Basic Engine: Other Saab 9-5 I рестайлинг 2

Removing the power train

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1. Lay out wing covers, remove the covers over the battery and intake manifold and remove the battery and battery tray. Open the expansion tank cap.
2. (auto) Withdraw the breather hose that sticks up under the main fuse box.
3. Disconnect the ground cable between the gearbox and LH wheel housing. (auto) Disconnect the cables to the gearbox. (man) Unplug the reversing light connection from the gearbox. Raise the car and remove the lower engine cover.
4. Open the drain plug for the coolant. WARNING: To prevent breakage of the airbag contact roller through twisting, the steering wheel should be fixed in place. Do this by taping it to the dashboard, for instance.
5. Turn the front wheels to the straight ahead position and secure the steering wheel in this position. Undo the steering column locking bolt and move the steering column upwards.
6. Disconnect the throttle cable and move it aside.
7. Disconnect the EVAP canister purge valve's vacuum hose from the intake manifold.
8. Disconnect the brake servo vacuum hose by pressing the red sleeve downwards and pulling the hose upwards.
9. Separate the fuel connections with «ADAPTER, FUEL PRESSURE 83 94 744»(ref-274819-S01452694852007122400000) and plug them. NOTE: If necessary, cut a groove in the rubber seal. Exercise care when doing this so that it can be re-used afterwards.
10. Disconnect the positive cable at the distribution terminal and the negative cable at the gearbox.
11. (man.) Disconnect the clutch slave cylinder's hose and plug the hose.
12. (man) Engage 4th gear, remove the selector rod and engage 3rd gear.
13. (auto) Disconnect the selector lever cable and bend it aside against the bulkhead.
14. Disconnect the upper radiator hose and remove the bypass valve's vacuum hose.
15. Remove the hose between the pipe to the throttle body and charge air cooler and undo the electrical connector to the pressure/temperature gauge.
16. Remove the bypass valve with intake manifold and plug same.
17. Unplug the connector for the radiator fan or fans. Remove the fan cowling retaining bolts, disconnect the upper radiator hose at the top and the pipe connected to the oil cooler (aut.). Carefully lift out the fan cowl.
18. Remove the grille.
19. Disconnect the hose between the turbocharger and charge air cooler and plug same.
20. Remove the mass air flow sensor with rubber gaiter and unplug its connector.
21. Disconnect the lower radiator hose from the coolant pump, the hose by the expansion tank, and the hoses for the heat exchanger. For cars with ACC: Disconnect the vacuum hose from the bypass valve on the hose to the heat exchanger. Remove the radiator.
22. Remove the bracket with the connector for the engine wiring harness and the wiring harness mountings from the bulkhead. Unhook it and lay it on the engine.
23. Remove the wiper arms and cover over the wiper assembly. Use «PULLER 85 80 144»(ref-274819-S32284539062007122400000) NOTE: The plastic hooks go under the windscreen. The cover panel must first be pulled forwards.
24. Undo the nuts securing the control module connector. Unplug the connector and place it on the engine.
25. Remove the hub nuts on both sides and raise the car.
26. Remove the front wheels.
27. Drive in «WEDGES 83 95 238»(ref-274819-S35534301612007122400000) between the gearbox and subframe and between the oil sump and subframe.
28. Raise the car. Remove the A/C compressor's retaining bolts.
29. Remove the retaining nuts and air hose from the air filter housing.
30. Lower the car to the floor.
31. Suspend the condenser cooler, charge air cooler and A/C compressor to the radiator member with «STRAPS 83 95 212»(ref-274819-S11048383982007122400000) . The engine oil cooler is dismantled with the engine and fastened to the subframe with, for instance, cable ties.
32. Unplug the A/C compressor connector and undo the quick-release coupling on the vacuum hose connected to the wastegate.
33. Remove the right-hand engine mounting complete with yoke.
34. Relieve the pressure on the belt tensioner using a ratchet handle and lift off the multigroove belt.
35. Remove the left-hand engine mounting's retaining nuts.
36. Remove the power steering fluid reservoir with hoses and place it on the engine.
37. Pinch off the hose between the steering servo and reservoir.
38. Remove the sheet metal mounting on the pipe to the steering servo. Slightly loosen the steering servo hose so that it becomes moveable.
39. (auto) Unplug the quick-release couplings to gearbox oil cooler and plug. Use «83 95 261 TOOLS, FUEL LINE»(ref-274819-S20901671082007122400000) . Mark the hoses to tell them apart.
40. Raise the car higher.
41. Remove the three steering swivel joint retaining nuts on both sides.
42. Undo the nuts securing the anti-roll bar supports to the suspension strut.
43. Undo the two outer track-rod ends. Use «87 91 287 PULLER, 150MM»(ref-274820-S09563393592007122400000)
44. Carefully tap the drive shafts out of the hubs.
45. Remove the oil cooler and suspend it from the front of the engine frame.
46. Separate the exhaust pipe behind the catalytic converter and remove the temperature sensor.
47. Run Lifting trolley 83 94 739 with «ASSEMBLY FIXTURE 83 95 196»(ref-274819-S36906271642007122400000) under the car. Align the fixture with «ADJUSTING FEET 83 95 170»(ref-274819-S01128449662007122400000) under the subframe with the locating studs at front left and rear right.
48. Remove the 10 subframe and supporting plate retaining bolts. From chassis number W3050999, the inner sleeve in the subframe bushings has been made 38 mm long instead of previously 35 mm. If the bushing is 35 mm, a 3 mm spacer must be fitted between the bushing and washer. WARNING: The spacer washer must not be fitted together with a bushing with 38 mm inner sleeve.
49. Lower the lifting trolley approx. 25 cm and thus also the subframe and power train. Make sure that the swivel joints release and lift out the drive shafts. Unhook the hose for the engine oil cooler from its bracket on the subframe.
50. Pull the trolley as far back as possible to provide room for the A/C compressor and lower carefully.
51. Then lower the power train complete with subframe, steering gear and front exhaust pipe.

