train using the trolley lift. Detach the lower spindle joints from the steering swivel members and move aside the suspension arms. Make sure that nothing catches or gets damaged.

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1. Position the trolley lift with power train and adjust its position in relation to the body. Use 82 93 102 Extension, 500 mm, 3/8 square through the holes in the subframe to the attachments in the body. See «CENTERING TOOL, ENGINE AND SUBFRAME»(ref-275839-S09940813002007122900000) .
2. Raise the train until the inner drive shaft universal joints are level with the wheel hubs and insert the hub nuts. Make sure that nothing catches or gets damaged.
3. Lift a little higher and position the lower swivel joints to the steering swivel members. If necessary, adjust the trolley lift screws to provide even contact with the body. Check that the guide pins are positioned correctly relative the reference holes in the body.
4. Move the subframe stays back into position. Position and insert the bolts through the subframe to the body.
5. Raise the engine all the way and tighten the subframe bolts and the rear bolts of the stays. Tightening torque, subframe: 75 Nm + 135° (55 lbf ft +135°) Tightening torque, stay: 90 Nm + 45° (66 lbf ft +45°)
6. Lower the trolley lift and move it out of the way.
7. Tighten the bolts on the lower swivel joints. Tightening torque 50 Nm (37 lbf ft). IMPORTANT: Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.
8. Position the lower anti-roll bar links and tighten them while gripping the flats with a thin spanner. Tightening torque 64 Nm (47 lbf ft)
9. Position and tighten the outer steering links. Lower the car. Tightening torque 35 Nm (26 lbf ft)
10. Fit the right and left-hand engine mountings. Tightening torque, right to body: 45 Nm + 90° (33 lbf ft + 90°) Tightening torque, right to engine: 50 Nm + 180° (37 lbf ft + 180°) Tightening torque, left: 80 Nm (59 lbf ft)
11. Remove the straps and the radiator member.
12. Auto: Connect the breather hose of the automatic transmission. Remove the cable tie and fit the shifter cable to the gearbox.
13. Man: Fit the quick coupling on the clutch slave cylinder. Remove the hose pinch-off pliers from the clutch hose. Remove the cable tie and fit the shifter cables on the gearbox.
14. Connect the quick coupling of the breather line.
15. Remove the plugs and connect the fuel line to the fuel rail.
16. Connect the brake servo vacuum pipe.
17. Fit the coolant hose and position it in the holder on the engine.
18. Raise the car.
19. Install the angle sensor cable on the subframe. Plug in the connector.
20. Remove the centering fixtures from the subframe.
21. Fit the A/C compressor retaining bolts and A/C compressor connector. Tightening torque 24 Nm (18 lbf ft).
22. Fit the power steering pipes to the radiator assembly.
23. Connect the steering shaft to the steering gear. Use locking fluid on the bolts. Tightening torque 30 Nm (22 lbf ft)
24. Lower the car.
25. Remove the cable tie and reposition the engine wiring harness.
26. Plug in the connector on the structural member.
27. Attach the ground cables and the clamp for the engine harness.
28. Fit the retaining bolt for the engine harness connector in the main fuse box.
29. Attach the positive cable to the positive terminal of the battery.
30. Fit the cover on the electrical center and undo the two retaining bolts.
31. Attach the breather hoses to the coolant reservoir.
32. Attach the charge air pipe between the throttle body and charge air cooler.
33. Plug in the boost pressure sensor connector (688).
34. Remove the plugs and install the lower radiator hose. Auto: Connect the oil pipes to the radiator.
35. Move the radiator assembly forward slightly and install the fan cowling.
36. Fit the bolts.
37. Attach the upper radiator hose to the engine.
38. Fit the upper radiator brackets to the body.
39. Fit the cover over the radiator core.
40. Plug in the connector and attach the clips securing the cables on the fan cowling.
41. Fit the air cleaner casing and connect the intake hose. Fit the air cleaner and the air cleaner casing.
42. Fit the turbocharger intake pipe.
43. Attach the secondary air pipe to the turbocharger intake manifold.
44. Fit the ventilation hose to the turbocharger and attach the dipstick tube breather hose.
45. Plug in the connector to the mass air flow sensor.
46. Fit the upper radiator member.
47. Plug in the horn connector.
48. Reposition the right-hand headlight.
49. Fit the bonnet wire quick coupling.
50. Fit the turbocharger intake manifold to the radiator member.
51. Plug in the bonnet switch connector, fit the cable clip and install the battery tray.
52. Fit the cable duct on the battery tray.
53. Fit the fuse holder on the battery tray.
54. Fit the filler pipe of the washer fluid reservoir.
55. Install the main fuse box in front of the battery tray.
56. Fit the battery.
57. Raise the car.
58. Install the rear catalytic converter. Tightening torque, flange: 30 Nm (22 lbf ft) Tightening torque, clip: 40 Nm (30 lbf ft)
59. Fit the coolant connection.
60. Fit the dryer filter bolts on the radiator.
61. Fit the oil cooler's radiator hose to the radiator.
62. Fit the hose between the charge air cooler and the charge air pipe.
63. Fit the cover on the right-hand side.
64. Fit the lower charge air pipe to the fan cowling.
65. Attach the charge air hose between the charge air pipe and the charge air cooler.
66. Fit the cover on the left-hand side.
67. Fit the bumper.
68. Unload the belt tensioner. Use a 1/4 " puller and fit the drive belt. CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000)
69. Install the right wing liner and the front part of the left wing liner.
70. Plug in the headlight washer hose.
71. Fit and plug in the connector and fit the lower spoiler shield.
72. Lower the car slightly and mount the front wheels. See «WHEELS»(ref-275842-S00354976112007122900000)
73. Tighten the center nuts of the drive shafts. Tightening torque 230 Nm (170 lbf ft).
74. Fit the negative cable and battery cover.
75. Remove the wing covers.
76. Check oil level and top up as necessary. Fill with coolant to approx. 20 mm above the mark on the expansion tank. If a new engine is fitted, follow the instructions given in «BLEEDING THE COOLING SYSTEM WHEN WORKING WITH THE OIL COOLER»(ref-275852-S03845072162007122900000) .
77. Close the expansion tank cap.
78. Auto: If the gearbox was drained, check the automatic transmission fluid level as described in «CHECKING THE TRANSMISSION FLUID LEVEL»(ref-275843-S10888626052007122900000) .
79. Remove the wing covers and restore car electrical functions, see «PROCEDURES AFTER DISCONNECTING THE BATTERY (2006)»(ref-275860-S17719632962007122900000) or «PROCEDURE AFTER DISCONNECTING THE BATTERY (2007)»(ref-279916-S18926929322008021800000) .
80. Fit the upper engine cover.

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1. Remove «CAMSHAFT COVERS, REMOVED ENGINE»(ref-275854-S24663228022007122900000) .
2. Remove the coolant port. Remove the seal and O-ring.
3. Remove the front and rear solenoid valves of the variable camshaft. Remove the seals.
4. Remove the front and rear position sensor of the camshaft.
5. Remove the coolant pump pulley.
6. Remove the belt tensioner and screw.
7. Remove the bolt holding the crankshaft pulley using «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY»(ref-275854-S05764320762007122900000) (handle only) and «EN-47981 HOLDING TOOL, PULLEY»(ref-275854-S18686389472007122900000) . NOTE: The pulley is pressed onto the crankshaft.
8. Remove the pulley using «EN-47982 PULLER»(ref-275854-S17851804252007122900000) , «EN-47981 HOLDING TOOL, PULLEY»(ref-275854-S18686389472007122900000) and «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY»(ref-275854-S05764320762007122900000) (handle only)
9. Remove the timing cover. Use a pry bar to carefully pry loose the cover plus a screw that is carefully screwed in (to press the cover loose).
10. Clean sealing surfaces of gasket residue and the like.

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1. Apply a 2 mm thick bead of 93 160 951 Flange sealant on the sealing surface as the timing cover. Fit a new seal at the coolant pump.
2. Fit the timing cover. Tightening torque 25 Nm (18 lbf ft)
3. Fit the pulley to the crankshaft. Use KM-J 41998 Fitting tool to press the pulley into place.
4. Fit the bolt using «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY»(ref-275854-S05764320762007122900000) (handle only) and «EN-47981 HOLDING TOOL, PULLEY»(ref-275854-S18686389472007122900000) . Tightening torque: 100 Nm + 150° (74 lbf ft + 150°)
5. Fit the belt tensioner and the screw
6. Fit the coolant pump pulley using a screwdriver as a holding tool. Tightening torque: 12 Nm (9 lbf ft)
7. Fit the front and rear camshaft position sensors using new seals. Tightening torque 10 Nm (7 lbf ft)
8. Fit the seals and the front and rear solenoid valves of the variable camshaft. Tightening torque 10 Nm (7 lbf ft)
9. Fit the coolant port using a new seal and O-ring. Tightening torque 10 Nm (7 lbf ft)
10. Fit «CAMSHAFT COVERS, REMOVED ENGINE»(ref-275854-S24663228022007122900000) .

