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4.5.2. Removal and installation of the inlet pipeline, belt of the GRM drive and heads of cylinders

 PERFORMANCE ORDER

  1. Lay protective covers on wings.
  2. For removal of a forward head of cylinders remove the battery; for removal of a back head – disconnect a negative wire from the battery.
  3. Open a cover of a broad tank of the cooling system of the engine.
  4. The car also establish to Poddomkratta it on props.
  5. Remove the lower cover of the engine and lower OZh from a radiator.
  6. Remove a turbocompressor arm, paying attention that on the same arm the protective plate of the CKP sensor is fixed.
  7. Establish wedges between a stretcher and the pallet of a case, and also between a stretcher and transmission.
  8. At removal of a forward head of cylinders disconnect the giving turbocompressor tube from the intercooler, having left on it a collar.
  9. Perform the operations described in in item 4 – 8 Sections Reduction of the Piston of the First Cylinder in the provision of VMT and replacement of a belt of the drive of auxiliary units and its natyazhitel, do not remove a pulley of a bent shaft yet.
  1. Unhook a cable of the drive of a butterfly valve (18 on an illustration). Remove vacuum hoses and separate pressure sensor socket from the top inlet pipeline (19).
  1. Disconnect a vacuum hose, 2 hoses of the cooling system, the giving and perepuskny tubes from the throttle case. Separate the socket of the case of a throttle and disconnect a purge valve hose from below of the throttle case (20 on an illustration).
  1. Separate the socket of modules of ignition and injectors (21 on an illustration).
  1. At removal of a forward head of cylinders separate the socket of the sensor of pressure/temperature and remove the turbocompressor valve.
  2. At removal of a back head of cylinders:
    • Release sockets a lambda probes from holders on the back SAI valve. For this purpose wring out a clamp and press sockets;
    • Remove SAI tube arm from a head of cylinders. Separate sockets on a final collector. Disconnect a hose from the SAI valve, having squeezed clamps and having pulled the socket up;
  1. Disconnect fuel lines. Remove the top section of the inlet pipeline.
  1. Remove average (24 on an illustration) and the lower (25) sections of the inlet pipeline. Zakuporte of an opening paper or rags.
  1. Remove a splitter (26 on an illustration) cooling systems and take it aside.

Do not damage laying.

  1. Remove a pulley of a bent shaft.
  2. Install the piston of the first cylinder in the provision of VMT of the end of a step of compression and block cogwheels cranked and camshafts by means of special devices.
  1. Give fixture of a roller of a natyazhitel of a belt of the GRM drive and adjusting rollers. Use the special device for fixing of adjusting rollers (29 on an illustration).
  1. Mark the direction of the movement of a belt of the GRM drive (30 on an illustration). For installation simplification (if the taken-off belt is supposed to be reused) mark the provision of a belt concerning cogwheels of cranked and distributive shaft. Remove the fixing devices installed at reduction of the piston of the first cylinder in the provision of VMT from cogwheels.
  2. Shoot the lower adjusting video together with the washer located behind it. Take off a driving belt.
  1. Remove assembly of adjusting and tension rollers.
  1. Remove the module of ignition and a cover of a head of cylinders.

Do not assume that sealing rings of a cover of a head of cylinders fell in the engine.


  1. Turn a bent shaft in situation 60 a hail. to VMT also note this situation (34 on an illustration).
  1. Remove cogwheels of camshafts (35 on an illustration), the water pump (36) and a back cover of a driving belt (37).
  1. At removal of a back head of cylinders to a poddomkratta the car also disconnect forward section of an exhaust pipe from a back final collector.
  1. At removal of a forward head of cylinders perform the following operations described in the item with 29 on 38.
  1. Remove the thermofilter of a forward final collector (38 on an illustration).
  1. Give sockets of fastening of hoses to the forward SAI valve for what squeeze clamps and pull the socket back (39 on an illustration).
  2. Pick up the phone of SAI and the valve from a final collector (40 on an illustration).
  3. Pick up the phone of ventilation of a case between an inlet tube of a turbocompressor and a head of cylinders, and also a hose from an oil separator. Take a tube aside.
  4. Pick up the inlet phone of a turbocompressor and take it aside (42 on an illustration).
  5. Disconnect a final hose of a turbocompressor to the intercooler (43 on an illustration).
  1. Disconnect a water hose (44 on an illustration) from the thermostat case.
  1. Disconnect a forward final collector from a turbocompressor (45 on an illustration).
  2. Remove cooling tubes (46 on an illustration) and supply of oil (47) from a turbocompressor.
  1. Give fixture and remove the camshaft of inlet valves (48 on an illustration). Give bolts half way for approach. Pay attention to tags on covers of bearings. The last should uncover the bearing closest to the loaded pushers of valves. Remove epiploons.

