Basic Engine, V6: Overhaul Saab 9-5 I рестайлинг

To assemble the engine

Wash all sealing surfaces with benzine, making sure that they are perfectly clean.

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1. Fit all main bearings in position and oil them.
2. Fit the slotted ring. Lock the bolts with part No. (10) 74 96 268. Place the crankshaft in position. IMPORTANT: The slotted ring must be handled with great care. Make sure that the main bearing member's adjuster sleeves are unscrewed if they are not fitted tightly in place.
3. Oil all main bearing caps and fit them in their places, making sure that they are the right way round. Fit the main bearing member and tighten the main bearing cap bolts. Tightening torque 50 Nm (37 lbf ft) + 60° +/- 15°
4. Screw the adjuster sleeves down flush. Coat the main bearing member bolts with part No. (10) 74 96 268 and tighten them. Tightening torque: 20 Nm (15 lbf ft)
5. Spray part No. (10) 81 52 381 into the mating joints at the rear main bearing. Do not stop until the compound is forced out at the sides.
6. Turn the engine and angle it so that cylinders 1-3-5 are vertical. Oil these pistons and rings, adjust the position of the ring gaps and fit the pistons in their cylinders. The arrow on the crown of the piston must be facing the timing end of the engine. Use Piston fitting tool part no. «83 95 113»(ref-212208-S01352915302005122300000) and carefully tap down the pistons into the cylinder bores. Repeat for cylinders 2-4-6.
7. Oil and fit all big-end bearing caps in their respective places, making sure they are fitted the right way round. Blow the contact surfaces clean with compressed air. If they are damaged the connecting rod must be changed. Tightening torque 35 Nm (26 lbf ft) + 45° +/- 15°
8. Fit a new rear crankshaft seal using Fitting set for rear crankshaft seal part no. 83 94 967 and part no. 83 94 975. Fit the drive plate. Coat the bolts with part no. (10) 74 96 292. Tightening torque 65 Nm (48 lbf ft) + 30°
9. Fit the oil pump with a new gasket. Coat the gasket with part No. (10) 93 21 795.
10. Fit a new front crankshaft seal. Use Fitting set for front crankshaft seal part no. 83 94 942.
11. Fit Counterstay «83 95 063»(ref-212208-S02545993922005122300000) . Coat the back of the camshaft belt sprocket with part no. (10) 93 21 795 and tighten the sprocket. Tightening torque 250 Nm (184.5 lbf ft) + 45°
12. Connect the oil pressure sensor.
13. Turn the engine. Apply part No. (10) 81 52 381 to the mating joints.
14. Fit the oil antislosh baffle. Lock the bolts with part No. (10) 74 96 268. Tightening torque: 8 Nm (6 lbf ft)
15. Fit the oil suction pipe complete with O-ring. Lock the bolts with part No. (10) 74 96 268. Tightening torque: 8 Nm (6 lbf ft)
16. Fit the oil sump with a new gasket. Secure the bolts with part No. (10) 74 96 268. Check that the drain plug is tightened firmly. Tightening torque, oil sump 15 Nm (11 lbf ft) Tightening torque, drain plug 25 Nm (18.5 lbf ft)
17. Turn over the engine. Clean the heat exchanger cover with benzine. Apply 87 81 841 Silicone flange sealant to the sealing surfaces. Fit the heat exchanger with new O-rings. Tighten the cover. Tightening torque: 20 Nm (15 lbf ft)
18. Connect the oil pipes to the heat exchanger using new seals. Tighten the connections. Tightening torque: 30 Nm (22 lbf ft).
19. Fit new cylinder head gaskets, minding the oil passages. For cylinders 1-3-5, the marking OBEN/TOP must face the gearbox end and for cylinders 2-4-6, the marking must face the timing end of the engine. IMPORTANT: Be sure to select the correct gasket (Thinner for LEV engines)
20. Rotate the crankshaft to 60° BTDC. Fit the cylinder heads with new bolts. Tighten the bolts in the order shown in the illustration. Tightening torque 25 Nm (18.5 lbf ft) + 90°
21. Remove the protective sleeves and fit the valve tappets.