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1. Remove the Camshaft cover, front, B284. Remove the Camshaft cover, rear, B284. WARNING: The cooling system is under pressure. Hot coolant and steam can escape. Open the cap slowly to release the pressure. Carelessness can cause eye and burn injuries
2. Open the expansion tank cap and relieve any excess pressure.
3. Raise the car.
4. Undo the right-hand side of the spoiler shield.
5. Place a suitable receptacle under the radiator. Connect a hose (A) to the radiator and drain the coolant. Close the cock (B) and refit the spoiler shield.
6. Remove the front right wheel.
7. Remove the right wing liner (A).
8. Remove the power steering's hydraulic line from the holder (A) on the front axle member.
9. Remove Engine mounting, right.
10. Unload the belt tensioner. (A) Use a 1/4" drawbar handle and remove the drive belt from the A/C compressor pulley.
11. Remove the bolt holding the crankshaft pulley using «83 95 360 HOLDING TOOL, CRANKSHAFT, PULLEY, CRANKSHAFT, PULLEY»(ref-275854-S05764320762007122900000) (shaft only) and holding tool «EN-47981 HOLDING TOOL, PULLEY»(ref-275854-S18686389472007122900000) (A). NOTE: The pulley is pressed onto the crankshaft.
12. Remove the pulley using «EN-47982 PULLER»(ref-275854-S17851804252007122900000) and «EN-47981 HOLDING TOOL, PULLEY»(ref-275854-S18686389472007122900000) (A).
13. Remove the transmission housing at the bottom by removing the bolts. (A)
14. Remove the wiring harness holder from the bottom of the transmission housing by removing the bolt (B).
15. Lower the car.
16. Detach the coolant line (A) from the coolant outlet pipe by removing the bolt (B).
17. Remove the coolant outlet pipe (A) by detaching the coolant hose and removing the clamp and bolts.
18. Remove the coolant pump belt pulley (B) by removing the bolts. Counterhold with a screwdriver.
19. Remove the coolant pump by removing the bolts (A).
20. Remove the power steering pump at the top by undoing the bolted joint (A).
21. Raise the car.
22. Remove the power steering pump at the bottom by removing the bolt (B). Move the power steering pump towards the front of the car.
23. Lower the car.
24. Remove the wiring harness holder from the top of the transmission housing by removing the bolt (A).
25. Remove the drive belt tensioner by undoing the bolts (B).
26. Remove the camshaft setting's valve (C) for cylinder 1-3-5 by removing the bolt.
27. Remove the camshaft setting's valve (D) for cylinder 2-4-6 by removing the bolt.
28. Remove the upper bolts (E) of the transmission housing.
29. Remove the wiring harness holder from the wiring harnesses.
30. Remove the timing cover (A). Carefully prise the cover loose with a pry bar and a bolt (B) that is carefully screwed in (to press off the cover).

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1. Clean the sealing surfaces.
2. Fit «EN-46109-2 CENTERING TOOL»(ref-275854-S23510918042007122900000) (A) in the engine block and cylinder head.
3. Apply 93 165 267 Flange sealant. Apply an approximately 3 mm thick bead on the transmission housing sealing surfaces (A).
4. Position the transmission housing with the help of another technician. Check that the sealant bead is undamaged when positioning the transmission housing.
5. Fit the upper bolts (A) of the transmission housing. Remove the centering tools. Tightening torque 23 Nm (16.9 lbf ft)
6. Fasten the wiring harness holder to the wiring harnesses.
7. Raise the car.
8. Fit the lower bolts (B) of the transmission housing. Tightening torque 23 Nm (16.9 lbf ft)
9. Fit the pulley (A) to the crankshaft. Use «J-41998 FITTING TOOL»(ref-275854-S06777088222007122900000) to press on the pulley.
10. Fit the bolt using «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY»(ref-275854-S05764320762007122900000) (handle only) and «EN-47981 HOLDING TOOL, PULLEY»(ref-275854-S18686389472007122900000) . Tightening torque: 100 Nm + 150° (74 lbf ft + 150°)
11. Lower the car.
12. Fit the camshaft setting solenoid valve (B) for cylinder 2-4-6. Tightening torque 10 Nm (7.3 lbf ft)
13. Fit the camshaft setting solenoid valve (A) for cylinder 1-3-5. Tightening torque 10 Nm (7.3 lbf ft)
14. Fit the belt tensioner and the bolts (C). Tightening torque 22 Nm (16.2 lbf ft)
15. Fasten the wiring harness holder at the top. Tighten the bolt.
16. Fasten the wiring harness holder at the bottom. Tighten the bolt.
17. Secure the power steering pump. Tighten the bolts (A) and bolt (B). Tightening torque 22 Nm (16.2 lbf ft)
18. Fit the coolant pump (A). Use a new seal. Tightening torque 10 Nm (7.3 lbf ft)
19. Fit the coolant pump's belt pulley (A). Use a screwdriver as a holding tool. Tightening torque 12 Nm (9 lbf ft)
20. Fit the coolant outlet pipe (B). Use new seals. Tightening torque, bolts: 12 Nm (9 lbf ft) Fit the coolant hose and hose clip.
21. Unload the belt tensioner (C). Use a 1/4 drawbar handle and fit the drive belt (D).
22. Fit Engine mounting, right.
23. Fit the coolant line (A) on the coolant outlet pipe. Use a new sealing ring. Fit the bolt (B). Tightening torque, bolts: 8 Nm (6 lbf ft)
24. Raise the car.
25. Secure the power steering's fluid line in the holder (A) on the front axle member.
26. Lower the car halfway.
27. Fit the right wing liner (A).
28. Fit the front right wheel ( «WHEEL»(ref-275842-S20194743172007122900000) ).
29. Fit the Camshaft cover, front, B284. Remove the Camshaft cover, rear, B284.
30. «BLEEDING AND CHARGING THE COOLING SYSTEM»(ref-275856-S10550426312007122900000) .

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1. Remove the battery cover and the negative cable. WARNING: The cooling system is under pressure. Hot coolant and steam can escape. Open the cap slowly to release the pressure. Carelessness can cause eye and burn injuries
2. Open the cap to the expansion tank, release any overpressure.
3. Raise the car.
4. Undo the right-hand side of the spoiler shield.
5. 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.
6. Lower the car. IMPORTANT: When removing the air cleaner casing cover, be careful not to damage the brake vacuum pump sensor.
7. Remove the upper section of the air cleaner.
8. Remove the lower section of the air filter. IMPORTANT: Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275842-S26624887112007122900000) .
9. Unplug the mass air flow sensor connector. Detach the secondary air pipe, the delivery hose from the turbocharger intake manifold and the crankcase ventilation pipes.
10. Detach the turbocharger intake manifold from the air filter housing cover and the turbocharger.
11. Remove the upper engine cover.
12. Remove the charge air pipe by first removing the clamps and the charge pressure sensor connectors. Detach the power steering line.
13. Remove the coolant return line by first removing the wiring harnesses.
14. Remove the connector and the ground connection to the engine control module
15. Remove the engine control module bolts.
16. Remove the wiring harnesses holders by removing the cable duct, the connectors and the nut. Unplug the connector to the intake manifold pressure sensor. Remove the bolt, cable tie and connector.
17. Undo the quick coupling and remove the vacuum line from the upper section of the intake manifold.
18. Remove the crankcase ventilation lines by removing the bolt and removing the holder.
19. Remove the holder to the injector's connector.
20. Remove the throttle body connector and remove the upper section of the intake manifold. WARNING: The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures: Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc. Absolutely No Smoking! Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used. Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin. Wear protective goggles.
21. Undo the quick couplings and remove the bleeder valve plus lines.
22. Place a collecting pan under the car.
23. Detach the fuel line, wiping up any fuel spill with a cloth.
24. Remove the power steering reservoir by removing the bolt, return hose and clamp. Seal the hose and reservoir. Turn the reservoir to the side.
25. Unplug the connectors to the fuel pressure sensor.
26. Remove the wiring harnesses from the cylinder head for cylinders 1-3-5. Unplug the camshaft position sensor connector, the connector to the camshaft setting valve and the holder.
27. Remove the wiring harnesses from the cylinder head for cylinders 2-4-6. Unplug the camshaft position sensor connector, the connector to the camshaft setting valve and the holder.
28. Remove the wiring harness for the injectors by first unplugging the injectors' connectors.
29. Remove the fuel rail with injectors.
30. Remove the lower section of the intake manifold. Seal the inlet ducts to the cylinder head with lintless rags.
31. Remove the ignition coils for cylinders 2-4-6 by first unplugging the connectors.
32. Remove the wiring harness holder from the camshaft cover for cylinders 1-3-5.
33. Remove the ignition coils for cylinders 1-3-5 by first unplugging the connectors.
34. Remove the ground cable from the wiring harnesses by carefully cutting open the tape strip (arrows). Place the ground cable to one side.
35. Remove the wiring harnesses plus connectors. Remove the cable tie.
36. Remove «BATTERY COVER, BOTTOM (2006)»(ref-275860-S10461848692007122900000) or «BATTERY COVER, BOTTOM (2007)»(ref-279916-S39619585692008021800000) .
37. Loosen the expansion tank from the mounting.
38. Remove the turbocharger heat shield panel.
39. Remove the crankcase ventilation line from the turbocharger.
40. Remove the crankcase ventilation check valve from the camshaft cover for cylinders 1-3-5.
41. Undo the quick coupling and remove the secondary air system's valve for cylinders 2-4-6.
42. Undo the upper quick coupling by removing the bolt and removing the secondary air system's delivery line.
43. Remove the turbocharger diaphragm unit by undoing the bolt and pressing it out.
44. Remove the secondary air system's delivery line for cylinders 1-3-5.
45. Remove the secondary air system's delivery line for cylinders 2-4-6.
46. Remove the ventilation line to the oil dipstick's guide tube by undoing the quick coupling.
47. Remove the engine's wiring harness from cylinders 2-4-6 by unplugging the connectors, and by removing the head shield and the ground cable from the cylinder head. Fold the wiring harnesses to the side.
48. Remove the engine's transport lug by removing the bolts.
49. Remove the camshaft cover for cylinders 2-4-6 by removing the bolts.
50. Remove the camshaft cover for cylinders 1-3-5 by removing the bolts.
51. Raise the car to half height.
52. Remove the front wheels.
53. Remove the right wing liner.
54. Remove the power steering hydraulic line from the holder on the front axle beam.
55. Remove «ENGINE MOUNTING, RIGHT»(ref-275854-S23590498842007122900000) .
56. Relieve the load on the belt tensioner. Use a 1/4 puller handle and remove the driver belt from the A/C compressor pulley.
57. Remove the bolt holding the crankshaft pulley using «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY»(ref-275854-S05764320762007122900000) (handle only) and «EN-47981 HOLDING TOOL, PULLEY»(ref-275854-S18686389472007122900000) . NOTE: The pulley is pressed onto the crankshaft.
58. Remove the pulley using «EN-47982 PULLER»(ref-275854-S17851804252007122900000) and «EN-47981 HOLDING TOOL, PULLEY»(ref-275854-S18686389472007122900000) .
59. Remove the transmission housing at the bottom by removing the bolts.
60. Remove the wiring harness holder from the bottom of the transmission housing by removing the bolt.
61. Lower the car.
62. Remove the coolant line from the coolant outlet pipe by removing the bolt.
63. Remove the coolant outlet pipe by removing the coolant hose, remove the clamp and remove the bolts.
64. Remove the coolant pump pulley by removing the bolts. Hold firm with a screwdriver.
65. Remove the coolant pump by removing the bolts.
66. Remove the power steering pump at the top by removing the bolted joint.
67. Raise the car.
68. Remove the power steering pump at the bottom by removing the bolt. Move the power steering pump towards the front of the car
69. Lower the car.
70. Remove the drive belt tensioner by removing the bolt.
71. Remove the camshaft setting valve for cylinders 1-3-5 by removing the bolt.
72. Remove the camshaft setting valve for cylinders 2-4-6 by removing the bolt.
73. Remove the upper bolts of the transmission housing.
74. Remove the timing cover. Carefully prize the cover loose with a pry bar and a screw that is carefully screwed in (to press the cover loose).
75. Remove the starter motor's wiring harness holder from the wiring harnesses.

