Camshaft

/ 9-3 (9440) / 2004 / 2. Engine / 4-cylinder diesel / Basic engine / Adjustment/replacement / Camshaft

(in-situ)

To remove

1.	Protect the wings with covers.

2.	Remove the battery cover and the negative battery cable.

3.	Remove the upper engine cover.

4.	Remove the turbocharger intake hose and plug the inlet on the turbocharger. Remove the crankcase ventilation hose and unplug the mass air flow sensor.

5.	Remove the air filter housing lid and the air filter. Detach the intake hose and remove the filter housing.

6.	Remove the charge air hose and charge air pipe from the turbocharger, and the charge air pipe from the fan cowling. Plug the connections.

7.	Undo the rear wiring harness mounting from the camshaft cover.

8.	Disconnect the glow plug connectors and bend aside the wiring harness.

9.	Raise the car and remove the right-hand front wheel and right-hand wing liner.

10.	Remove the lower engine cover.

11.	Mark the belt's direction of rotation. Detension and remove the poly-V-belt.

12.	Remove the belt tensioner. Place the belt tensioner standing upright.

13.	Remove the coolant pipe from the gearbox and cylinder block.

14.	Remove the crankshaft position sensor.

15.	Lower the car and unplug the connector from the pressure/temperature sensor.

16.	Slacken the bolt holding the coolant pipe bracket to the camshaft cover.

17.	Undo the A/C pressure sensor connector.

18.	Remove the bolts by the vacuum pump securing the cable duct.

19.	Disconnect the hoses from the vacuum pump and remove the vacuum pump. Have a rag at hand to catch any oil spills.

20.	Remove the camshaft cover and move aside the fuel lines.

21.	Turn the crankshaft to just before the mark for TDC for cylinder 1. Check that both the cams for cylinder 1 are pointing obliquely upward.

22.	Raise the car and insert 83 95 352 Adjustment tool, crankshaft into the hole for the crankshaft position sensor. Press the tool in while turning the crankshaft to zero. The tool should enter a recess in the crankshaft and lock it.

23.	Lower the car and fit 83 95 386 Adjustment tool, camshaft to the camshaft and cylinder head.

24.	Remove the bolts from the cover on the timing cover. Carefully insert a pallet knife behind the cover and prise it off.

25.	Insert 83 95 337 Adjustment tool, fuel pump into the recess on the fuel distribution pump.

26.	Remove the upper timing chain tensioner.

27.	Remove 83 95 337 Adjustment tool, fuel pump from the outlet on the fuel pump.

28.	Attach a long cable tie to the timing chain. This will be used as a handle.

29.	Remove the camshaft sprocket using an open-ended wrench on the hexagonal key to hold the camshaft still.

30.	Carefully place the chain to one side.

31.	Slacken the bolts securing the camshaft bearing caps 0.5-1 turn at a time in the order illustrated. Start with no. 1.

32.	Lift off the camshaft bearing caps and remove the camshaft.

33.	Changing the camshaft also requires the removal of the valve bridges.

To fit

1.	Clean any left-over gasket material from the sealing surfaces.

2.	Check the camshaft and bearing seats for wear. Change if necessary.

3.	If the camshaft is changed, new valve bridges must be fitted. Important Note how the valve bridges are fitted. The markings are on the side of the valve bridges facing the fuel bridges.

4.	Sparingly apply 83 95 691 Flange sealant to the sealing surfaces of the 5th camshaft bearing cap. See illustration.

5.	Lubricate the camshaft and contact surfaces of the valve bridges with engine oil.

6.	Fit the camshaft with the two cams for cylinder 1 pointing up. Position the camshaft bearing caps in their respective positions.

7.	Tighten the camshaft bearing cap bolts 0.5-1 turn at a time in the order illustrated. Tightening torque 20 Nm (15 lbf ft)

8.	Lift up the timing chain and fit the camshaft sprocket so that it runs freely on the camshaft. Fit a new bolt and tighten finger tight.

