How to Replace timing belt on Saab 9-3 1.9 TiD (9440) 2004-2010

Replacement Interval Guide

• Saab recommend:
• →06MY:
• Replacement every 72,000 miles.
• 07MY→:
• Replacement every 90,000 miles or 10 years.
• The previous use and service history of the vehicle must always be taken into account.

Check For Engine Damage

CAUTION: This engine has been identified as an INTERFERENCE engine in which the possibility of valve-to-piston damage in the event of a timing belt failure is MOST LIKELY to occur. A compression check of all cylinders should be performed before removing the cylinder head.

Repair Times – hrs

Remove & install:
9-3 TiD	1,60
9-3 TTiD/ 9-3 X TTiD	2,20
9-5	1,40

Special Tools

• Auxiliary drive belt tensioner locking tool – No.87 92 335.
• Crankshaft timing tool – No.32 025 009.
• Exhaust camshaft locking tool – No.32 025 008.

Special Precautions

• Disconnect battery earth lead.
• DO NOT turn crankshaft or camshaft when timing belt removed.
• Remove glow plugs to ease turning engine.
• Turn engine in normal direction of rotation (unless otherwise stated).
• DO NOT turn engine via camshaft or other sprockets.
• Observe all tightening torques.

Removal

1. Raise and support vehicle.
2. Remove:
   • RH front wheel.
   • RH front inner wing panel.
   • Engine undershield.
3. Turn auxiliary drive belt tensioner to release tension on belt. Use suitable spanner.
4. Lock auxiliary drive belt tensioner [1] . Use tool No.87 92 335.
5. Remove:
   • Auxiliary drive belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.
   • Crankshaft pulley bolts [2] .
   • Crankshaft pulley [3] .
   • 9-3: Auxiliary drive belt guide pulley.
   • Engine top cover.
   • Turbocharger air hoses (if required).
6. Support engine.
7. 9-3: Disconnect AC pressure switch multi-plug.
8. Remove:
   • 9-3: Air filter housing.
   • RH engine mounting.
   • Timing belt covers [4] & [5] .
9. Detach crankcase breather hose from cylinder head.
10. Remove blanking plug in cylinder head for exhaust camshaft locking tool.
11. Fit exhaust camshaft locking tool [6] . Tool No.32 025 008.
12. Turn crankshaft in direction of rotation until camshaft locking tool heard to engage [6] .
13. Ensure camshaft sprocket timing mark aligned at 3 o’clock position [7] .
14. Ensure pin on crankshaft sprocket at 6 o’clock position [8] .
15. Slacken tensioner sprocket bolt [9] .
16. Move tensioner sprocket away from belt. Lightly tighten bolt.
17. Remove timing belt.NOTE: Mark direction of rotation on belt with chalk if belt is to be reused.

Installation

1. Ensure pin on crankshaft sprocket at 6 o’clock position [8] .
2. Ensure exhaust camshaft locked in position [6] .
3. Ensure camshaft sprocket timing mark aligned at 3 o’clock position [7] .
4. Fit timing belt, starting at crankshaft sprocket. Ensure belt is taut between sprockets.
5. Ensure timing belt marks aligned [10] .
6. Remove oil pump bolt. Insert stud of crankshaft timing tool [11] . Tool No.32 025 009.
7. Fit timing tool to crankshaft sprocket [12] . Tool No.32 025 009. Ensure pin on crankshaft sprocket located correctly in tool [8] . Secure with bolt [13] .
8. Screw an M8 bolt into timing belt rear cover [14] .
9. Lever tensioner sprocket bracket at position [15] until pointer [16] and mark [17] aligned.
10. Tighten tensioner sprocket bolt to 25 Nm [9] .
11. Remove:
    • Crankshaft timing tool [12] .
    • Exhaust camshaft locking tool [6] .
12. Turn crankshaft two turns clockwise.
13. Ensure pin on crankshaft sprocket at 6 o’clock position [8] .
14. Fit exhaust camshaft locking tool [6] .
15. Fit crankshaft timing tool [12] . Ensure pin on crankshaft sprocket located correctly in tool [8] . Secure with bolt [13] .
16. Ensure pointer and mark aligned [16] & [17] .
17. Remove timing tool [12] .
18. Fit oil pump bolt.
19. Remove exhaust camshaft locking tool [6] . Fit blanking plug.
20. Install components in reverse order of removal.
21. Tighten crankshaft pulley bolts [2] . Tightening torque: 25 Nm.