Basic Engine, 4-CYLINDER Petrol: Overhaul Saab 9-3 I

To assemble the engine block

All engine components should be thoroughly cleaned before fitting.

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Scheme 185

Scheme 186

Scheme 187

Scheme 188

Scheme 189

1. Fit the piston cooling nozzles. Place all main bearings in their correct positions and coat them with oil. Tightening torque, piston cooling nozzle: 18 Nm (13 lbf ft). IMPORTANT: The field rotor flange must be treated very carefully. Make sure the main bearing adjustment sleeves are unscrewed, if they are not fastened.
2. Fit the slotted ring, place the crankshaft in position and fit the two thrust washers at the main bearing between the No. 2 and No. 3 cylinders. Fit the washers with the embossed side facing towards the main bearing so that the bearing surface is the right way round. (Scheme 176): Placing Crankshaft In Position And Fit Two Thrust Washers At Main Bearing
3. Lubricate and fit all main bearing caps in their correct places, making sure that they are the right way round. Tightening torque: 20 Nm + 70 (15 lbf ft + 70).
4. Turn the compression rings so that the gaps in the rings are moved 180° and located directly opposite the gudgeon pin ends. Also make sure that the upper and lower spring gap on the three-piece oil scraper ring are not lined up opposite each other. (Scheme 177): Turning Compression Rings So That Gaps In Rings
5. Fit protective collars 75 19 531 on the crankshaft studs, oil the pistons and rings, then fit the pistons in their respective cylinders. The arrow markings on the piston crown should be turned towards the engine's transmission side. Use piston fitting tool 78 62 287 and carefully tap down the pistons in the bores.
6. Lubricate and fit all big-end bearing caps in their original positions, making sure that they are the right way round (number to number, groove in shell to groove in shell). Tightening torque: 20 Nm + 70 (15 lbf ft + 70).
7. Apply a bead of flange sealant, part no. 93 21 795, approximately 1 mm wide to the mating face of the end plate and fit the end plate. Be careful with the sealant. (Scheme 178): Applying A Bead Of Flange Sealant
8. Align the crankshaft with the wedge straight up (corresponding to the 0 mark on the crankshaft pulley).
9. Loosely fit the flywheel or, alternatively, the companion disc. Use thread locking adhesive, part no. 74 96 292, to the bolts. Make sure the marking is straight up towards the cylinder head.
10. Fit the disc and pressure plate.
11. Fit the flywheel locking attachment 83 94 868 and tighten the bolts. Tightening torque, flywheel or companion disc: 20 Nm +50° (15 lbf ft)+50°
12. Lubricate the bearing surfaces on the balancer shafts and in the bearing housings and insert the balancer shafts into their respective tunnels, taking the utmost care to avoid damaging the bearing shells inside. IMPORTANT: Fit the shaft with the small thrust ring marked INL on the inlet side. Fit the shaft with the large thrust ring marked EXH on the exhaust side. (Scheme 179): Lubricating Bearing Surfaces On Balancer Shafts And In Bearing Housings
13. Check the timing chain and fit the chain guard and chain onto the crankshaft end with the markings facing each other. Screw on the safety plate.
14. First fit the fixed chain guide, which is common to the timing chain and balancer shaft chain, and then the pivoted chain guides for the timing and balancer shaft chains.
15. Fit the balancer shaft sprocket and the oil pump driver onto the crankshaft end.
16. Cock the balancer shaft chain tensioner and insert a paper clip or similar object through the hole in the cylinder to prevent triggering of the tensioner. Before this, check that the plunger is turned to the position where it really is pressed out by the spring. (Scheme 180): Identifying Balancer Shaft Chain Tensioner
17. Fit the chain tensioner. Tightening torque: 10 Nm (7 lbf ft). IMPORTANT: It is extremely important for the function that the correct tightening torque is applied when fitting.