Scheme 597

Scheme 598

Scheme 599

Scheme 600

Scheme 601

Scheme 602

Scheme 603

Scheme 604

Scheme 605

Scheme 606

Scheme 607

Scheme 608

Scheme 609

Scheme 610

Scheme 611

Scheme 612

Scheme 613

Scheme 614

Scheme 615

Scheme 616

Scheme 617

Scheme 618

Scheme 619

Scheme 620

Scheme 621

Scheme 622

Scheme 623

Scheme 624

Scheme 625

Scheme 626

Scheme 627

Scheme 628

Scheme 629

Scheme 630

Scheme 631

Scheme 632

Scheme 633

Scheme 634

Scheme 635

Scheme 636

Scheme 637

Scheme 638

Scheme 639

Scheme 640

Scheme 641

Scheme 642

1. Clean the sealing surfaces.
2. Fit «EN-46109-2 CENTERING TOOL»(ref-275854-S23510918042007122900000) in the engine block and cylinder head.
3. Apply 93 165 267 Flange sealant. Apply an approx. 3 mm thick bead on the sealing surfaces of the transmission housing.
4. Install the transmission housing with help from an assistant. Check that the sealing bead remains undamaged during the alignment of the transmission housing.
5. Fit the upper bolts for the transmission housing. Remove the centering tools. Tightening torque 23 Nm
6. Secure the starter motor's wiring harness holder on the wiring harnesses.
7. Raise the car.
8. Fit the lower bolts of the transmission housing. Tightening torque 23 Nm
9. Fit the lower bolt to the power steering pump. Tightening torque 22 Nm
10. Fit the pulley to the crankshaft. Use «J-41998 FITTING TOOL»(ref-275854-S06777088222007122900000) to press on the pulley.
11. Fit the bolt using «83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY»(ref-275854-S05764320762007122900000) (handle only) and «EN-47981 HOLDING TOOL, PULLEY»(ref-275854-S18686389472007122900000) . Tightening torque: 100 Nm + 150° (74 lbf ft + 150°)
12. Secure the starter motor's wiring harness holder at the bottom. Tighten the bolt.
13. Lower the car.
14. Fit the camshaft setting solenoid valve for cylinders 2-4-6. Tightening torque 10 Nm
15. Fit the camshaft setting solenoid valve for cylinders 1-3-5. Tightening torque 10 Nm
16. Fit the belt tensioner and the bolt Tightening torque 22 Nm
17. Secure the starter motor's wiring harness holder at the top. Tighten the bolt.
18. Secure the power steering pump at the top. Tightening torque 22 Nm
19. Fit the mounting bolts to the engine pad's attaching plate. Tightening torque 44 Nm
20. Fit the coolant pump. Use a new gasket. Tightening torque 10 Nm
21. Fit the coolant pump's belt pulley. Counterhold with a screwdriver. Tightening torque 12 Nm (9 lbf ft)
22. Fit the coolant outlet pipe. Use a new gasket. Tightening torque, bolts: 12 Nm (9 lbf ft) Fit the coolant hose and secure the clamp.
23. Unload the belt tensioner. Use a 1/4 " puller and fit the drive belt.
24. Fit «ENGINE MOUNTING, RIGHT»(ref-275854-S23590498842007122900000) .
25. Fit the holder to the power steering line. Tightening torque, bolt 8 Nm (6 lbf ft)
26. Fit the coolant line to the coolant outlet pipe. Use a new sealing ring. Tightening torque 8 Nm (6 lbf ft)
27. Raise the car.
28. Secure the power steering hydraulic line in the holder on the front axle beam.
29. Lower the car to half height.
30. Fit the right-hand wing liner.
31. Fit the «WHEEL»(ref-275842-S20194743172007122900000) .
32. Clean the camshaft cover sealing surfaces.
33. Replace the camshaft cover gasket for cylinders 2-4-6.
34. Apply an approx. 3 mm thick bead of sealing compound on the separating points of the cylinder head and transmission housing. Use 93 165 267 Flange sealant.
35. Fit the camshaft cover for cylinders 2-4-6. Tightening torque, bolts: 10 Nm (8 lbf ft)
36. Fit the engine's transport lug. Tightening torque, bolt 65 Nm (48 lbf ft)
37. Clean the camshaft cover sealing surfaces.
38. Replace the camshaft cover gasket for cylinders 1-3-5. Use new gaskets.
39. Apply an approx. 3 mm thick bead of sealing compound on the separating points of the cylinder head and transmission housing. Use 93 165 267 Flange sealant.
40. Fit the camshaft cover for cylinders 1-3-5. Tightening torque, bolts: 10 Nm (8 lbf ft) IMPORTANT: Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275842-S26624887112007122900000) .
41. Fit the engine wiring harnesses to the cylinder head for cylinders 2-4-6 by plugging in the connectors on the cylinder head for cylinders 2-4-6. Fit the heat shield and fit the ground cable on the cylinder head for cylinders 2-4-6. Fit the bolts. Secure the wiring harnesses. Secure the engine control module's ground cable in the wiring harnesses. Fit the cable ties.
42. Fit the secondary air system line for cylinders 2-4-6. Fit the exhaust pipe. Tightening torque, bolts: 10 Nm (8 lbf ft)
43. Fit the ventilation line to the oil dipstick's guide tube. Connect the quick coupling.
44. Fit the turbocharger diaphragm unit by fitting the bolts.
45. Fit the secondary air system's delivery line. Connect the quick couplings.
46. Fit the secondary air system's check valve for cylinders 2-4-6. Use a new gasket. Tighten the bolts and connect the quick coupling.
47. Fit the secondary air system's delivery line and bolt.
48. Fit the check valve to the crankcase ventilation on the camshaft cover for cylinders 1-3-5.
49. Fit the crankcase ventilation line on the turbocharger. Tightening torque, bolt 10 Nm (8 lbf ft)
50. Fit the turbocharger's upper heat shield panel. Fit the nut. Tightening torque, bolts: 10 Nm (8 lbf ft)
51. Fit the expansion tank in the holder.
52. Fit «BATTERY COVER, BOTTOM, B284 (2006)»(ref-275860-S10461848692007122900000) or «BATTERY COVER, BOTTOM (2007)»(ref-279916-S39619585692008021800000) .
53. Fit the charge pressure regulator's wiring harness. Plug in the connector. Fit the cable tie.
54. Fit the ignition coils for cylinders 2-4-6. Plug in the connectors. Tightening torque, bolts: 10 Nm (8 lbf ft)
55. Fit the wiring harness holder on the camshaft cover for cylinders 1-3-5. Secure in the holder.
56. Fit the ignition coils for cylinders 1-3-5. Plug in the connectors and fit the bolts. Tightening torque, bolts: 10 Nm (8 lbf ft)
57. Fit the lower section of the intake manifold with a new seal. Remove the rags from the inlet ducts. Tightening torque, bolts: 23 Nm (17 lbf ft)
58. Fit the fuel rail with injectors. Tightening torque, bolts: 10 Nm (8 lbf ft)
59. Fit the injectors' wiring harness. Plug in the connectors.
60. Plug in the connectors to the fuel pressure sensor.
61. Fit the wiring harness to the camshaft guide for cylinders 2-4-6. Plug in the connectors and secure in the holder.
62. Connect the wiring harness to the camshaft guide for cylinders 1-3-5. Plug in the connectors and secure in the holder.
63. Fit the power steering reservoir. Fit the return hose. Secure the clamp. Tightening torque, bolt 9 Nm (7 lbf ft).
64. Connect the fuel delivery line.
65. Fit the bleeder valve plus lines. Connect the quick couplings. Plug in the connectors to the bleeder valve.
66. Fit the upper section of the intake manifold. Plug in the throttle body's connector. Use new gaskets. Tightening torque, bolts: 23 Nm (17 lbf ft)
67. Fit the holder to the injector's connector. Tightening torque, bolt 10 Nm (8 lbf ft)
68. Fit the lines for the crankcase ventilation. Tightening torque, bolt 10 Nm (8 lbf ft)
69. Fit the vacuum line on the upper section of the intake manifold. Connect the quick coupling.
70. Fit the wiring harnesses' holders. Fit the bolt. Plug in the connectors for the intake manifold's pressure sensor. Fit the cable cables. Secure the connectors. Fit the cable duct. Plug in the connectors. Fit the nut.
71. Fit the engine control module. Fit the bolts. Tightening torque, bolts: 10 Nm (8 lbf ft)
72. Fit the ground connection. Plug in the engine control module connector.
73. Fit the coolant return line. Fit the clamps. Tightening torque, bolts: 10 Nm (8 lbf ft)
74. Fit the charge air pipe. Fit the clamp. Tightening torque, clamp 3.5 Nm Plug in the charge pressure sensor connector. Secure the power steering line with clips.
75. Fit the air intake pipe. Tightening torque, clamp: 3.5 Nm (2.5 lbf ft) Tightening torque, bolt 1.5 Nm (1.1 lbf ft).
76. Fit the air filter housing with the mass air flow sensor as follows: Plug in the mass air flow sensor connector. Secure the cable ties. Fit the secondary air system's intake manifold. Secure the line. Connect the quick coupling.
77. Fit the upper engine cover. Remove the oil filler opening's screw cap. Fit the protective cover. Fit the oil filler opening's screw cap.
78. Fill and bleed the cooling system, see «BLEEDING AND CHARGING THE COOLING SYSTEM»(ref-275856-S10550426312007122900000) .
79. Connect the negative cable and fit the battery cover. Tightening torque, clamps 3.5 Nm (2.5 lbf ft)
80. Close the bonnet.