22. Place the camshafts in position and fit the stuffing boxes and bearing caps. Start where the cams point downwards and load the tappets. Coat the cylinder head contact surfaces of the front bearing caps sparingly with part No. (10) 74 96 268, see illustration above. Cylinders 1-3-5 (rear) The locating pin on the camshafts should point towards the inside bolts for the camshaft bearing caps. Cylinders 2-4-6 (front) The locating pin for the intake camshaft should be in line (downwards) with the inside bolts for the camshaft bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head. Tightening torque: 8 Nm (6 lbf ft) IMPORTANT: Tighten the bolts in stages - 1/2 to 1 turn at a time. The markings on the camshaft bearing caps and the cylinder head must match. The caps marked L1-L8 are for the cylinder head with cylinders 1-3-5 and the caps marked R1-R8 are for the cylinder head with cylinder 2-4-6. The camshaft bearing seats in each cylinder head are numbered 1-8.
23. Fit the inner (rear) timing cover.
24. Fit the coolant pump with a new O-ring. Coat the O-ring and sealing surface on the cylinder block with non-acidic vaseline. Tightening torque 25 Nm (18.5 lbf ft)
25. Fit the new adjuster roller. Tightening torque 40 Nm (30 lbf ft)
26. Fit the bracket with tensioning roller and the upper adjuster roller. Tightening torque 40 Nm (30 lbf ft)
27. Lubricate and fit new camshaft seals with Assembly tool for camshaft seal part no. 83 94 959. Fit the camshaft sprockets. The number in the sprocket hub should match the number on the camshaft. Tightening torque 50 Nm (37 lbf ft) + 60° WARNING: The jaws of the open-ended spanner used as a counterstay when fitting the camshaft sprockets must not be too long. There is otherwise a risk of damaging the metal so that the tappets become locked.
28. Carefully turn the camshafts so that the markings on the camshaft sprockets are aligned with the grooves on the inner (rear) timing cover. Use KM-800-20. Lock the camshafts with Adjustment tools for camshaft sprockets and timing belt «83 95 006 Assembly kit for camshaft sprockets and camshaft drive belt, V6»(ref-212208-S17545001022005122300000) KM-800-1 (cylinders 1-3-5) and KM-800-2 (cylinders 2-4-6).
29. Turn the crankshaft in the direction of rotation of the engine until just before TDC. Fit KM-800-10 on the crankshaft and turn the crankshaft to TDC. Press the movable arm against the flat part of the coolant pump flange and attach it.
30. Fit the camshaft belt according to the markings on the belt and the marked direction of rotation. Use «83 95 006 Assembly kit for camshaft sprockets and camshaft drive belt, V6»(ref-212208-S17545001022005122300000) to keep the belt in place. Fit the guide roller. Make sure that the washer is in place. Carefully check that the markings on the timing belt are aligned with the corresponding markings on the camshaft sprocket. Raise the car and check the marking on the crankshaft. Lower the car and remove the tool KM-800-30. Tightening torque, guide roller, 40 Nm (30 lbf ft)
31. Ensure the adjusting nut on the upper adjusting roller rotates freely and is not tight. Adjust the tensioning pulley with a 5 mm Allen key until the two lines on the tensioning pulley correspond with each other. Tighten. Tightening torque: 20 Nm (15 lbf ft) Remove the locking tool for camshaft sprockets 1 and 2. Fit tool KM-800-20. Then, adjust the upper adjusting roller anticlockwise with tool 83 94 983 until the markings on the camshaft sprockets are aligned with the corresponding markings on KM-800-20. Tighten. Use tool 83 94 983 as a counterstay. Tightening torque 40 Nm (30 lbf ft) Remove KM-800-20 and the other locking tools.
32. Turn the crankshaft two revolutions until just before the zero mark and fit locking tool KM-800-10 on it. Carefully turn the crankshaft in the engine's direction of rotation until the arm abuts against the coolant pump flange and tighten it. Fit tool KM-800-20 and check that the markings on the camshaft sprockets are opposite the markings on the tool and that the edge of the belt coincides with the edge of the sprockets. IMPORTANT: Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.