Give bolts of fastening of a back head to the sequences, return specified illustrations. The camshaft of inlet valves is not required to be removed.

  1. Take pushers of valves and arrange them so that then to establish on former places.
  2. Give bolts of fastening of a head of cylinders. At first give bolts on a quarter of a turn, and then half way. Remove a head of cylinders, trying not to bend valves.

Installation

 PERFORMANCE ORDER

  1. Perform control measurements of a head of cylinders and compare them to requirements of Specifications.
  2. Make sure that the camshaft is in situation 60 a hail. to VMT.
  3. Clear the interfaced surfaces of the remains of sealing materials and lay on the block of cylinders new laying by the inscription "OBEN/TOP" up.
  4. Establish pushers of valves on their former places.
  5. Establish into place a head of cylinders and tighten it new bolts with the required efforts and in the sequence provided on an illustration below.

Tighten bolts of fastening of a forward head of cylinders in the sequence, return specified illustrations.

  1. Grease with a thin layer of motive oil the final camshaft and lay it in a head of cylinders.
  1. Orient tags on camshafts according to an illustration (A – a forward head of cylinders; B – back).
  1. Establish covers of bearings of camshafts, paying attention to the tags applied on covers and on a head of cylinders. Apply on the surface of a head of cylinders interfaced to covers of forward bearings of camshafts (C on an illustration) a thin layer of sealant (No. 74 96 268 according to the Saab catalog). Tighten bolts of fastening of covers of bearings with effort of 8 N • m.
  1. Establish a back cover of a belt of the GRM drive and cogwheels of camshafts according to the tags put on wheels and on a cover.

Number on a cogwheel has to coincide with number on a shaft. Tighten bolts of fastening of cogwheels with the required efforts.

  1. Make sure that pure dry sealing rings of a cover of a head of cylinders are laid by it on the places and establish a cover of a head of cylinders.
  2. Install the ignition module.
  3. At installation of a forward head of cylinders install the components listed on illustrations in the sequence, the return to an order of dismantle of components.
Removal of hoses of a turbocompressor.
Removal of the SAI components and hoses of a turbocompressor.
  1. At installation of a back head of cylinders install the SAI components and connect forward section of an exhaust pipe to a back final collector.
  1. Install the water pump and assembly of tension and adjusting rollers.
  2. Install the fixing devices on cogwheels of camshafts.
  1. Turn a bent shaft almost to a tag "0" and install on it special adaptation. Then turn a bent shaft till the moment when the lever adaptation rests against a flange of the water pump and remove adaptation.
  1. Lay on cogwheels a GRM drive belt according to the tags made at removal. Establish the lower tension roller, but do not tighten its fixture yet. Make sure that the washer is in the place. Adjust a hand the provision of a roller (counterclockwise) so that the belt did not move. Make sure that tags on a driving belt and on cogwheels of camshafts and a bent shaft coincide.
  2. Install the tension measuring instrument on a GRM drive belt. Slightly tighten the central bolts of fastening of adjusting rollers. Turn the lower adjusting roller so to receive a tension of a belt from 275 to 300 N • m then tighten a bolt of fastening of a roller. Again check a tension of a driving belt if necessary again adjust it.

Adjustment of a tension of a driving belt at this stage is the preparatory procedure and its result cannot be used as check at a final tension of a belt.


  1. Make sure that the adjusting nut on the top adjusting roller rotates freely and it is not tightened. Correct the provision of a tension roller by means of a prutkovy key on 5 mm so that tags on it coincided and tighten a bolt of fastening of a tension roller.
  1. Remove the fixing devices from cogwheels of 1 and 2 camshafts. Install special adaptation and turn the top adjusting roller counterclockwise so that tags on cogwheels of camshafts coincided with the corresponding tags on special adaptation. Tighten a nut of fastening of the top adjusting roller.
  2. Remove all special devices.
  3. Turn the engine on two whole revolutions that the bent shaft slightly did not reach a tag "0". Install special adaptation on the camshaft and turn a shaft till the moment when the lever of adaptation rests against a flange of the water pump. Remove adaptation, establish a control template of provision of VMT and make sure that tags on it are located opposite to tags on cogwheels of camshafts. Make sure that the belt of the GRM drive lies aflush with cogwheels, and the tag And is about 2 mm above B tag. If the last condition is not satisfied, adjustment of phases GRM should be made at first.
  4. Establish a cooling system splitter, and then and all other being removed components in the sequence, the return to an order of dismantle of components. Tighten fixture with the required efforts.