Drain the oil from the engine and the fluid from the gearbox.

Scheme 643

Scheme 644

Scheme 645

Scheme 646

Scheme 647

Scheme 648

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

Scheme 654

Scheme 655

Scheme 656

Scheme 657

Scheme 658

Scheme 659

Scheme 660

Scheme 661

Scheme 662

Scheme 663

Scheme 664

Scheme 665

1. Detach the generator electrical connections and remove the generator.
2. Remove the generator bracket.
3. Remove the right-hand drive shaft with intermediate shaft.
4. Remove the bearing anchorage of the intermediate shaft.
5. Remove the engine mounting from the engine.
6. Remove the drive belt.
7. Remove the power steering pump. Let the servo hoses remain on the pump.
8. Unplug the control module connectors and disconnect the ground cable.
9. Unhook the power steering reservoir and servo hose clips.
10. Remove the A/C bracket and the turbocharger delivery pipe mounting.
11. Remove the power steering pump bracket.
12. Remove the secondary air injection pump complete with connectors, hoses and mountings.
13. Detach the turbocharger delivery hose from the turbocharger.
14. Detach the coolant hoses from the oil cooler. Collect any fluid spill.
15. Detach the coolant pipe with hoses from the thermostat housing.
16. Remove the starter motor with electrical connections.
17. Auto: Remove the bolts holding the torque converter in place.
18. Remove the wiring harness between the starter motor and generator as well as the one from the rear of the intake manifold. Release the two clips from the back of the engine and the cable duct on the gearbox. Man: Remove the cable mounting from the gearbox. Auto: Remove the clamp and ground cable from the plate bracket and unplug the connector from the gear selector position sensor/control module.
19. Detach the 7-pin connector and the cable duct from the intake manifold.
20. Remove the upper heat shield from the turbocharger.
21. Remove the lower heat shield from the turbocharger.
22. Unplug the connectors of the heated oxygen sensors.
23. Detach the upper oxygen sensor from the catalytic converter.
24. Remove the catalytic converter with mounting.
25. Remove the upper mounting of the catalytic converter from the engine.
26. Remove the coolant pipe between the heat exchanger and thermostat housing.
27. Unplug the connectors and remove the engine control module with mounting.
28. Connect 83 92 409 Lifting yoke to the engine and unload with an engine lift.
29. Remove the bolts holding the torque arms to the subframe.
30. Raise the engine from the subframe.
31. Remove the 4 lower bolts of the gearbox.
32. Place the engine on the floor.
33. Remove the gearbox bolts and lift away the gearbox. Auto: Press the torque converter against the gearbox.
34. Auto: Fit «87 92 574 HOLDER»(ref-275854-S18204747502007122900000) to hold the torque converter in place.
35. Transfer the crankcase ventilation hose.

1. Remove «REAR CAMSHAFT COVER»(ref-275854-S07148504142007122900000) or «FRONT CAMSHAFT COVER»(ref-275854-S28178670922007122900000) .
2. Remove «VALVE MECHANISM, REAR CYLINDER HEAD, B284 (OLD VERSION)»(ref-275854-S41703001322007122900000) or «VALVE MECHANISM, FRONT CYLINDER HEAD, B284 (OLD VERSION)»(ref-275854-S36181162132007122900000)

Scheme 666

Scheme 667

Scheme 668

Scheme 669

Scheme 670

Scheme 671

Scheme 672

Scheme 673

Scheme 674

Scheme 675

Scheme 676

1. Remove «REAR CAMSHAFT COVER»(ref-275854-S07148504142007122900000)
2. Remove the spark plugs.
3. Remove the camshaft solenoid valve (695R) (A)
4. Remove the camshaft position sensor (555R) (B).
5. Rotate the engine so that the markings on the camshaft sprockets are visible (A) and the indentations align with the cylinder head. Use «EN-46105 ADJUSTMENT TOOL»(ref-275854-S27477933482007122900000) as a gauge (the camshafts are now in their neutral position) (B).
6. Fit «EN-46106 FLYWHEEL LOCKING ATTACHMENT»(ref-275854-S27760648232007122900000) (A).
7. Mark the chain and camshaft sprockets so they can be refitted in the same position.
8. Slightly loosen the bolts holding the camshaft sprockets (A). Counterhold using an open spanner on the camshaft flats (do not remove the bolts).
9. Fit EN-46108-2 Fixing tool to the camshaft chain on the intake side (B). Check that the tool grips the chain firmly.
10. Fit EN-46108-1 Fixing tool to the camshaft chain on the exhaust side (C). Check that the tool grips the chain firmly.
11. Tighten «EN-46108 FIXING TOOL»(ref-275854-S11807981242007122900000) so that the chain is unloaded. IMPORTANT: It is extremely important that tool no. EN-46108 is properly fitted. If the chain is not unloaded when the camshaft sprocket bolts are removed, the automatic chain tensioner is triggered. If this occurs, the timing cover must be removed to adjust the chain tensioner.
12. Remove the camshaft sprockets' bolts (D).
13. Remove the sprockets from the camshafts (E).
14. Remove the camshafts' bearing caps by loosening the bolts in stages - 1/2 to 1 turn (A). It is important that removal ends at the bearing cap where the tappets are loaded. Note the markings on the bearing caps when refitting to ensure that they are in the correct locations.
15. Lift out the camshafts (B) and note the rear marking on the camshafts.
16. Remove the roller rockers and the hydraulic adjuster elements (A). Store them in 83 93 787 Valve stand so they do not get mixed up. IMPORTANT: Cover all return oil ducts in the cylinder head so that the valve cone or contaminants cannot fall down into the engine.
17. Fit EN-46110-eu Valve spring tool (A).
18. Fit «83 94 173 AIR NIPPLE FOR SPARK PLUG HOLE»(ref-275854-S09118552122007122900000) (A). Connect compressed air and put the piston and valves under pressure.
19. Press down the valve plate (B) with EN-46110-eu Valve spring tool. IMPORTANT: The compressed air must not be disconnected when the valve cone is removed. Do not press on the valve stem either as counter-pressure in the cylinder could reduce and the valve could fall down into the cylinder.
20. Remove the valve cone with a magnet (A).
21. Lift out the spring plate and valve spring (A).

Scheme 677

Scheme 678

1. Clean all parts and check contact surfaces and bearing surfaces for wear.
2. Fit the valve spring and spring plate (A).
3. Press down the valve plate with EN-46110-eu Valve spring tool.
4. Fit the valve cone (A) using «EN-46117 FITTING TOOL»(ref-275854-S08549377532007122900000) .
5. Unload the valve and remove EN-46110-eu Valve spring tool.
6. Disconnect the compressed air connection and remove the air nipple.
7. Position the camshafts and use EN-46105-1 Adjustment tool to check that the camshafts are mounted at the correct angle.
8. Fit the bearing caps (markings on caps). Start where the cams point down and load the tappets. Tightening torque 10 Nm (7 lbf ft) IMPORTANT: Tighten the bolts in stages - 1/2 to 1 turn.
9. Check that the markings (A) on the chain match the markings on the sprockets.
10. Fit the sprockets with the chain on the camshafts. Tighten the bolts by hand (A).
11. Remove EN-46108-2 Fixing tool (B).
12. Remove EN-46108-1 Fixing tool (C).
13. Tighten the bolts for both camshaft sprockets, counter-holding with an open spanner on the camshaft flats (D). Tightening torque: 65 Nm (48 lbf ft)
14. Remove «EN-46106 FLYWHEEL LOCKING ATTACHMENT»(ref-275854-S27760648232007122900000) .
15. Fit the camshaft position sensor (555R) using a new gasket (B). Tightening torque 10 Nm (7 lbf ft)
16. Fit the camshaft solenoid valve (695R) using a new seal (A). Tightening torque 10 Nm (7 lbf ft)
17. Fit the spark plugs.
18. Fit «REAR CAMSHAFT COVER»(ref-275854-S07148504142007122900000)