33. Fit the timing cover.
34. Fit the coolant pump pulley and crankshaft pulley. Tightening torque, coolant pump pulley 8 Nm (6 lbf ft) Tightening torque, crankshaft pulley 20 Nm (15 lbf ft)
35. Fit new gaskets on the camshaft covers and wipe clean. Lubricate with a soap solution and place part No. (10) 81 52 381 in the corners at the camshaft bearing caps. Fit the camshaft covers. Tightening torque: 8 Nm (6 lbf ft)
36. Fit the spark plugs using spark plug socket 83 95 485. Tightening torque 25 Nm (18.5 lbf ft)
37. Fit the ignition discharge modules. Connect the cables to the ignition discharge modules and fit the engine wiring harness.
38. Fit the crankcase breather housing.
39. Fit the coolant bridge with new copper gaskets. Coat the bolts with part No. (10) 74 96 284. Tightening torque: 30 Nm (22 lbf ft).
40. Fit the thermostat with a new O-ring. Moisten the O-ring with coolant. Tightening torque: 20 Nm (15 lbf ft)
41. Refit the coolant pipe with new O-rings. This will be easier if the O-rings are moistened with coolant.
42. Fit the lower intake manifold with new gaskets. Tightening torque: 20 Nm (15 lbf ft)
43. Fit the middle intake manifold. Connect the cables to the injectors. Tightening torque: 20 Nm (15 lbf ft)
44. Fit the upper intake manifold with a new gasket. Tightening torque: 20 Nm (15 lbf ft)
45. Fit the front exhaust manifold with a new gasket. Clean the sealing surfaces before fitting. Tightening torque: 20 Nm (15 lbf ft) NOTE: Smear the studs and gaskets sparingly with Molycote 1000, part No. 30 20 971, or similar, to prevent them baking on.
46. Fit the rear exhaust manifold with a new gasket. Fit the heat shield over the rear exhaust manifold.
47. Fit the oil filter and connect the oil filter adapter's oil pipes. Tightening torque, oil filter 10 Nm (7.5 lbf ft) Tightening torque, oil pipe 25 Nm (18.5 lbf ft)
48. Fit the crankshaft position sensor with a new O-ring. Tightening torque: 8 Nm (6 lbf ft)
49. Connect the turbo's water and oil pipes. Tightening torque, oil return pipe, M6 bolt 14 Nm (10 lbf ft) Tightening torque, oil pipe, turbo 20 Nm (15 lbf ft) Tightening torque, oil pipe, oil filter adapter 20 Nm (15 lbf ft) Tightening torque, water pipe 25 Nm (18.5 lbf ft) Tightening torque, cylinder head bolt 14 Nm (10 lbf ft) IMPORTANT: It is extremely important for oil to be present in the turbocharger when the engine starts. Fill the turbo's oil inlet and pipe with oil. Spin the turbine wheel (impeller) several times to lubricate the bearings with oil.
50. Fit the turbo's bracket. Tightening torque 24 Nm (18 lbf ft)
51. Fit the dipstick.
52. Connect the cable to the oil pressure sensor.
53. Connect the temperature sensor to the coolant bridge.
54. Connect the vacuum hose and water hose to the throttle. Also plug in the throttle's connector.
55. Fit and connect the generator. Connect the cable for the oil pressure sensor to the generator.
56. Fit the belt tensioner. Tightening torque 40 Nm (30 lbf ft)
57. Fit a lifting sling and lift the power unit away from the stand. Remove the holder.
58. Position the gearbox and tighten the bolts. Fit the front exhaust pipe with heated oxygen sensor, power steering pump and power unit to the subframe. Tightening torque, gearbox 70 Nm (52 lbf ft)
59. Remove the torque converter's fixing tool.
60. Bolt the drive plate and torque converter together by gradually rotating the crankshaft so that all the bolts can be tightened. Tightening torque: 60 Nm (44 lbf ft)
61. Fit the plastic plug under the starter motor.
62. Fit the starter motor and connect the cables.
63. Fit the support bearing bracket with pipe and inboard drive-shaft universal joint.
64. Fit the bracket for the engine wiring harness.
65. Fill up with oil. The power unit is now ready to be fitted in the car.

