Engine - Repair (2.0L & 2.3L): Other Saab 9-3 I

FUEL PRESSURE RELEASE

To release fuel pressure, disconnect fuel lines at fuel pressure regulator and fuel injection manifold.

Note. Remove engine and transaxle as a unit. On 9-3, transaxle housing is attached to engine lower crankcase pan.

9-5

Note. Steps with corresponding illustrations will have a number in parentheses included. This number refers to the step in the illustration only, and may not be the same as the step number in text.

Cylinder Head

Measure cylinder head height after resurfacing. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Cylinder head warpage information is not available from manufacturer.

Valve Springs

1. Remove camshafts. Remove valve lifters with magnet. Install Lifter Bore Sleeves (83 93 746) to protect lifter bores. Position Valve Retainer Remover (83 94 181) squarely on valve head and tap firmly with hammer. Remove keepers with magnet. Remove springs and caps.
2. To assemble, install valve spring and cap over valve stem. Position retainers into groove in spring cap. Using Valve Retainer Remover (83 94 181) and Valve Retainer Installer Sleeve (83 94 207), carefully tap retainers into groove of valve stem. To complete assembly, reverse disassembly procedure.

Valve Stem Oil Seals

Remove seals using Pliers (83 94 157). Ensure protective sleeves for lifter guides are in place. Install seals using Installer (83 93 803). Remove shank from installer. Insert seal into installer. Insert Installer into guide. Tap seal into position with plastic mallet.

Valve Guides

To replace guide, flush hot water through head and pull valve guide from top of head using Guide Puller (83 93 811), Spacer (83 93 829), and Nut (83 93 845). To install, flush hot water through head and press in new valve guide from bottom side.

Valve Seat

Grind intake and exhaust valve seats to an angle of 45 degrees.

Fitting Pistons

1. To fit pistons to cylinder bores, use a feeler gauge 1/2" (12.7 mm) wide and a spring scale. Oil cylinder lightly. Insert piston without rings. Attach spring scale to feeler gauge.
2. Check piston clearance by inserting feeler gauge between piston and cylinder wall at right angle to piston pin. See «PISTONS, PINS & RINGS»(ref-8773-S41491830122000092200000) table under ENGINE SPECIFICATIONS. Repeat test at various bore depths. Standard and oversize pistons are available. See «PISTON DIAMETER SPECIFICATIONS»(ref-8773-S26094891272000092200000) table.

PISTON DIAMETER SPECIFICATIONS

Piston Rings

1. Check piston rings end gap and side clearance. Use an inverted piston to push ring down into bore. On worn bores, measure at lower end of bore. See «PISTONS, PINS & RINGS»(ref-8773-S41491830122000092200000) table under ENGINE SPECIFICATIONS.
2. Lubricate pistons and rings. Install rings onto pistons. Stagger ring gaps. Compression ring gaps must be located 180 degrees from each other. Oil ring gaps must be equally spaced from each other.

Rod Bearings

Using a micrometer, measure rod bearing journal diameter, taper, and out-of-round. Measure bearing clearance with Plastigage.

Crankshaft & Main Bearings

Turn engine upside-down to prevent weight of crankshaft from affecting measurements. Measure bearing clearance with Plastigage positioned to one side of journal centerline.

Thrust Bearing

Center main bearing is thrust bearing. If crankshaft end play exceeds specification, install new thrust washer. Thrust washer oil grooves should face toward crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS.

Cylinder Block

Check each cylinder for wear, cracks, or damage. Ensure oil passages are clean. Ensure freeze plugs are in good condition.

Oil Pressure

Oil pressure is 43 psi (3.0 kg/cm 2 ) at 2000 RPM.