18. Inspect the balancer shaft chain and fit it and the idler sprocket so that the upper setting markings behind the balancer shaft sprocket and bearing housing are aligned with each other. Tauten the chain between the crankshaft and balancer shafts. Fit the idler sprocket last of all. Hold the bolt in place with your thumb, mesh the teeth of the sprocket with the chain and "roll" it into position along the chain. (Scheme 181): Fitting Timing Cover Using Two Bolts Only And Do Not Tighten Them
19. Check the marking on the balancer shaft sprocket and remove the flywheel locking attachment.
20. Setting: Fit the timing cover using two bolts only and do not tighten them. Mount the crankshaft pulley. Rotate the pulley one revolution. Reset the pulley relative to the timing cover. Remove the timing cover and crankshaft pulley carefully, making sure that the crankshaft does not move, and check the settings of the balancer shafts.
21. Make sure the mating face on the timing cover is completely clean. Apply a bead of flange sealant, part no. 93 21 795, approx. 1 mm wide on the timing cover. Apply the bead in the center of the sealing surfaces.
22. Fit the timing cover. Make sure the upper plane of the cover is aligned with the engine block plane. Apply a 10-20 mm long bead of Loctite 518, part no. 93 21 795, on the inside of the timing cover contact surfaces (towards the cylinder head). Tightening torque: 22 Nm (16 lbf ft). (Scheme 182): Fitting Timing Cover
23. Fit the flywheel locking attachment and crankshaft pulley. Remove the flywheel locking attachment. Tightening torque: 175 Nm (130 lbf ft).
24. Fit the oil pump pressure pipe using new O-rings and check that there are no impurities or other foreign matter in the oil sump. (Scheme 183): Fitting Oil Pump Pressure Pipe Using New O-Rings
25. Fit the adapter housing and oil filter. Fit new O-rings lubricated with engine oil.
26. Check that the strainer of the oil sump is clean. Fit using new O-rings.
27. Make sure the mating surface on the oil sump is completely clean and apply an even coat of flange sealant, part no. 93 21 795. Turn over the engine and fit the oil sump. Tightening torque: 22 Nm (16 lbf ft).
28. Thoroughly clean all gasket surfaces. Apply a 2 mm thick, 10-20 mm long bead of Loctite 518, part no. 93 21 795, on the inside of the timing cover's upper contact surface (towards the cylinder head). Turn the engine in the stand, rotate the crankshaft 45° to lower the pistons. Fit a rubber band round the chain guides and mount the cylinder head with a new gasket. Check that it is correctly seated on the guide sleeves and that the chain is not trapped. Tighten the cylinder head bolts in three stages: Stage I: 40 Nm (30 lbf ft) Stage II: 60 Nm (44 lbf ft) Stage III: A further 90° Tighten the bolts in the order shown in the illustration. (Scheme 184): Fitting Rubber Band Round Chain Guides And Mount Cylinder Head With A New Gasket
29. Fit the two bolts between the timing cover and cylinder head. Tightening torque: 22 Nm (16 lbf ft). (Scheme 185): Removing Rubber Band And Checking Camshafts Are In Alignment With Their Setting Marks
30. Remove the rubber band and check that the camshafts are in alignment with their setting marks and turn the crankshaft back to the 0 mark.
31. Fit the camshaft sprockets and chain. Start with the outlet camshaft. The marking on the wheels should be aligned with the chain markings. (Only applies to entirely zeroed engine.) Do not tighten the bolts yet!
32. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner. (Scheme 186): Fitting Chain Tensioner
33. Fit the chain tensioner, using a 27 mm socket. Tightening torque: 63 Nm (47 lbf ft).
34. Fit the chain tensioner plug with push rod and spring. Tightening torque: 22 Nm (16 lbf ft).
35. Check that the chain is correctly seated in the guides. Rotate the crankshaft two complete turns and check the settings of the crankshaft pulley and camshafts.