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1. Drape the wing protectors over the wings and remove the engine cover.
2. Note the radio code where applicable. Detach the vent hose and remove the battery.
3. Open the cap on the expansion tank and release the pressure.
4. Raise the car.
5. Remove the lower engine cover.
6. Drain the coolant from the radiator.
7. Remove the turbo bracket, minding the protective plate for the crankshaft position sensor mounted on the same bracket.
8. Insert two «83 95 238»(ref-212208-S14859113752005122300000) Wedges, between the oil sump and subframe and between the gearbox and subframe.
9. Detach the turbocharger delivery pipe from the charge air cooler, leave on the clamp. Lower the car.
10. Remove the mass air flow sensor with hose.
11. Detach the power steering hose from the holder.
12. Remove the right-hand engine attachment with bracket and engine mount.
13. Undo the retaining bolts from the coolant pump pulley and power steering pump pulley
14. Release the multigroove belt from tension.
15. Remove the coolant pump pulley and power steering pump pulley.
16. Remove the belt tensioner and generator air intake.
17. Remove the timing cover.
18. Unhook the throttle cable.
19. Remove the vacuum hoses and unplug the pressure sensor's connector from the upper intake manifold.
20. Detach the vacuum hose and the two water hoses from the throttle body. Remove the turbocharger delivery pipe. Remove the turbocharger delivery pipe with bypass pipe and valve from the throttle body and unplug the connector for the pressure/temp sensor. Unplug the throttle body connector and detach the purge valve hose from underneath the throttle body.
21. Unplug the connectors from the ignition discharge module and injectors.
22. Detach the fuel lines.
23. Undo the upper intake manifold and move it aside.
24. Remove the middle intake manifold.
25. Remove the lower intake manifold. Plug the holes with paper or the like.
26. Undo the coolant bridge and move it aside. Mind the gaskets.
27. Remove the crankshaft pulley.
28. Zero the engine. The markings on the camshaft sprockets and the timing cover must be aligned, use tool KM-800-20, as must the crankshaft marking. Fit the locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and locking tool KM-800-10 for the crankshaft see Fitting set in illustration below.
29. Detach the tensioning pulley and the adjuster roller. Remove the guide roller. Use 83 94 983 Adjustment wrench, timing belt, V6 as counterstay on the adjuster rollers.
30. Mark the direction of rotation on the item to be refitted. In order to facilitate fitting the belt can be marked with each camshaft marking as well as with the crankshaft marking. Remove the tool KM-800-10 from the crankshaft. Remove the camshaft belt.
31. Undo the adjuster roller bolts.
32. Remove the ignition discharge module.
33. Remove the camshaft cover. Make sure that the O-rings are in place and that they do not fall into the engine.
34. Rotate the crankshaft to 60° BTDC. Note the marking.
35. Remove the camshaft sprockets. WARNING: The jaws of the open-ended spanner used as a counterstay when removing the camshaft sprockets must not be too long. There is otherwise a risk of damaging the metal so that the tappets become locked.
36. Remove the coolant pump.
37. Remove the inner timing cover.
38. Remove the front exhaust manifold heat shield.
39. Undo the hose connection to the front SAI valve by pressing together the clip and pulling back.
40. Remove the SAI pipe with valve from the exhaust manifold
41. Undo the crankshaft ventilation pipe between the turbo intake pipe and the cylinder head as well as the hose from the oil trap. Bend aside the pipe.
42. Undo the turbo intake pipe. Bend aside the pipe.
43. Detach the turbo's outlet hose to the charge air cooler.
44. Detach the water hose from the thermostat housing.
45. Detach the front exhaust manifold from the turbo.
46. Remove the turbo water pipe.
47. Remove the turbo's oil pipes.
48. Undo and remove the exhaust camshaft. Undo the bolts in stages, 1/2 to 1 turn at a time. Note the marking on the bearing caps. It is important to finish removal at the bearing cap where the tappets are under load. Remove the stuffing box. NOTE: The intake camshaft need not be removed.
49. Remove the tappets with the 83 91 401 Magnetic tool. Keep the tappets in the 83 93 787 Valve rack.
50. Undo the cylinder head bolts in the order shown. First slacken them a 1/4 turn and then 1/2 a turn. Remove the cylinder head. Be careful when putting it down as the intake camshaft is still in place and the valve stems could be bent accidentally.