Scheme 679

Scheme 680

Scheme 681

Scheme 682

Scheme 683

Scheme 684

Scheme 685

Scheme 686

Scheme 687

Scheme 688

Scheme 689

Scheme 690

1. Remove «REAR CAMSHAFT COVER»(ref-275854-S07148504142007122900000)
2. Remove the spark plugs.
3. Remove the camshaft solenoid valve (695R).
4. Remove the camshaft position sensor (555R).
5. Rotate the engine so that the markings on the camshaft sprockets are visible and the indentations align with the cylinder head. Use «EN-46105 ADJUSTMENT TOOL»(ref-275854-S27477933482007122900000) as a gauge (the camshafts are now in their neutral position).
6. Fit «EN-46106 FLYWHEEL LOCKING ATTACHMENT»(ref-275854-S27760648232007122900000) .
7. Mark the chain and camshaft sprocket so they can be refitted in the same position.
8. Slightly loosen the bolts holding the camshaft sprockets. Counterhold using an open spanner on the camshaft flats (do not remove the bolts).
9. Fit EN-46108-2 Fixing tool to the camshaft chain on the intake side. Check that the tool grips the chain firmly.
10. Fit EN-46108-1 Fixing tool to the camshaft chain on the exhaust side. Check that the tool grips the chain firmly.
11. Tighten «EN-46108 FIXING TOOL»(ref-275854-S11807981242007122900000) so that the chain is unloaded. IMPORTANT: It is extremely important that tool no. EN-46108 is properly fitted. If the chain is not unloaded when the camshaft sprocket bolts are removed, the automatic chain tensioner is triggered. If this occurs, the timing cover must be removed to adjust the chain tensioner.
12. Remove the camshaft sprocket bolts.
13. Remove the sprockets from the camshafts.
14. Remove the camshaft bearing caps by loosening the bolts in stages - 1/2 to 1 turn. It is important that removal ends at the bearing cap where the tappets are loaded. Note the markings on the bearing caps when refitting to ensure that they are in the correct spots.
15. Lift out the camshafts and note the rear marking on the camshafts. The last letters in the marking: RI = intake camshaft, rear cylinder bank. RE = exhaust camshaft, rear cylinder bank.
16. Remove the roller rockers and the hydraulic adjuster elements. Store them in 83 93 787 Valve stand so they do not get mixed up. IMPORTANT: Cover all return oil ducts in the cylinder head so that the valve cone or contaminants cannot fall down into the engine.
17. Fit EN-46110-eu Valve spring tool
18. Fit «83 94 173 AIR NIPPLE FOR SPARK PLUG HOLE»(ref-275854-S09118552122007122900000) . Connect compressed air and put the piston and valves under pressure.
19. Press down the valve plate with EN-46110-eu Valve spring tool. IMPORTANT: The compressed air must not be disconnected when the valve cone is removed. Do not press on the valve stem either as counter-pressure in the cylinder could reduce and the valve could fall down into the cylinder.
20. Remove the valve cone with a magnet.
21. Lift out the spring plate and valve spring.
22. Lift out the valve guide seal using 83 94 157 Pliers, valve guide seal.

Scheme 691

Scheme 692

Scheme 693

Scheme 694

Scheme 695

1. Clean all parts and check contact surfaces and bearing surfaces for wear.
2. Fit the valve guide seal using 83 94 157 Pliers, valve guide seal.
3. Fit the valve spring and spring plate.
4. Press down the valve plate with EN-46110-eu Valve spring tool.
5. Fit the valve cone using «EN-46117 FITTING TOOL»(ref-275854-S08549377532007122900000) .
6. Unload the valve and remove EN-46110-eu Valve spring tool.
7. Disconnect the compressed air and remove the air nipple.
8. Position the camshafts and use EN-46105-1 Adjustment tool to check that the camshafts are mounted at the correct angle. The last letters in the marking: RI = intake camshaft, rear cylinder bank. RE = exhaust camshaft, rear cylinder bank.
9. Fit the bearing caps (markings on caps). Start where the cams point down and load the tappets. Tightening torque 10 Nm (7 lbf ft) IMPORTANT: Tighten the bolts in stages - 1/2 to 1 turn.
10. Fit the sprockets with chain on the camshafts. Tighten the bolts by hand.
11. Check that the marks on the chain match the markings on the sprockets.
12. Remove EN-46108-2 Fixing tool.
13. Remove EN-46108-1 Fixing tool.
14. Tighten the bolts of both camshaft sprockets, counter-holding with an open spanner on the camshaft flats. Tightening torque: 65 Nm (48 lbf ft)
15. Remove «EN-46106 FLYWHEEL LOCKING ATTACHMENT»(ref-275854-S27760648232007122900000) .
16. Fit the camshaft position sensor (555R) using a new gasket. Tightening torque 10 Nm (7 lbf ft)
17. Fit the camshaft solenoid valve (695R) using a new seal. Tightening torque 10 Nm (7 lbf ft)
18. Fit the spark plugs.
19. Fit «REAR CAMSHAFT COVER»(ref-275854-S07148504142007122900000)

Scheme 696

Scheme 697

Scheme 698

Scheme 699

Scheme 700

Scheme 701

Scheme 702

Scheme 703

Scheme 704

1. Remove «FRONT CAMSHAFT COVER»(ref-275854-S28178670922007122900000)
2. Remove the spark plugs.
3. Remove the coolant port (A).
4. Remove the camshaft solenoid valve (695F) (B).
5. Remove the camshaft position sensor (555F) (C).
6. Rotate the crankshaft so that the markings on the camshaft sprockets are visible (A), and the indentations align with the cylinder head. Use EN-46105-1 Adjustment tool as a gauge (the camshafts are now in their neutral position).
7. Fit «EN-46106 FLYWHEEL LOCKING ATTACHMENT»(ref-275854-S27760648232007122900000) (A).
8. Mark the chain and camshaft sprocket so they can be refitted in the same position.
9. Loosen the torque on the bolts holding the camshaft sprockets (A). Counterhold using an open spanner on the camshaft flats (do not remove the bolts).
10. Fit EN-46108-1 Fixing tool to the camshaft chain on the intake side (B). Check that the tool grips the chain firmly.
11. Fit EN-46108-2 Fixing tool to the camshaft chain on the exhaust side (C). Check that the tool grips the chain firmly.
12. Tighten «EN-46108 FIXING TOOL»(ref-275854-S11807981242007122900000) so that the chain is unloaded. IMPORTANT: It is extremely important that tool no. EN-46108 is properly fitted. If the chain is not unloaded when the camshaft sprocket bolts are removed, the automatic chain tensioner is triggered. If this occurs, the timing cover must be removed to adjust the chain tensioner.
13. Remove the camshaft sprocket bolts (D).
14. Remove the sprockets from the camshafts.
15. Remove the camshaft bearing caps by loosening the bolts in stages - 1/2 to 1 turn (A). It is important that the removal ends at the bearing cap where the tappets are loaded. Note the markings on the bearing caps when refitting to ensure that they are in the correct locations.
16. Lift out the camshafts and note the rear marking on the camshafts (B).
17. Remove the roller rockers and the hydraulic adjuster elements (A). Store them in 83 93 787 Valve stand so they do not get mixed up. IMPORTANT: Cover all return oil ducts in the cylinder head so that the valve cone or contaminants cannot fall down into the engine.
18. Fit EN-46110-eu Valve spring tool (A).
19. Fit «83 94 173 AIR NIPPLE FOR SPARK PLUG HOLE»(ref-275854-S09118552122007122900000) . Connect compressed air and put the piston and valves under pressure (A).
20. Press down the valve plate with EN-46110-eu Valve spring tool (B).
21. Remove the valve cone with a magnet (A). IMPORTANT: The compressed air must not be disconnected when the valve cone is removed. Do not press on the valve stem either as counter-pressure in the cylinder could reduce and the valve could fall down into the cylinder.

Scheme 705

1. Fit the valve cone using «EN-46117 FITTING TOOL»(ref-275854-S08549377532007122900000) (A).
2. Unload the valve and remove EN-46110-eu Valve spring tool.
3. Disconnect the compressed air and remove the air nipple.
4. Position the camshafts and use «EN-46105 ADJUSTMENT TOOL»(ref-275854-S27477933482007122900000) to check that the camshafts are mounted at the correct angle (B).
5. Fit the bearing caps (markings on caps) (A). Start where the cams point down and load the tappets. Note: tighten the bolts in stages - 1/2 to 1 turn. Tightening torque 10 Nm (7 lbf ft) IMPORTANT: Tighten the bolts in stages - 1/2 to 1 turn.
6. Fit the sprockets with chain on the camshafts. Tighten the bolts by hand.
7. Check that the marks on the chain match the markings on the sprockets.
8. Remove EN-46108-2 Fixing tool (A).
9. Remove EN-46108-1 Fixing tool (B).
10. Tighten the bolts of both camshaft sprockets, counter-holding with an open spanner on the camshaft flats (C). Tightening torque: 65 Nm (48 lbf ft)
11. Remove «EN-46106 FLYWHEEL LOCKING ATTACHMENT»(ref-275854-S27760648232007122900000) .
12. Fit the camshaft position sensor (555F) using a new gasket (C). Tightening torque 10 Nm (7 lbf ft)
13. Fit the camshaft solenoid valve (695F) using a new seal (B). Tightening torque 10 Nm (7 lbf ft)
14. Fit the coolant port using a new seal and gasket (A). Tightening torque 10 Nm (7 lbf ft)
15. Fit the spark plugs.
16. Fit «FRONT CAMSHAFT COVER»(ref-275854-S28178670922007122900000) or «REAR CAMSHAFT COVER»(ref-275854-S07148504142007122900000) .

Scheme 706

Scheme 707

Scheme 708

Scheme 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

Scheme 715

Scheme 716

Scheme 717

1. Remove «FRONT CAMSHAFT COVER»(ref-275854-S28178670922007122900000)
2. Remove the spark plugs.
3. Remove the coolant port.
4. Remove the camshaft solenoid valve (695F).
5. Remove the camshaft position sensor (555F).
6. Rotate the crankshaft so that the markings on the camshaft sprockets are visible and the indentations align with the cylinder head. Use EN-46105-1 Adjustment tool as a gauge (the camshafts are now in their neutral position).
7. Fit «EN-46106 FLYWHEEL LOCKING ATTACHMENT»(ref-275854-S27760648232007122900000) .
8. Mark the chain and camshaft sprocket so they can be refitted in the same position.
9. Reduce the tightening torque of the bolts holding the camshaft sprockets. Counterhold using an open spanner on the camshaft flats (do not remove the bolts).
10. Fit EN-46108-1 Fixing tool to the camshaft chain on the intake side. Check that the tool grips the chain firmly.
11. Fit EN-46108-2 Fixing tool to the camshaft chain on the exhaust side. Check that the tool grips the chain firmly.
12. Tighten «EN-46108 FIXING TOOL»(ref-275854-S11807981242007122900000) so that the chain is unloaded. IMPORTANT: It is extremely important that tool no. EN-46108 is properly fitted. If the chain is not unloaded when the camshaft sprocket bolts are removed, the automatic chain tensioner is triggered. If this occurs, the timing cover must be removed to adjust the chain tensioner.
13. Remove the camshaft sprocket bolts.
14. Remove the sprockets from the camshafts.
15. Remove the camshaft bearing caps by loosening the bolts in stages - 1/2 to 1 turn. It is important that removal ends at the bearing cap where the tappets are loaded. Note the markings on the bearing caps when refitting to ensure that they are in the correct spots.
16. Lift out the camshafts and note the rear marking on the camshafts. The last letters in the marking: LI = intake camshaft, front cylinder bank. LE = exhaust camshaft, front cylinder bank.
17. Remove the roller rockers and the hydraulic adjuster elements. Store them in 83 93 787 Valve stand so they do not get mixed up. IMPORTANT: Cover all return oil ducts in the cylinder head so that the valve cone or contaminants cannot fall down into the engine.
18. Fit EN-46110-eu Valve spring tool
19. Fit «83 94 173 AIR NIPPLE FOR SPARK PLUG HOLE»(ref-275854-S09118552122007122900000) . Connect compressed air and put the piston and valves under pressure.
20. Press down the valve plate with EN-46110-eu Valve spring tool.
21. Remove the valve cone with a magnet. IMPORTANT: The compressed air must not be disconnected when the valve cone is removed. Do not press on the valve stem either as counter-pressure in the cylinder could reduce and the valve could fall down into the cylinder.
22. Lift out the spring plate and valve spring.
23. Lift out the valve guide seal using 83 94 157 Pliers, valve guide seal.

