SAAB WIS ONLINE

PRE-RELEASE

Fitting the spare part cylinder block

Fitting the spare part cylinder block

To fit


1. Fit 83 94 751 Holder, engine and lift up the cylinder block into 78 74 878 Floor stand .

2. Fit the dipstick pipe with new O-rings.


3. Fit new oil filter and change O-ring on the oil filter cover. Use 83 96 129 Oil filter tool B207 and camshaft drive chain tensioner .

Tightening torque 25 Nm (18 lbf ft)

4. Check that the spare part cylinder block is zeroed using the markings on the pulley and timing cover.

5. Place a new gasket on the cylinder block.

6. Fit the cylinder head in the order shown in the illustration. Insert the bolts carefully. The threads in the cylinder block can become damaged if they are lowered too rapidly. Make sure it fits properly onto the guide sleeves.

Tightening torque step 1, 30 Nm (22 lbf ft)

Tightening torque, step 2: 150°

Tightening torque, step 3: 15°

Tightening torque, bolts for timing section, 35 Nm (26 lbf ft)

Important

The colour markings on the balancer shaft chain must correspond with the markings on the gears.



7. Fit the balancer shaft chain sprocket and wedge. Fit the balancer shaft chain. Start fitting on the water pump pinion. Continue as follows:

7.A. The silver-coloured link must be fitted to the exhaust side balancer shaft sprocket.


7.B. The copper-coloured link must be fitted to the intake side balancer shaft sprocket.

7.C. The silver-coloured link must be fitted to crankshaft sprocket.

8. Fit the balancer shaft chain guide rails. Use 74 96 268 Thread locking adhesive .

Tightening torque 10 Nm (7 lbf ft)

9. Fit the chain tensioner. Fit the chain tensioner and secure with tool 83 96 392 Lock pin .


10. Fit the chain tensioner screws. Use 74 96 268 Thread locking adhesive .

Tightening torque 10 Nm (7 lbf ft)

11. Remove the tool from the tensioner. Press the tensioner guide rail to check that backward movement of the plunger is prevented.

12. Fit the crankshaft sprocket.

13. Clean the camshaft and sprocket contact surfaces from oil and grease.


14. Fit the tensioner guide.

Tightening torque 10 Nm (7 lbf ft)


15. Lay the chain on the intake sprocket and lower the chain. Fit the sprocket on the camshaft and insert the bolt.

16. Fit the chain on the crankshaft sprocket and fit the chain guide. Fit the lower bolt.

Tightening torque 10 Nm (7 lbf ft)

17. Fit the exhaust sprocket and enter the bolt.

18. Fit the upper bolt. Fit the plug on the cylinder head.

19. Fit the timing chain tensioner using the following method:

19.A. Turn the camshaft drive tensioner clockwise with a screwdriver until it engages in the tensioned position.


19.B. Place the plunger in the chain tensioner sleeve. Fit the circlip and check that it is fitted correctly in the groove.

Note

Check that the O-ring and gasket are intact. If damaged, replace the chain tensioner assembly.



19.C. Fit the chain tensioner.

Tightening torque 75 Nm (55 lbf ft)


20. Release/activate the chain tensioner by carefully pressing on the transmission chain or chain guide (as shown). Use a screwdriver. Check that the tensioner releases.


21. Remove the exhaust camshaft and intake camshaft bearing caps no. 2 and no. 7. Position EN-48368 Adjustment tool, camshaft (B207 210 hp) and EN-48366 Adjustment tool, camshaft (B207 150 - 175 hp) by manually pressing the tools down onto the camshafts without tightening the bolts. Turn the camshaft until the tool aligns with the spanner on the camshaft flats. Tighten the adjustment tools' bolts.

Tightening torque 10 Nm (7 lbf ft)


22. Fit the timing cover with a new gasket.

Tightening torque 20 Nm (15 lbf ft)


23. Position the 83 96 202 Fitting tool, front crankshaft seal B207 protective collar on the crankshaft. Lubricate the new sealing ring with acid-free Vaseline and position it on the fitting tool.


24. Position the fitting tool on the crankshaft. Tighten the sealing ring using the crankshaft pulley bolt until it is flush with the timing cover. Remove the tool.

25. Fit the crankshaft pulley with a new bolt. Use 83 95 360 Holding tool, crankshaft pulley (shaft only) and 83 96 210 Holding tool, crankshaft pulley, B207 .

Tightening torque 100 Nm + 75° (74 lbf ft + 75°)

26. Check that the markings on the crankshaft pulley and the timing cover are aligned. Tighten the camshaft gears a first time. Use a spanner to grip the camshaft flats.