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1. Ensure the crankshaft is at 60° BTDC.
2. Clean all mating surfaces and position the gasket. Note the guides for the gasket and check that it is marked OBEN/TOP. Be sure to select the correct gasket for LEV engines. IMPORTANT: Be sure to select the correct gasket (Thinner for LEV engines)
3. Fit the tappets.
4. Place the cylinder head in position. Use new bolts. Tighten in the order shown. Tightening torques: Step I: 25 Nm (18.5 lbf ft) Step II: Tighten a further 90° Step III: Tighten a further 90° Step IV: Tighten a further 90°
5. Place the exhaust camshaft in position. Check that it is placed correctly. Lubricate generously with oil. Cylinders 2-4-6 (front) The locating pins for the intake camshaft should be in line (downwards) with the inside bolts for the camshaft bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head. Take note of the markings on the bearing cap and cylinder head. Apply a very thin layer of 74 96 268 Thread locking adhesive to the front contact surface of the bearing cap with the cylinder head. see illustration below. Fit the stuffing box and bearing caps and tighten the bolts. Tighten them in steps of 1/2 to 1 turn. Tightening torque: 8 Nm (6 lbf ft)
6. Fit the inner (rear) timing cover.
7. Fit the camshaft sprockets correctly in relation to the locating pins. Check the position against the markings in the timing cover. The number in the sprocket hub should match the number on the camshaft. Tightening torque: 50 Nm (37 lbf ft) + 60° WARNING: The jaws of the open-ended spanner used as a counterstay when fitting the camshaft sprockets must not be too long. There is otherwise a risk of damaging the metal so that the tappets become locked.
8. Check that the O-rings are in place in the camshaft cover and wipe clean. Lubricate with a soap solution and place part No. (10) 81 52 381 in the corners at the camshaft bearing caps. Tightening torque: 8 Nm (6 lbf ft)
9. Fit the ignition discharge module.
10. Fit the turbo oil pipes. Tightening torques: Oil pipe, turbo: 20 Nm (15 lbf ft) Oil pipe, oil filter adapter: 20 Nm (18.5 lbf ft) Oil return pipe: 14 Nm (10 lbf ft)
11. Fit the turbo's water pipes. Tightening torques: Water pipe: 25 Nm (18.5 lbf ft) Cylinder head retaining bolt 14 Nm (10 lbf ft)
12. Connect the water hose to the thermostat housing.
13. Fit the front exhaust pipe to the turbo. Tightening torque: 24 Nm (18 lbf ft) IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.
14. Fit the hose between the turbo and the charge air cooler.
15. Fit the crankcase breather pipe to the turbo intake pipe. Note the gasket. Tightening torque: 24 Nm (18 lbf ft)
16. Fit the turbo's intake pipe. Tightening torques: V-clamp: 3 Nm (2.2 lbf ft) U-clamp, cylinder head 14 Nm (10.3 lbf ft)
17. Fit the SAI pipe using new gaskets to the front exhaust manifold.
18. Fit the hose connection to the valve, check the connection.
19. Fit the crankcase ventilation pipe between the cylinder head and the turbo intake pipe. Connect the hose from the oil trap. Tightening torque: Banjo screw, intake pipe 24 Nm (17.7 lbf ft)
20. Fit the coolant pump. Tightening torque 25 Nm (18.5 lbf ft)
21. Fit the bracket with tensioning roller and the upper adjuster roller.
22. Fit locking tool KM-800-1 on No. 1 and No. 2 camshaft sprockets and locking tool KM-800-2 on No. 3 and No. 4 camshaft sprockets. See «83 95 006 Assembly kit for camshaft sprockets and camshaft drive belt, V6»(ref-212208-S17545001022005122300000) .
23. Rotate the crankshaft to just before the 0° mark and fit tool KM-800-10. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump flange and remove the tool.
24. Fit the camshaft belt according to the markings on the belt and the marked direction of rotation. Use 83 95 006 Adjustment tools for camshaft sprockets and timing belt, V6 KM-800-30 to keep the belt in place. Fit the guide roller. Make sure that the washer is in place. Carefully check that the markings on the timing belt are aligned with the corresponding markings on the camshaft sprocket. Raise the car and check the marking on the crankshaft. Lower the car and remove the tool KM-800-30. Tightening torque, guide roller, 40 Nm (30 lbf ft)