Scheme 718

Scheme 719

Scheme 720

Scheme 721

Scheme 722

Scheme 723

1. Clean all parts and check contact surfaces and bearing surfaces for wear.
2. Fit the valve guide seal using 83 94 157 Pliers, valve guide seal.
3. Fit the valve spring and spring plate.
4. Press down the valve plate with EN-46110-eu Valve spring tool.
5. Fit the valve cone using «EN-46117 FITTING TOOL»(ref-275854-S08549377532007122900000) .
6. Unload the valve and remove EN-46110-eu Valve spring tool.
7. Disconnect the compressed air and remove the air nipple.
8. Position the camshafts and use «EN-46105 ADJUSTMENT TOOL»(ref-275854-S27477933482007122900000) to check that the camshafts are mounted at the correct angle. The last letters in the marking: LI = intake camshaft, front cylinder bank. LE = exhaust camshaft, front cylinder bank.
9. Fit the bearing caps (markings on caps). Start where the cams point down and load the tappets. Note: Tighten the bolts in stages - 1/2 to 1 turn. Tightening torque 10 Nm (7 lbf ft) IMPORTANT: Tighten the bolts in stages - 1/2 to 1 turn.
10. Fit the sprockets with chain on the camshafts. Tighten the bolts by hand.
11. Check that the marks on the chain match the markings on the sprockets.
12. Remove EN-46108-2 Fixing tool.
13. Remove «EN-46108 FIXING TOOL»(ref-275854-S11807981242007122900000) .
14. Tighten the bolts of both camshaft sprockets, counter-holding with an open spanner on the camshaft flats. Tightening torque: 65 Nm (48 lbf ft)
15. Remove «EN-46106 FLYWHEEL LOCKING ATTACHMENT»(ref-275854-S27760648232007122900000) .
16. Fit the camshaft position sensor (555F) using a new gasket. Tightening torque 10 Nm (7 lbf ft)
17. Fit the camshaft solenoid valve (695F) using a new seal. Tightening torque 10 Nm (7 lbf ft)
18. Fit the coolant port using a new seal and gasket. Tightening torque 10 Nm (7 lbf ft)
19. Fit the spark plugs.
20. Fit «FRONT CAMSHAFT COVER»(ref-275854-S28178670922007122900000)

Scheme 724

Scheme 725

Scheme 726

Scheme 727

Scheme 728

Scheme 729

Scheme 730

Scheme 731

Scheme 732

Scheme 733

Scheme 734

Scheme 735

Scheme 736

1. Remove «HEAT SHIELD BETWEEN THE ENGINE AND TURBOCHARGER»(ref-275851-S36356088282007122900000) .
2. Remove the bleeder pipe.
3. Release the quick-coupling of the secondary air pipe and put the pipe aside.
4. Remove the power steering fluid reservoir's bolt.
5. Unplug the connectors from ignition coils 2, 4 and 6.
6. Remove the left grounding point.
7. Raise the heat shield and unplug the coolant temperature sensor connector.
8. Release the right ground cable from the wiring harness.
9. Remove the wiring harness from the camshaft cover.
10. Unplug the connectors from the camshaft position sensor and the camshaft solenoid valve.
11. Raise the wiring harness slightly.
12. Remove the ground cable of the engine control module.
13. Unplug the engine control module connectors (608A and 608B).
14. Detach the cable duct from the intake manifold.
15. Unplug the atmospheric pressure sensor connectors.
16. Detach the corner bracket and move it aside.
17. Remove the bolt holding the injector bracket in place and unplug the connector.
18. Detach the brake vacuum hose from the intake manifold.
19. Detach the crankcase ventilation from the intake manifold.
20. Unplug the fuel pressure sensor connector. WARNING: The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures: Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc. Absolutely No Smoking! Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used. Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin. Wear protective goggles.
21. Detach the fuel line, wiping up any fuel spill with a cloth.
22. Remove the intake manifold bolts.
23. Raise the intake manifold and unplug the throttle body connector. Lift away the intake manifold.
24. Remove the gasket and cover the inlet ducts.
25. Unplug the connectors from the camshaft position sensor and the camshaft solenoid valve.
26. Raise the wiring harness slightly.
27. Remove the connector and pipe from the fuel bleeder valve. Lift away the valve.
28. Detach the vacuum pipe from the venturi valve.
29. Unplug the 7-pin contact connector.
30. Unplug the lower oxygen sensor connector and the connectors of ignition coils 1, 3 and 5.
31. Remove ignition coils 1, 3 and 5.
32. Remove the rear cable duct from the camshaft cover. Use an angled screwdriver to release the 3 clips from the cable duct. Press the cable duct back toward the bulkhead.
33. Remove the camshaft cover bolts.
34. Raise the wiring harness and servo reservoir. Remove the camshaft cover.
35. Remove the camshaft cover gasket and seals around the spark plug holes.

Scheme 737

Scheme 738

Scheme 739

Scheme 740

Scheme 741

Scheme 742

Scheme 743

Scheme 744

Scheme 745

Scheme 746

Scheme 747

Scheme 748

Scheme 749

Scheme 750

1. Fit new seals on the camshaft cover. Use «J-5590 DRIFT»(ref-275854-S13060798162007122900000) and «J-24254-A FITTING TOOL»(ref-275854-S11456263832007122900000) .
2. Add a spot of 93 160 951 Flange sealant to each mating surface between the cylinder head and timing cover.
3. Position the camshaft cover.
4. Fit the bolts using new seals. Tightening torque 10 Nm (7 lbf ft)
5. Fit the cable duct on the camshaft cover.
6. Fit ignition coils 1, 3 and 5.
7. Fit the connectors of the lower oxygen sensor and ignition coils 1, 3 and 5.
8. Plug in the 7-pin contact connector.
9. Fit the vacuum pipe to the venturi valve.
10. Fit the connector and pipe to the fuel bleeder valve.
11. Fit the wiring harness to the camshaft cover.
12. Plug in the connectors of the camshaft position sensor and the camshaft solenoid valve.
13. Clean the sealing surface between the intake manifold and the cylinder head. Fit a new gasket.
14. Position the intake manifold and plug in the throttle body connector.
15. Fit the intake manifold bolts. Tightening torque 23 Nm (17 lbf ft)
16. Fit the fuel line.
17. Fit the fuel pressure sensor connector.
18. Fit the crankcase ventilation to the intake manifold.
19. Fit the brake vacuum hose to the intake manifold.
20. Plug in the injector connectors and fit the bracket.
21. Reposition the corner bracket and fit the bolts.
22. Plug in the atmospheric pressure sensor connector.
23. Fit the cable duct to the intake manifold.
24. Plug in the engine control module connectors (608A and 608B).
25. Fit the ground cable of the engine control module.
26. Plug in the connectors of the camshaft position sensor and the camshaft solenoid valve.
27. Fit the wiring harness to the camshaft cover using new cable ties.
28. Secure the ground cable to the wiring harness.
29. Plug in the coolant temperature sensor connector and press down the heat shield.
30. Fit ignition coils 2, 4 and 6. Plug in the connectors.
31. Fit the left grounding point.
32. Fit the power steering fluid reservoir's bolt. Tightening torque 10 Nm (7 lbf ft)
33. Fit the secondary air pipe and check that the quick-coupling engages.
34. Fit the bleeder pipe. Tightening torque 10 Nm (7 lbf ft)
35. Fit «HEAT SHIELD BETWEEN THE ENGINE AND TURBOCHARGER»(ref-275851-S36356088282007122900000) .

Scheme 751

Scheme 752

Scheme 753

Scheme 754

Scheme 755

Scheme 756

Scheme 757

Scheme 758

Scheme 759

Scheme 760

Scheme 761

1. Remove «HEAT SHIELD BETWEEN THE ENGINE AND TURBOCHARGER»(ref-275851-S36356088282007122900000) .
2. Remove the bleeder pipe.
3. Remove the front secondary air pipe complete with valve and bracket.
4. Remove the power steering fluid reservoir's bolt.
5. Remove the left grounding point.
6. Unplug the connectors and remove ignition coils 2, 4 and 6.
7. Raise the heat shield and unplug the coolant temperature sensor connector.
8. Release the right ground cable from the wiring harness.
9. Remove the wiring harness from the camshaft cover.
10. Unplug the connectors from the camshaft position sensor and the camshaft solenoid valve.
11. Raise the wiring harness slightly.
12. Remove the ground cable of the engine control module.
13. Unplug the engine control module connectors (608A and 608B).
14. Detach the cable duct from the intake manifold.
15. Unplug the atmospheric pressure sensor connector.
16. Detach the corner bracket and move it aside.
17. Remove the bolt holding the injector bracket in place and unplug the connector.
18. Detach the brake vacuum hose from the intake manifold.
19. Detach the crankcase ventilation from the intake manifold.
20. Unplug the fuel pressure sensor connector. WARNING: The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures: Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc. Absolutely No Smoking! Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used. Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin. Wear protective goggles.
21. Detach the fuel line, wiping up any fuel spill with a cloth.
22. Remove the intake manifold bolts.
23. Raise the intake manifold and unplug the throttle body connector. Lift away the intake manifold.
24. Remove the gasket and cover the inlet ducts.
25. Loosen the lifting eye. Remove one of the bolts and fold the lifting eye down.
26. Remove the camshaft cover bolts and seals.
27. Remove the camshaft cover.
28. Remove the camshaft cover gasket and seals around the spark plug holes.

