Title: 2009/5/4 Rough/Erratic Idle After Engine or Cylinder Head Replacement-Incorrect Cam Alignment Tool Used - PIC4286C

Date: 05/04/2009
To: Service Department
From: Technical Assistance
______________________________________________

Subject: Rough/Erratic Idle After Engine or Cylinder Head Replacement-Incorrect Cam Alignment Tool Used - keywords

Models:
2003 - 2009 Saab 9-3 Sedan
2004 - 2009 Saab 9-3 Convertible
2006 - 2009 Saab 9-3 Combi
With 4 cylinder engine B207 (VIN S, N and Y)

The following diagnosis might be helpful if the vehicle exhibits the symptom(s) described in this PI.

CONDITION/CONCERN:

A technician may notice a rough idle or vibration from the engine after the camshaft timing was reset due to a cylinder head or short engine replacement. The technician may not be aware that he has used the incorrect tool. The tech may note during the timing procedure that the camshaft alignment tools do not fit correctly over the camshaft lobes.

RECOMMENDATION/INSTRUCTIONS:

If you encounter a rough idle, hesitation/surge and or DTC's after a camshaft, cylinder head and or short block service on a 2003-09 Saab 9-3 with a B207 4 cylinder engine, please verify the correct camshaft timing tools were used. Look at the 8th digit of the VIN to find the engine code.

Check the tool number or color of the individual camshaft locks. Tool numbers 83 96 020 and 83 96 038 (blue in color) are only for the (VIN S) engine. Tool numbers 83 96 053 and 83 96 061 (gold in color) are only for the (VIN N or Y) engine. For 2007-09MY's a new set of camshaft alignment tool kits have been released and the tool number for the 210HP (VIN Y) engine is EN-48368 (Aluminum/White in color) they will not retrofit to earlier vehicles. If the wrong tools are used, a rough idle will result and DTC's for misfire may set. The tech may comment that the exhaust cam lock did not fit correctly on the camshaft. Valve damage should not occur due to using the wrong tools.

The numbers/colors for the 2003-06 timing tools are:
The kit for the 175HP engine is 83 96 046 - Blue in color (VIN S) Look at the 8th digit of the VIN to find the code.
The kit for the 210HP engine is 83 96 079 - Gold in Color (VIN N or Y) Look at the 8th digit of the VIN to find the code.

NOTE: For 2007-09 a new set of camshaft alignment tool kits have been released. They will not retrofit to earlier vehicles.
The kit for the 175HP engine is EN-48366 - Green in color (NA for USA)
The kit for the 210HP engine is EN-48368 - Aluminum/White in color. All B207 engines from 2007 forward are VIN digit Y.


Please follow this diagnostic or repair process thoroughly and complete each step. If the condition exhibited is resolved without completing every step, the remaining steps do not need to be performed.