25. Ensure the adjusting nut on the upper adjusting roller rotates freely and is not tight. Adjust the tensioning pulley with a 5 mm Allen key until the two lines on the tensioning pulley correspond with each other. Tighten. Tightening torque: 20 Nm (15 lbf ft) Remove the locking tool for camshaft sprockets 1 and 2. Fit tool KM-800-20. Then, adjust the upper adjusting roller anticlockwise with tool 83 94 983 until the markings on the camshaft sprockets are aligned with the corresponding markings on KM-800-20. Tighten. Use tool 83 94 983 as a counterstay. Tightening torque: 40 Nm (30 lbf ft) Remove KM-800-20 and the other locking tools.
26. Rotate the engine two revolutions in the direction of rotation until just before the zero mark and fit locking tool KM-800-10 on the crankshaft. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump and tighten it. Fit tool KM-800-20 and ensure the markings on the camshaft sprockets are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprockets. IMPORTANT: Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.
27. Fit the coolant bridge. Coat the bolts with (10) 74 96 284. Mind the gaskets. Tightening torque: 30 Nm (22 lbf ft).
28. Fit the lower intake manifold with new gaskets. Tightening torque: 20 Nm (15 lbf ft)
29. Fit the middle intake manifold. Tightening torque: 20 Nm (15 lbf ft)
30. Fit the upper intake manifold with a new gasket. Tightening torque: 20 Nm (15 lbf ft)
31. Connect the fuel lines.
32. Plug in the connectors for the ignition discharge module and injectors.
33. Connect the turbo delivery pipe to the throttle body.
34. Raise the car, connect the turbo delivery pipe to the charge air cooler. Tighten the hose clip at the charge air cooler.
35. Lower the car and tighten the hose clip at the throttle body.
36. Plug in the temp/pressure sensor connector. Fit the bypass pipe with valve.
37. Connect the vacuum hose and the two water hoses to the throttle body. Plug in the throttle body connector and the hose to the venting valve on the underside of the throttle body. Tightening torques: Bypass pipe 8 Nm (6 lbf ft)
38. Connect the vacuum hoses and plug in the pressure/temperature sensor connector to the upper intake manifold.
39. Refit the throttle cable.
40. Fit the crankshaft pulley with the notch facing the projection on the engine (diagonally upwards-forwards). Tightening torque: 20 Nm (15 lbf ft)
41. Fit the timing cover. Tightening torque: 8 Nm (6 lbf ft)
42. Fit the belt tensioner and the generator air intake.
43. Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.
44. Fit the multigroove belt.
45. Tighten the retaining bolts on the pulleys. Tightening torques: Belt pulley/coolant pump: 8 Nm (6 lbf ft) Belt pulley/power steering pump: 20 Nm (15 lbf ft)
46. Fit the right-hand engine attachment with bracket and engine mount. Tightening torques: To body 63 Nm (46.5 lbf ft)
47. Fit the power steering hose in the holder
48. Fit the mass air flow sensor with hose.
49. Raise the car.
50. Lower the engine by carefully removing the wedges.
51. Fit the turbo bracket. Mind the protective plate for the crankshaft position sensor mounted on the same bracket.
52. Lower the car to the floor.
53. Fit the battery with bleeder hose.
54. Fill up with coolant. Do not forget to close the radiator drain cock first. Screw on the expansion tank filler cap.
55. Bleed the cooling system as follows: Fill the system up to the MAX level, close the expansion tank filler cap, start the engine and warm it up (by running it at varying rpm) until the radiator fan starts. Unscrew the expansion tank filler cap and top up again to the MAX level. Close the filler cap and run the engine at varying rpm until the radiator fan starts three more times. Switch off the engine and top up as necessary to the MAX level. NOTE: The A/C should be OFF.
56. Raise the car.
57. Check for leakage.
58. Fit the lower engine cover.
59. Lower the car to the floor.
60. Fit the upper engine cover and remove the wing protectors.
61. Reset the clock and, where appropriate, the radio code.