Scheme 762

Scheme 763

Scheme 764

Scheme 765

Scheme 766

Scheme 767

Scheme 768

Scheme 769

Scheme 770

Scheme 771

Scheme 772

1. Fit new seals on the camshaft cover. Use «J-5590 DRIFT»(ref-275854-S13060798162007122900000) and «J-24254-A FITTING TOOL»(ref-275854-S11456263832007122900000) .
2. Add a spot of 93 160 951 Flange sealant to the mating surface between the cylinder head and timing cover.
3. Position the camshaft cover.
4. Fit the bolts using new seals. Tightening torque 10 Nm (7 lbf ft)
5. Fold the eye up and fit the bolt. Tightening torque: 65 Nm (48 lbf ft)
6. Clean the sealing surface between the intake manifold and the cylinder head. Fit a new gasket.
7. Position the intake manifold and plug in the throttle body connector.
8. Fit the intake manifold bolts. Tightening torque 23 Nm (17 lbf ft)
9. Fit the fuel line.
10. Fit the fuel pressure sensor connector.
11. Fit the crankcase ventilation to the intake manifold.
12. Fit the brake vacuum hose to the intake manifold.
13. Plug in the injector connectors and fit the bracket.
14. Reposition the corner bracket and fit the bolts.
15. Plug in the atmospheric pressure sensor connector.
16. Fit the cable duct to the intake manifold.
17. Plug in the engine control module connectors (608A and 608B).
18. Fit the ground cable of the engine control module.
19. Plug in the connectors of the camshaft position sensor and the camshaft solenoid valve.
20. Fit the wiring harness to the camshaft cover using new cable ties.
21. Secure the ground cable to the wiring harness.
22. Plug in the coolant temperature sensor connector and press down the heat shield.
23. Fit ignition coils 2, 4 and 6. Plug in the connectors.
24. Fit the left grounding point.
25. Fit the power steering fluid reservoir's bolt. Tightening torque 10 Nm (7 lbf ft)
26. Fit the front secondary air pipe complete with valve and bracket. Use a new gasket. Tightening torque to exhaust manifold: 22 Nm (16 lbf ft) Tightening torque, bracket: 65 Nm (48 lbf ft)
27. Fit the bleeder pipe. Tightening torque 10 Nm (7 lbf ft)
28. Fit «HEAT SHIELD BETWEEN THE ENGINE AND TURBOCHARGER»(ref-275851-S36356088282007122900000) .

Scheme 773

Scheme 774

Scheme 775

Scheme 776

Scheme 777

Scheme 778

Scheme 779

Scheme 780

Scheme 781

Scheme 782

Scheme 783

Scheme 784

Scheme 785

Scheme 786

Scheme 787

Scheme 788

Scheme 789

Scheme 790

Scheme 791

1. Remove the power train from the car. See «POWER TRAIN REMOVAL»(ref-275854-S33378151892007122900000) .
2. Remove other equipment from the engine. See «REPLACING THE ENGINE (POWER TRAIN ON THE SUBFRAME)»(ref-275854-S23392676652007122900000)
3. Fit «32 025 048 HOLDER»(ref-275854-S39511806852007122900000) on the engine and place the engine on an engine stand.
4. Remove the bolt holding the dipstick guide tube and lift away the tube. Remove the O-ring.
5. Remove the heat shield of the front exhaust manifold.
6. Detach the intermediate exhaust pipe from the turbo and from the front exhaust manifold.
7. Detach the return coolant pipe from the turbocharger and heat shield.
8. Unplug the bypass valve connector.
9. Detach the vacuum hoses and the crankcase ventilation pipe from the turbo.
10. Detach the oil delivery pipe from the engine and remove the bolt.
11. Remove the oil delivery pipe's banjo screws from the turbo. Lift away the pipe.
12. Remove the turbocharger oil return pipe from the turbocharger.
13. Remove the coolant pipe's banjo screw from the turbocharger.
14. Remove the nuts holding the rear intermediate exhaust pipe from the turbocharger.
15. Remove the screw holding the turbocharger to the bracketing using a socket and a long pull rod.
16. Remove the turbocharger.
17. Remove the upper mounting of the front catalytic converter.
18. Remove the heat shield between the turbocharger and engine.
19. Remove the secondary intake manifold.
20. Remove the front secondary air pipe and the valve.
21. Remove the front lifting eye.
22. Remove the engine vent pipe from the intake manifold.
23. Remove the corner bracket from the intake manifold.
24. Unplug the connectors of the injectors' wiring harness.
25. Detach the brake vacuum hose from the intake manifold and venturi valve.
26. Detach the crankcase ventilation pipes from the intake manifold.
27. Unplug the throttle body connector and remove the cable from the clip.
28. Unplug the fuel pressure sensor connector.
29. Blow clean around the intake manifold base. Loosen the secondary air valve mounting and twist it down.
30. Lift up the wiring harness so that the fuel pressure sensor is exposed. Remove the bolts and carefully lift off both intake manifolds as a unit. Remove the gasket and cover the inlet duct.
31. Unplug the connectors of ignition coils 2, 4 and 6 and detach the front ground connections.
32. Raise the heat shield and unplug the coolant temperature sensor connector.
33. Remove the knock sensor and unplug the oil pressure sensor connector.
34. Remove the solenoid valve of the front and rear camshafts plus the rear camshaft position sensor.
35. Unplug the connectors of ignition coils 1, 3 and 5.
36. Detach the cable duct from the timing cover.
37. Remove the wiring harness from its anchorages.
38. Secure the wiring harness on the rear of the engine using a cable tie.
39. Remove ignition coils 2, 4 and 6.
40. Remove the front camshaft cover.
41. Remove the gasket and the spark plug hole seals.
42. Remove ignition coils 1, 3 and 5.
43. Remove the rear camshaft cover.
44. Remove the gasket and the spark plug hole seals.

Scheme 792

Scheme 793

Scheme 794

Scheme 795

Scheme 796

Scheme 797

Scheme 798

Scheme 799

Scheme 800

Scheme 801

Scheme 802

Scheme 803

Scheme 804

Scheme 805

Scheme 806

Scheme 807

Scheme 808

Scheme 809

Scheme 810

Scheme 811

1. Fit the spark plug hole seals and the gasket of the rear camshaft cover. Use J-5590 Drift and J-24254-A Fitting tool.
2. Add a spot of 93 160 951 Flange sealant on each mating surface between the cylinder head and timing cover. Fit the rear camshaft cover. Tightening torque 10 Nm (7 lbf ft)
3. Fit ignition coils 1, 3 and 5.
4. Fit the spark plug hole seals and the gasket of the front camshaft cover. Use J-5590 Drift and sleeve J-24254-A Fitting tool.
5. Add a spot of 93 160 951 Flange sealant on each mating surface between the cylinder head and timing cover. Fit the front camshaft cover. Tightening torque 10 Nm (7 lbf ft)
6. Fit ignition coils 2, 4 and 6.
7. Fit the wiring harness in its anchorages.
8. Fit the cable duct to the timing cover.
9. Fit the connectors to ignition coils 1, 3 and 5.
10. Fit the connectors to the front and rear camshaft position sensor plus the connectors to the front and rear camshaft's solenoid valve.
11. Fit the oil delivery sensor connector and the knock sensor.
12. Raise the heat shield and fit the coolant temperature sensor connector.
13. Fit the front ground connections and the connectors of ignition coils 2, 4 and 6.
14. Lift up the wiring harness so that the fuel pressure sensor is exposed. Fit a new gasket and carefully fit the two intake manifolds as a unit. Tightening torque 23 Nm (17 lbf ft)
15. Fit the secondary air valve mounting.
16. Fit the fuel pressure sensor connector.
17. Fit the cable in the clip and plug in the throttle body connector.
18. Fit the crankcase ventilation pipes to the intake manifold.
19. Attach the brake vacuum hose to the intake manifold and valve.
20. Attach the connectors of the injectors' wiring harness to the injectors.
21. Fit the corner bracket to the intake manifold.
22. Attach the engine vent pipe to the intake manifold.
23. Fit the front lifting eye. Tightening torque: 65 Nm (48 lbf ft)
24. Fit the valve and the front secondary air pipe.
25. Fit the secondary intake manifold.
26. Fit the heat shield between the turbocharger and engine.
27. Fit the upper mounting of the front catalytic converter. Tightening torque, M10: 42 Nm (31 lbf ft)
28. Position the turbocharger, being careful not to damage the return oil pipe. Install the turbocharger.
29. Fit the bolt holding the turbocharger to the bracket. Tightening torque: 65 Nm (48 lbf ft)
30. Fit the nuts holding the rear intermediate exhaust pipe to the turbocharger. Tightening torque 30 Nm (22 lbf ft) IMPORTANT: The conical side of the nut should face the center exhaust pipe.
31. Fit the coolant pipe's banjo screw to the turbocharger. Tightening torque 30 Nm (22 lbf ft)
32. Fit the turbocharger oil return pipe to the turbocharger. Tightening torque: 14 Nm (10 lbf ft)
33. Fit the oil delivery pipe's banjo screws to the turbocharger. Tightening torque, banjo screw: 30 Nm (22 lbf ft)
34. Fit the bolt and the oil delivery pipe to the engine.
35. Fit the crankcase ventilation pipe to the turbocharger and fit the vacuum hoses.
36. Plug in the bypass valve connector.
37. Fit the return coolant pipe to the turbocharger and heat shield. Tightening torque, banjo screw: 30 Nm (22 lbf ft)
38. Attach the intermediate exhaust pipe to the turbocharger and to the front exhaust manifold. Fit put the nuts in place and then tighten in the order illustrated. Tightening torque 30 Nm (22 lbf ft) IMPORTANT: The conical side of the nut should face the center exhaust pipe.
39. Fit the heat shield of the front exhaust manifold.
40. Fit the O-rings plus the bolt holding the dipstick guide tube.
41. Remove the engine from the stand and remove the holder from the engine.
42. Fit other equipment to the engine. See «REPLACING THE ENGINE (POWER TRAIN ON THE SUBFRAME)»(ref-275854-S23392676652007122900000) .
43. Fit the power train to the car. See «POWER TRAIN REMOVAL»(ref-275854-S33378151892007122900000) .