36. Tighten the camshaft sprocket bolts. Tightening torque: 63 Nm (47 lbf ft).
37. Check the condition and play of the spark plugs. Replace them if necessary. Fit the spark plugs. Tightening torque: 28 Nm (21 lbf ft). (Scheme 187): Cleaning The Sealing Surface Of The Camshaft Cover
38. Clean the sealing surface of the camshaft cover with benzine.
39. Apply a thin layer of gasket adhesive, part no. 46 20 084, in the outer and inner gasket seats on the camshaft cover. Fit the gaskets.
40. Apply oil to the opening on the camshaft cover and fit the cover, starting at the opening. Then, tighten the bolt located furthest to the front at the timing chain end. Continue all the way round the outside and inside. (Scheme 187) Tightening torque: 15 Nm (11 lbf ft).
41. Fit the banjo pipe to the charge air pipe.
42. Lubricate the ignition discharge module contact surfaces with Krytox, part no. 30 19 312. Fit the ignition discharge module. Tightening torque: 11 Nm (8 lbf ft).
43. Check the coolant pump O-rings. Replace as necessary. Clean the hole in the block and fit the connector with the large vane pointing horizontally towards the flywheel side. Lubricate the O-rings with acid-free Vaseline and fit the coolant pump and pipe. (Scheme 188): Checking Coolant Pump O-Rings
44. Fit the thermostat and thermostat housing.
45. Fit the input and output pipes of the water pump. Be aware of the bolt lengths.
46. Fit the crankshaft position sensor with protective cover.
47. Clean the gasket surfaces and fit a new exhaust manifold gasket. (Scheme 189): Fitting Crankshaft Position Sensor With Protective Cover
48. Fit the turbocharger with exhaust manifold and stay. Tightening torque: 25 Nm (19 lbf ft).
49. Connect the coolant and oil pipes. IMPORTANT: The rubber gaskets must be placed closest to the adapter housing and water pump respectively in the cylinder head.
50. Fit the servo pump bracket.
51. Fit the A/C compressor bracket.
52. Fit the APC valve.
53. Clean all gasket surfaces between the intake manifold and cylinder head. see scheme 286: Fitting Fuel Distribution Pip With Clips
54. Align the intake manifold gaskets with the aid of the outer retaining bolts and fit the intake manifold. Tightening torque: 22 Nm (16 lbf ft). IMPORTANT: Cars with intermediate piece have a gasket on both sides of the intermediate. (Not applicable to LEV cars.)
55. (B235R) Fit the rear lifting eye. Fit the fuel distribution pip with clips.
56. Reconnect the hoses from the throttle body.
57. Fit the oil filler pipe with mounting. Fit a new O-ring. see scheme 287: Fitting Connector Housing Bracket At Intake Manifold
58. Fit the connector housing bracket at the intake manifold.
59. Man: Fit the gearbox with flywheel cover plate.
60. Aut: Fit the gearbox without cover plate
61. Connect a lifting sling and lift the engine from the stand to the subframe.
62. Remove the holder.
63. Fit the rear engine mounting bracket and the gearbox retaining bolts. Remove the plug. see scheme 288: Removing Plug And Replace Packing Box In Gearbox
64. Replace the packing box in the gearbox and fit the left-hand drive shaft. Use 83 95 162 Protective collar, drive shafts.
65. Position the engine on the subframe and fit the rear engine mounting, tightening it with a torque wrench. Tightening torque: 50 Nm (37 lbf ft).
66. Remove the plug and replace the packing box in the gearbox. Fit the bearing bracket with intermediate shaft and inner driver shaft. Use fitting tool 83 95 162. Check the fluid level in the gearbox and top up as necessary.
67. Fit the oil trap and connect its hoses.
68. Fit the generator bracket.
69. Fit the intake manifold stay.
70. Fit the rail with wiring harness.
71. Fit and connect the generator.
72. Fit the starter motor and belt tensioner.
73. Check that the oil plug is tight. Loosely fit the belt on the auxiliary unit. The power train is now ready for fitting in the car. Tightening torque 25 Nm (19 lbf ft).