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1. Cover the wings and remove the engine cover. Remove the battery cover.
2. Note the radio code, where applicable, and remove the negative cable from the battery.
3. Open the cap on the expansion tank and release the pressure.
4. Raise the car.
5. Remove the bottom engine covers.
6. Drain the coolant from the radiator.
7. Insert two «83 95 238»(ref-212208-S14859113752005122300000) Wedges, between the oil sump and subframe and between the gearbox and subframe.
8. Lower the car to the floor.
9. Remove the mass air flow sensor with hose.
10. Detach the power steering hose from the holder.
11. Remove the right-hand engine attachment with bracket and engine mount.
12. Undo the retaining bolts from the coolant pump pulley and power steering pump pulley
13. Release the multigroove belt from tension.
14. Remove the coolant pump pulley and power steering pump pulley.
15. Remove the belt tensioner and generator air intake.
16. Remove the timing cover.
17. Unhook the throttle cable.
18. Remove the vacuum hoses and unplug the pressure sensor's connector from the upper intake manifold.
19. Detach the oxygen sensor connectors from the holder on the rear SAI valve by releasing the catch and pushing them down.
20. Undo the SAI pipe mounting from the cylinder head. Detach the connections on the exhaust manifold. Undo the hose connection to the SAI valve by pressing together the clip and pulling back.
21. Undo the vacuum hose and the two water hoses from the throttle body. Remove the turbo delivery hose with bypass pipe.
22. Unplug the throttle body connector and detach the hose to the purge valve from underneath the throttle body.
23. Detach the fuel lines.
24. Undo the upper intake manifold and move it aside. Unplug the connectors from the ignition discharge module and injectors.
25. Remove the middle intake manifold.
26. Remove the lower intake manifold. Plug the holes with paper or the like.
27. Undo the coolant bridge and move it aside. Mind the gaskets.
28. Remove the crankshaft pulley.
29. Zero the engine. The markings on the camshaft sprockets and the timing cover must be aligned, use tool KM-800-20, as must the crankshaft marking. Fit the locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and locking tool KM-800-10 for the crankshaft.
30. Detach the tensioning pulley and the adjuster roller. Remove the guide roller. Use 83 94 983 Adjustment wrench, timing belt, V6 as counterstay on the adjuster rollers.
31. Mark the direction of rotation on the item to be refitted. In order to facilitate fitting the belt can be marked with each camshaft marking as well as with the crankshaft marking. Remove the tool KM-800-10 from the crankshaft. Remove the camshaft belt.
32. Remove the bracket with tensioning roller and the upper adjuster roller.
33. Remove the ignition discharge module.
34. Remove the camshaft cover. Make sure that the O-rings are in place and that they do not fall into the engine.
35. Rotate the crankshaft to 60° BTDC. Note the marking.
36. Remove the camshaft sprockets. WARNING: The jaws of the open-ended spanner used as a counterstay when removing the camshaft sprockets must not be too long. There is otherwise a risk of damaging the metal so that the tappets become locked.
37. Remove the coolant pump.
38. Remove the inner timing cover.
39. Raise the car and detach the front exhaust pipe from the rear exhaust manifold.
40. Lower the car. Undo the exhaust camshaft and remove it. Undo the bolts alternately 1/2 to 1 turn. Note the markings on the caps. It is important to finish removal at the bearing cap where the tappets are under load. Remove the stuffing box. NOTE: The intake camshaft need not be removed.
41. Remove the tappets with the magnetic tool part no. 83 91 401. Keep the tappets in the 83 93 787 Valve rack
42. Undo the cylinder head bolts in the order shown. First slacken them a 1/4 turn and then 1/2 a turn. Remove the cylinder head. Be careful when putting it down as the intake camshaft is still in place and the valve stems could be bent accidentally.