Scheme 812

Scheme 813

Scheme 814

1. Man: Put the gear lever in neutral. Auto: Put the selector lever in position P. Remove the key from the ignition switch.
2. Remove «SPARK PLUG»(ref-275854-S20085298312007122900000) .
3. Remove relay no. 8 in the Underhood electrical center 342.
4. Connect 83 93 886 Diagnostics cable, LH system to relay holder sleeves 87 and 30. Make sure that the switch is in the OFF position.
5. Fit the Motometer compression tester for petrol engines to cylinder 1 with a new card.
6. Run the starter motor using the test lead switch until the needle stops rising.
7. Repeat the procedure on the other cylinders. For minimum compression, see «PISTONS»(ref-275854-S24704559422007122900000) .

Scheme 815

Scheme 816

Scheme 817

Scheme 818

Scheme 819

1. Drain the coolant.
2. Lower the car.
3. Remove the upper engine cover.
4. Detach the turbocharger intake hose. IMPORTANT: When removing the air cleaner casing cover, be careful not to damage the brake vacuum pump sensor.
5. Remove the air cleaner casing cover and the air cleaner.
6. Detach the intake hose and remove the air cleaner casing.
7. Remove the coolant pipe from the port.
8. Position a jack under the oil sump and relieve the load on the engine mounting.
9. Remove the engine pad from the body and bracket.
10. Unplug the connector from the intake air sensor.
11. Detach the upper turbocharger delivery pipe from the throttle body and detach the lower delivery pipe.
12. Remove the P-clamp of the servo pipe.
13. Remove the engine bracket.
14. Detach the coolant hose from the port.
15. Remove the solenoid valve connector.
16. Remove the solenoid valve. NOTE: Be careful not to damage the seal!

Scheme 820

Scheme 821

Scheme 822

Scheme 823

Scheme 824

1. Fit the solenoid valve. Tightening torque 10 Nm (7.5 lbf ft) NOTE: Be careful not to damage the seal!
2. Plug in the connector.
3. Fit the coolant hose to the port.
4. Fit the engine bracket. Tightening torque, M12: 93 Nm (69 lbf ft) Tightening torque, M10: 42 Nm (31 lbf ft)
5. Fit the P-clamp of the servo pipe.
6. Fit the upper turbocharger delivery pipe to the throttle body and the lower delivery pipe.
7. Plug in the connector to the intake air sensor.
8. Fit and adjust the engine pad to the body. Tighten the bolts between the engine pad and the bracket. The engine pad and bracket should be aligned with each other. Tightening torque to engine: 45 Nm + 90° (30 lbf ft + 90°) Tightening torque to body: 50 Nm + 180° (37 lbf ft + 180°)
9. Remove the jack.
10. Fit the coolant pipe to the port using a new O-ring coated with a thin layer of acid-free Vaseline.
11. Fit the air cleaner casing and intake hose.
12. Fit the air cleaner and the air cleaner casing cover.
13. Fit the turbocharger inlet hose.
14. Fit the upper engine cover.
15. Fill with coolant.
16. Pressure test the cooling system.

Scheme 825

1. Remove the solenoid valve.
2. Remove the seal with a screwdriver.

Scheme 826

1. Clean the sealing surfaces.
2. Lightly coat the new seal with acid-free Vaseline.
3. Fit the seal using special tool 32 025 066 (EN-46103).
4. Fit the solenoid valve.

Scheme 827

Scheme 828

Scheme 829

1. Drain the coolant.
2. Lower the car.
3. Remove the upper engine cover.
4. Detach the turbocharger intake hose. IMPORTANT: When removing the air cleaner casing cover, be careful not to damage the brake vacuum pump sensor.
5. Remove the air cleaner casing cover and the air cleaner.
6. Detach the intake hose and remove the air cleaner casing.
7. Detach the coolant hose from the engine and move it aside.
8. Remove the solenoid valve connector.
9. Remove the solenoid valve. NOTE: Be careful not to damage the seal.

Scheme 830

Scheme 831

Scheme 832

1. Fit the solenoid valve. Tightening torque 10 Nm (7.5 lbf ft) NOTE: Be careful not to damage the seal.
2. Attach the connector to the solenoid valve.
3. Reposition and fit the coolant hose.
4. Fit the air cleaner casing and intake hose.
5. Fit the air cleaner and the air cleaner casing cover.
6. Fit the turbocharger inlet hose.
7. Replace the upper engine cover.
8. Fill with coolant.

Scheme 833

1. Remove the solenoid valve.
2. Remove the seal with a screwdriver.

Scheme 834

1. Clean the sealing surfaces.
2. Lightly coat the new seal with acid-free Vaseline.
3. Fit the seal using special tool 32 025 066 (EN-46103).
4. Fit the solenoid valve.

Note. There is no marking to check valve timing on the camshafts and cylinder heads. The timing chains have silver links that are to align with the marks on the sprockets. The links of the primary chain are marked with yellow.

Scheme 835

Scheme 836

Scheme 837

Scheme 838

Scheme 839

Scheme 840

1. Remove the Timing cover.
2. Rotate the crankshaft so that the cams of cylinder 1 point upward and inward at an angle, thus aligning the installation marks on the crankshaft sprocket and the oil pump. When the engine is approx. 15 degrees ATDC, use «EN-46111 Sleeve»(ref-275854-S08054206142007122900000) Sleeve to turn the engine.
3. Remove the timing chain tensioner for the rear cylinder bank.
4. Remove the chain tensioner gasket. IMPORTANT: The exhaust camshaft turns somewhat when tension is relieved from the chain.
5. Remove the guides and lift off the chain.
6. Remove the chain tensioner for the primary circuit and remove the gasket.
7. Remove the guides and lift off the chain.
8. Remove the rear primary sprocket.
9. Remove the timing chain tensioner of the front cylinder bank and remove the gasket.
10. Remove the guides and lift off the front primary sprocket. Lift off the chain.
11. Remove the crankshaft sprocket, counter-holding with a spanner on the camshaft flats.
12. Remove the camshafts' sprockets, counter-holding with a fixed spanner on the camshaft flats. IMPORTANT: The camshafts must not be rotated as the valves may collide with the pistons or other valves and be damaged.

Scheme 841

Scheme 842

Scheme 843

Scheme 844

Scheme 845

Scheme 846

Scheme 847

Scheme 848

Scheme 849

Scheme 850

1. Fit the camshafts' sprockets, counter-holding with a fixed spanner on the camshaft flats. Tightening torque: 65 Nm (48 lbf ft) NOTE: The intake sprocket is variable.
2. Fit the sprocket on the crankshaft. The marking should be visible. IMPORTANT: The crankshaft must not be rotated. Otherwise the pistons could damage the valves.
3. Check that the installation marks on the crankshaft sprocket and the oil pump are aligned. Use «EN-46111 SLEEVE»(ref-275854-S08054206142007122900000) to adjust the position of the crankshaft.
4. Fit the camshaft drive for the front cylinder bank. Position the chain on the camshaft sprockets so that the silver links align with the marks on the sprockets. The front cylinder bank sprockets are marked with an L.
5. Fit the primary sprocket so that the lower silver link is visible through the hole in the primary sprocket. Tightening torque: 65 Nm (48 lbf ft)
6. Fit the chain guides. Tightening torque 25 Nm (18 lbf ft)
7. Restore the chain tensioner to its previous position by removing the piston and turning the spring clockwise until it engages in the inner position. Use a screwdriver. Refit the piston in the tensioner and check that the groove in the piston is vertical so that is fits with the tensioner guide.
8. Fit the chain tensioner using a new gasket. Tightening torque 25 Nm (18 lbf ft)
9. Trigger/activate the chain tensioner by carefully pressing on the timing chain or guide.
10. Fit the rear primary sprocket. Tightening torque: 65 Nm (48 lbf ft)
11. Fit the primary chain so that the yellow links align with the markings on the primary sprockets and crankshaft sprocket.
12. Fit the front chain guide. Tightening torque 10 Nm (7 lbf ft)
13. Fit the upper guide. Tightening torque 25 Nm (18 lbf ft)
14. Restore the chain tensioner to its previous position by removing the piston and turning the spring clockwise until it engages in the inner position. Use a screwdriver. Refit the piston in the tensioner. Check that the groove in the piston is vertical so that is fits with the tensioner guide.
15. Fit the chain tensioner using a new gasket. Tightening torque 25 Nm (18 lbf ft)
16. Trigger/activate the chain tensioner by carefully pressing on the timing chain or guide.
17. Position the chain on the camshaft sprockets so that the silver links align with the markings on the sprockets. The rear cylinder bank sprockets are marked with an R.
18. Rotate the crankshaft approx. 1/4 turn approx. 100° ATDC so that the lower silver link aligns with the marking on the primary sprocket.
19. Fit the chain guides. Tightening torque 25 Nm (18 lbf ft)
20. Restore the chain tensioner to its previous position by removing the piston and turning the spring clockwise until it engages in the inner position. Use a screwdriver. Refit the piston in the tensioner. Check that the groove in the piston is vertical so that is fits with the tensioner guide.
21. Fit the chain tensioner using a new gasket. Trigger/activate the chain tensioner by carefully pressing on the timing chain or guide. Tightening torque 25 Nm (18 lbf ft)
22. Rotate the crankshaft one turn to check and ensure that all chain tensioners have been triggered and that the chain is correctly seated in the guide.
23. Fit «TIMING COVER»(ref-275854-S08547553002007122900000) .