9.	Reinsert 83 95 337 Adjustment tool, fuel pump into the recess on the fuel distribution pump.

10.	Fit 83 95 386 Adjustment tool, camshaft to the camshaft and cylinder head.

11.	Cut the cable tie and fit the adapter for 83 95 394 Adjustment tool, timing chain to the camshaft sprocket. Fit the adjustment tool to the cylinder head.

12.	Fix the position for the adapter on the camshaft sprocket by lightly twisting it anticlockwise with a ratchet handle. Tighten the adjustment screw on the tool. Important Adjustment tool 83 95 337 must be easy to remove and fit at all times. If not, slacken the adjusting screw on the tool slightly

13.	Tighten the bolt securing the camshaft sprocket using an open-ended wrench on the hexagonal key to hold the camshaft still. Tightening torque 90 Nm + 60° (66 lbf ft + 60°)

14.	Fit the upper timing chain tensioner using a new gasket. Tightening torque 60 Nm (44 lbf ft)

15.	Remove all the adjustment tools. Raise the car to remove 83 95 352 Adjustment tool, crankshaft .

16.	Lower the car and turn the crankshaft two turns using the centre bolt on the pulley to just before the mark for TDC for cylinder 1. Check that both cams for cylinder 1 point upward.

17.	Raise the car and insert 83 95 352 Adjustment tool, crankshaft into the hole for the crankshaft position sensor. Press the tool in while turning the crankshaft to zero. The tool should enter a recess in the crankshaft and lock it.

18.	Lower the car and check that the markings on the crankshaft pulley and timing cover are aligned. Also, the arrow on the single camshaft sprocket by the fuel distribution pump should be aligned with the recess on the pump.

19.	Insert 83 95 337 Adjustment tool, fuel pump into the recess in the fuel distribution pump.

20.	Fit 83 95 386 Adjustment tool, camshaft to the camshaft and cylinder head.

21.	Remove all the adjustment tools. Raise the car to remove 83 95 352 Adjustment tool, crankshaft .

22.	Fit the crankshaft position sensor using a new O-ring.

23.	Lower the car and cover the opening in the timing cover with a lint free cloth. Clean any old gasket remains from the sealing surfaces and clean the sealing surface on the cover.

24.	Apply a 2 mm bead of 83 95 691 Flange sealant to the cover. Remove the cloth from the timing cover and fit the cover. Tightening torque 6 Nm (5 lbf ft)

25.	Clean any old gasket remains from the sealing surfaces on the cylinder head. Position a new gasket on the camshaft cover. Apply 83 95 691 Flange sealant to the sealing surface as illustrated and fit the camshaft cover. Tightening torque 8 Nm (6 lbf ft)

26.	Position the vacuum pump. Apply 83 95 691 Flange sealant as illustrated and fit the vacuum pump with the adapter and a new gasket. Connect the hoses to the vacuum pump. Tightening torque 8 Nm (6 lbf ft)

27.	Fit the bolts securing the cable duct by the vacuum pump.

28.	Plug in the A/C pressure sensor connector.

29.	Fit the bolt holding the coolant pipe bracket to the camshaft cover.

30.	Plug in connector for the pressure/temperature sensor.

31.	Raise the car and fit the coolant pipe mounting to the gearbox and cylinder block.

32.	Fit the belt tensioner. Tightening torque, lower screw 24 Nm (18 lbf ft) Tightening torque, upper screw 42 Nm (31 lbf ft)

33.	Release the tension of the poly-V-belt and fit it in the direction of rotation marked. Check that the belt is correctly seated on all the pulleys.

34.	Fit the lower engine cover.

35.	Lower the car and fit the right-hand wing liner and front right wheel. See Wheels .

36.	Connect the glow plug connectors.

37.	Fit the rear wiring harness mounting to the camshaft cover.

38.	Fit the charge air hose and charge air pipe to the turbocharger and the charge air pipe to the fan cowling.

39.	Fit the air filter housing and connect the intake hose. Fit the air filter and air filter housing lid.

40.	Connect the crankcase ventilation hose and plug in the mass air flow sensor. Fit the turbocharger intake hose.

41.	Connect the negative battery cable and fit the battery cover.

42.	Fit the upper engine cover.

43.	Remove the covers from the wings and return the electrical system to its original state. Refer to Procedures after reconnecting the battery .

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