Scheme 574

Scheme 575

Scheme 576

Scheme 577

Scheme 578

Scheme 579

Scheme 580

Scheme 581

Scheme 582

Scheme 583

Scheme 584

Scheme 585

Scheme 586

Scheme 587

Scheme 588

Scheme 589

Scheme 590

Scheme 591

Scheme 592

1. Ensure the crankshaft is at 60° BTDC.
2. Clean all mating surfaces and position the gasket. Note the guides for the gasket and check that it is marked OBEN/TOP . IMPORTANT: Be sure to select the correct gasket (Thinner for LEV engines)
3. Fit the tappets.
4. Place the cylinder head in position. Use new bolts. Tighten in the order shown. Tightening torques: Step I: 25 Nm (18.5 lbf ft) Step II: Tighten a further 90° Step III: Tighten a further 90° Step IV: Tighten a further 90°
5. Place the exhaust camshaft in position. Check that it is placed correctly. Lubricate generously with oil. Cylinders 1-3-5 (rear) The locating pins for the camshafts should point to the inside bolts for the camshaft bearing caps. Observe the markings on the bearing caps and cylinder head. Coat the cylinder head contact surfaces of the front bearing caps sparingly with part No. (10) 74 96 268. Fit the stuffing box and bearing caps and tighten the bolts. Tighten them in steps of 1/2 to 1 turn. Tightening torque: 8 Nm (6 lbf ft)
6. Fit the inner (rear) timing cover.
7. Fit the camshaft sprockets correctly in relation to the locating pins. Check the position against the markings in the timing cover. Tightening torque: 50 Nm (37 lbf ft) + 60° WARNING: The jaws of the open-ended spanner used as a counterstay when fitting the camshaft sprockets must not be too long. There is otherwise a risk of damaging the metal so that the tappets become locked.
8. Check that the O-rings are in position in the camshaft cover and wipe clean. Lubricate with a soap solution and apply sealant, part No. (10) 81 52 381, in the corners of the camshaft bearing caps. Fit the camshaft cover. Tightening torque: 8 Nm (6 lbf ft)
9. Fit the ignition discharge module.
10. Connect the hose to the SAI pipe and check the connection.
11. Fit the SAI pipe with new gaskets to the exhaust manifold and cylinder head.
12. Fasten the oxygen sensor connectors to the holder.
13. Raise the car and fit the front exhaust pipe to the rear exhaust manifold. Tightening torque: 40 Nm (29.5 lbf ft).
14. Lower the car and fit the coolant pump. Tightening torque: 25 Nm (18.5 lbf ft).
15. Fit the bracket with tensioning roller and the upper adjuster roller.
16. Fit locking tool KM-800-1 on No. 1 and No. 2 camshaft sprockets and locking tool KM-800-2 on No. 3 and No. 4 camshaft sprockets.
17. Rotate the crankshaft to just before the 0° mark and fit tool KM-800-10. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump flange and remove the tool.
18. Fit the camshaft belt according to the markings on the belt and the marked direction of rotation. Use 83 95 006 Adjustment tools for camshaft sprockets and timing belt, V6 KM-800-30 to keep the belt in place. Fit the guide roller. Make sure that the washer is in place. Carefully check that the markings on the timing belt are aligned with the corresponding markings on the camshaft sprocket. Raise the car and check the marking on the crankshaft. Lower the car and remove the tool KM-800-30. Fit the locking tool KM-800-10. Tightening torque, guide roller, 40 Nm (30 lbf ft)
19. Ensure the adjusting nut on the upper adjusting roller rotates freely and is not tight. Adjust the tensioning pulley with a 5 mm Allen key until the two lines on the tensioning pulley correspond with each other. Tighten. Tightening torque: 20 Nm (15 lbf ft) Remove the locking tool for camshaft sprockets 1 and 2. Fit tool KM-800-20. Then, adjust the upper adjusting roller anticlockwise with tool 83 94 983 until the markings on the camshaft sprockets are aligned with the corresponding markings on KM-800-20. Tighten. Use tool 83 94 983 as a counterstay. Tightening torque: 40 Nm (30 lbf ft) Remove KM-800-20 and the other locking tools.
20. Rotate the engine two revolutions in the direction of rotation until just before the zero mark and fit locking tool KM-800-10 on the crankshaft. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump and tighten it. Fit tool KM-800-20 and ensure the markings on the camshaft sprockets are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprockets. IMPORTANT: Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.
21. Fit the coolant bridge. Coat the bolts with (10) 74 96 284. Mind the gaskets. Tightening torque: 30 Nm (22 lbf ft).
22. Fit the lower intake manifold with new gaskets. Tightening torque: 20 Nm (15 lbf ft)
23. Fit the middle intake manifold. Tightening torque: 20 Nm (15 lbf ft)
24. Fit the upper intake manifold with a new gasket. Tightening torque: 20 Nm (15 lbf ft)
25. Connect the fuel lines.
26. Plug in the connectors for the ignition discharge module and injectors.
27. Connect the turbo delivery pipe to the throttle body.
28. Fit the vacuum hose and the two water hoses to the throttle body as well as the throttle body's connector. Fit the hose to the venting valve on the underside of the throttle body.
29. Refit the throttle cable. IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.
30. Raise the car and connect the turbo delivery pipe to the charge air cooler. Tighten the hose clip at the charge air cooler. Lower the car.
31. Connect the vacuum hoses and plug in the pressure/temperature sensor connector to the upper intake manifold.
32. Fit the turbo bypass pipe with valve. Fit the pressure/temperature sensor connector. Tightening torque: 8 Nm (6 lbf ft)
33. Fit the crankshaft pulley with the notch facing the projection on the engine (diagonally upwards-forwards). Tightening torque: 20 Nm (15 lbf ft)
34. Fit the timing cover. Tightening torque: 8 Nm (6 lbf ft)
35. Fit the belt tensioner and the generator air intake.
36. Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.
37. Fit the multigroove belt.
38. Tighten the retaining bolts on the pulleys. Tightening torques: Belt pulley/coolant pump: 8 Nm (6 lbf ft) Belt pulley/power steering pump: 20 Nm (15 lbf ft)
39. Fit the right-hand engine attachment with bracket and engine mount. Tightening torques: To body 63 Nm (46.5 lbf ft)
40. Fit the power steering hose in the holder
41. Fit the mass air flow sensor with hose.
42. Raise the car.
43. Lower the engine by carefully removing the wedges.
44. Lower the car to the floor.
45. Reconnect the negative cable to the battery.
46. Fill up with coolant. Do not forget to close the radiator drain cock first. Screw on the expansion tank filler cap.
47. Bleed the cooling system as follows: Fill the system up to the MAX level, close the expansion tank filler cap, start the engine and warm it up (by running it at varying rpm) until the radiator fan starts. Unscrew the expansion tank filler cap and top up again to the MAX level. Close the filler cap and run the engine at varying rpm until the radiator fan starts three more times. Switch off the engine and top up as necessary to the MAX level. NOTE: The A/C should be OFF.
48. Raise the car.
49. Check for leakage.
50. Fit the lower engine covers.
51. Lower the car to the floor.
52. Fit the engine cover and remove the wing protectors.
53. Reset the clock and, where appropriate, the radio code.

Scheme 593

1. Clean the cylinder head sealing surfaces.
2. Using a straight-edge and feeler gauge, measure the cylinder head diagonally from corner to corner, as well as lengthwise and crosswise, to check for warping.