Tightening torque 30 Nm (22 lbf ft)


27. Remove the adjustment tool and fit the bearing caps.

Tightening torque 8 Nm (6 lbf ft)

28. Continue to tighten the camshaft gears to the final torque. Use a spanner to grip the camshaft flats.

Tightening torque 85 Nm + 30° (63 lbf ft +30°)

29. Rotate the crankshaft 2 turns in the direction of engine rotation until the mark on the crankshaft pulley agrees with the mark on the timing cover. Remove the bearing caps and fit EN-48368 Adjustment tool, camshaft (B207 210 hp) and EN-48366 Adjustment tool, camshaft (B207, 150 - 175 hp) again to check that the camshaft setting is correct. Remove the adjustment tools and refit the bearing caps.

Tightening torque 8 Nm (6 lbf ft)

30. Fit the timing chain's upper guide rail.

Tightening torque 10 Nm (7 lbf ft)

31. Fit the belt tensioner.

Tightening torque 50 Nm (37 lbf ft)


32. Fit the engine mounting bracket.

Tightening torque 93 Nm (69 lbf ft)

33. Fit the camshaft cover.

Tightening torque 10 Nm (7 lbf ft)

34. Fit the ground cable.


35. Fit the bracket.

36. Fit the ignition coils.

Tightening torque 8 Nm (6 lbf ft)

37. Fit 83 94 868 flywheel locking attachment . Fit the flywheel with new bolts.

Apply 74 96 292 Thread locking adhesive to the bolts. Tighten the bolts alternately.

Tightening torque, solid flywheel 53 Nm + 25° (49 lbf ft + 25°)

Tightening torque, dual mass flywheel 60 Nm +30° (44 lbf ft +30°)


38. Cars with automatic transmission : Fit the driver plate on the crankshaft.

Tightening torque 53 Nm + 25° (49 lbf ft + 25°)

39. Cars with manual gearbox: Place the driven plate and pressure plate on the flywheel and fit the bolts without tightening.

Cars with dual mass flywheel: The convex side of the driven plate must be turned towards the gearbox. Fit the bolts that hold the pressure plate and fit the clutch and driven plate hub.


40. Centre the driven plate with 87 92 327 Mandrel for centring, driven plate for B207 or 83 96 277 Mandrel for centring, 6-speed and tighten the bolts alternately. Apply 74 96 268 Thread locking adhesive to the threads.

Tightening torque 30 Nm (22 lbf ft)

41. Remove 83 94 868 Flywheel locking attachment .

42. Fit the bolt to the dipstick tube.


43. Fit the crankshaft position sensor.

44. Fit the lower intake manifold attachment bracket.

Tightening torque 22 Nm (16 lbf ft)

45. Cars with secondary air injection pump : Fit the pump.


46. Fit the alternator.

Tightening torque 20 Nm (15 lbf ft)

47. Fit the crankcase ventilation hose to the camshaft cover.


48. Fit the lower turbocharger attachment bracket.

Tightening torque 22 Nm (16 lbf ft)

49. Fit the turbocharger oil return pipe with a new gasket and O-ring.

Tightening torque 15 Nm (11 lbf ft)

50. Fit the turbocharger oil delivery pipe with new gaskets.

Tightening torque 28 Nm (21 lbf ft)

51. Secure the engine with an engine lift.

52. Lift the engine off the engine stand and lower it carefully onto a pallet. Remove 83 94 751 Holder, engine from the engine.

53. Fit 87 92 442 Lifting cable to the gearbox and raise the gearbox slightly. Fit the gearbox to the engine.

54. Fit the gearbox retaining bolts.

Tightening torque 70 Nm (52 lbf ft)



55. Raise the engine to the subframe and centre the engine on the subframe with 83 96 152.

56. Fit the torque arms to the oil sump and gearbox.

Tightening torque RH torque arm to oil sump, 37 Nm (27 lbf ft)

Tightening torque LH torque arm to gearbox, 70 Nm + 90° (52 lbf ft + 90°)

57. Remove the engine lift.

58. Remove 83 96 178 Lifting eyes, B207

59. Cars with automatic transmission : Remove 87 92 574 Holder that holds the torque converter in place. Press the torque converter toward the driver plate. Fit the plug.


60. Cars with automatic transmission : Apply 74 96 268 Thread locking adhesive to all bolts holding the torque converter to the driver plate. NB Use original bolts with associated washers. Using bolts that are too long can damage the torque converter.


61. Fit the 6 bolts without tightening them.

62. Turn the engine clockwise with the pulley and tighten the bolts when all are in place.

Tightening torque 30 Nm (22 lbf ft)

63. Fit the power steering pump to the cylinder head and replace the gasket.

Tightening torque 22 Nm (16 lbf ft)


64. Fit the water-cooled oil cooler with new gaskets.

Tightening torque 22 Nm (16 lbf ft)

65. Fit the starter motor.

Tightening torque 47 Nm (35 lbf ft)


66. Cars with secondary air injection pump : Fit the pipe between the pump and the valve.

67. Tap the new LH drive shaft seal into place using 87 92 657 Fitting drift, drive shaft seals. Lubricate the seal with gearbox oil.


68. Fit 83 95 162 Protective collar, drive shafts in the sealing ring.

69. Tap in the RH seal with 87 92 657 Fitting drift, drive shaft seals .


70. Position 83 95 162 Protective collar, drive shafts in the shaft seal. Insert the intermediate shaft into the gearbox until approximately 20 mm of the shaft remains. Pull out the collar and push in the rest of the intermediate shaft.


71. Fit the intermediate shaft bracket.

Tightening torque 47 Nm (35 lbf ft)


72. RH side : Fit the drive shaft in the intermediate shaft splines. Lubricate the shaft splines with 90 513 210 Universal paste . Make sure the seal against the intermediate shaft has been fitted.

73. LH side : Position 83 95 162 Protective collar, drive shafts and fit the drive shaft in the gearbox. Lubricate the shaft splines with gearbox oil. Remove the collar when approximately 20 mm of the shaft remains. Push in the shaft until the circlip snaps into place.

74. Fit the thermostat housing and pipe with new O-rings. Lubricate the pipe O-ring sparingly with 30 06 665 Vaseline .

Tightening torque 10 Nm (7 lbf ft)


75. Fit the turbocharger coolant pipe. Fit the banjo screws with new gaskets.

Tightening torque M12, 28 Nm (21 lbf ft)

Tightening torque M14, 40 Nm (30 lbf ft)

76. Fit the cylinder head breather hose.


77. Fit the hoses to the oil cooler. Check that the oil cooler hose clips do not rest against the lower radiator hose. Adjust if necessary.

78. Fit the catalytic converter with new nuts.

Tightening torque 25 Nm (18 lbf ft)


79. M03 : Plug in the temperature sensor connector.

80. Press the oxygen sensor connectors firmly into place in the bracket.

81. Fit the catalytic converter heat shield.

Tightening torque 10 Nm (7 lbf ft)


82. Fit the turbocharger heat shield.

Tightening torque 10 Nm (7 lbf ft)

83. Fit the lower charge air pipe.

Tightening torque 22 Nm (30 lbf ft)

84. Position the engine wiring harness and plug in the following connectors:

Important

Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to Connectors, handling and inspection .


84.A. Plug in the connector to the charge air control valve.


84.B. Plug in the connector to the coolant temperature sensor.

84.C. Plug in the engine control module connector.

84.D. Plug in the engine control module connector.

84.E. Plug in the connector to grounding point G7.

84.F. Plug in the charge air bypass valve connector.

84.G. Plug in the throttle body connector.

84.H. Plug in the 4 ignition coil connectors.

84.I. Plug in the connector to the ionization detection module.


84.J. M03: Plug in the connector to the exhaust temperature sensor.

84.K. Plug in the connector to the front oxygen sensor.

84.L. Plug in the connector to the rear oxygen sensor.

84.M. Plug in the connector to the atmospheric pressure sensor.


84.N. Plug in the connector to the intake manifold pressure sensor.

84.O. Fit the power steering fluid pressure switch.

84.P. Fit the starter motor contacts.


84.Q. Cars with secondary air injection pump : Plug in the secondary air injection pump connector.

84.R. Fit the oil pressure switch.

84.S. Plug in the connector to the crankshaft position sensor.

84.T. Plug in the EVAP canister purge valve connector.

84.U. Plug in the oil level sensor connector.

84.V. Plug in the alternator connector.

84.W. Plug in connector H8-9.

84.X. Plug in the reversing light connector.

84.Y. Fit the wiring harness retaining bolts.

85. Fit the cover to the spark plugs.


86. Fit the engine assembly, see Power unit, to fit.

87. Fill with engine oil, see Changing engine oil and oil filter .

88. Fill with gearbox oil:

Cars with automatic transmission : Checking oil level :

Cars with manual gearbox : see Filling/changing gearbox oil :

89. CV: Fit the chassis reinforcement, front subframe, CV.

90. Lower the car.

91. Carry out: Procedure after reconnecting the battery .


PRE-RELEASE