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1. Run the lifting trolley with power train under the raised car.
2. Lower the car with care and raise the lifting table.
3. Raise the engine with the lifting trolley, fitting the locating studs in their positions at front left and rear right. Make sure that the steering gear fits in place in the bulkhead.
4. Fit the drive shafts and screw on the three nuts securing the steering swivel joints. Tightening torque 60 Nm + 30° (44 lbf ft + 30°)
5. Fit the subframe retaining bolts and tighten them, using a torque wrench, and remove the lifting table. Tightening torque, Subframe 100 Nm + 45° (74 lbf ft + 45°) Tightening torque, Support plate 63 Nm (46 lbf ft). From chassis number W3050999, the inner sleeve in the subframe bushings has been made 38 mm long instead of previously 35 mm. If the bushing is 35 mm, a 3 mm spacer must be fitted between the bushing and washer. WARNING: The spacer washer must not be fitted together with a bushing with 38 mm inner sleeve.
6. Fit the exhaust pipe, temperature sensor and air cleaner in the subframe.
7. Fit the outer track-rod ends and anti-roll bar support in the suspension strut. Tightening torque: 84 Nm (62 lbf ft) Tightening torque, nut with steel lock: 95 Nm (66 lbf ft)
8. Fit the hub nuts but do not tighten them.
9. Fit the A/C-compressor and air filter housing retaining nuts and hose.
10. Lower the car to the floor. Fit the strap and tighten it.
11. Set the steering gear in the straight-ahead position and mount the steering column in the cabin. Tightening torque: 25 Nm (19 lbf ft)
12. Fit the left-hand engine mounting but without tightening it. Fit the right-hand engine mounting with yoke but do not tighten.
13. Raise the car slightly, remove the wedges and lower the car to the floor.
14. Tighten the engine mountings, using a torque wrench. Tightening torque 50 Nm (36 lbf ft)
15. Fit the selector lever cable. (aut)
16. Lock 4th gear with «LOCKING PIN, GEAR POSITION ADJUSTMENT 87 92 335»(ref-274821-S17274404782007122400000) (ring up) in the gearbox and (ring down) in the gear shift housing. Fit the selector rod. Remove the locking pins and fit a new plastic plug in the gearbox. Try changing gear. (man)
17. Move the bleeder hose up under the main fuse box. (aut)
18. Connect the hoses to the heat exchanger.
19. Connect the coolant hose to the expansion tank.
20. Secure the engine wiring harness with bracket to the bulkhead.
21. Fit the engine control module, the cover panel over the wiper mechanism and the wiper arms.
22. Connect the ground cable to the gearbox. WARNING: The ground cable connection is extremely important. Do not forget it. A fire could start if the ground cable is not connected!
23. Connect the positive cable to the positive terminal.
24. (aut.) Plug the connector with electrical leads into the gearbox. Fit the bracket in place.
25. (man.) Plug in the reversing lights connector.
26. Connect the quick-release couplings to the automatic transmission fluid cooler.
27. Couple together the two fuel connections and the rubber protectors.
28. Connect the vacuum hose from the brake servo to the intake manifold.
29. Connect the vacuum hose from the EVAP canister purge valve to the intake manifold.
30. Refit the throttle cable.
31. Raise the car slightly. IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.
32. Fit the hose between the turbocharger and charge air cooler.
33. Mount the engine oil cooler on the other coolers.
34. Fit the cover under the cooler.
35. Lower the car to the floor.
36. Remove the fastening straps supporting the coolers.
37. Check that the A/C compressor pipe is correctly positioned.
38. Fit the radiator fans and plug in the electrical connectors.
39. Refit the front grille.
40. Reconnect the upper and lower radiator hoses.
41. Refit the power steering fluid reservoir.
42. Reconnect the pipes to the power steering pump.
43. Reconnect the quick-release coupling on the vacuum hose connected to the turbo wastegate.
44. Plug in the A/C compressor's connector.
45. Refit the mass air flow sensor's rubber gaiter and plug in the connector.
46. Fit the bypass valve and intake manifold.
47. Fit the hose between the pressure pipe and charge air cooler and plug in the connector for the pressure/temperature sensor.
48. «FIT THE WHEELS»(ref-274828-S14401379102007122400000) .
49. Lower the car to the floor and retighten the hub nuts, using a torque wrench. Tightening torque: 230 Nm (170 lbf ft)
50. Fit the battery tray, the battery, the cover over the intake manifold and the battery cover. Remove the wing covers. Fit the vacuum hose to the heat exchanger shut-off valve (cars with AC).
51. Fill the radiator with coolant and check the system for leaks.
52. (auto) Add transmission fluid via the transmission dipstick tube.
53. Top up the engine oil, check other oil and fluid levels and top up as necessary. Make sure that the engine, engine bay and cabin are clean.
54. Secure all hoses and cables that have been disconnected. IMPORTANT: It is important to secure all hoses and cables correctly to minimize the risk of rattling noises and chafing. WARNING: The coolant is very hot and under high pressure. Risk of burn injuries when the pressure cap is opened. Be extremely careful.
55. Bleed the cooling system as follows: If the car is equipped with A/C or ACC, it must be turned off since these will start the radiator fan. Fill the system to the MAX level, close the pressure cap, start the engine and warm it, preferably at varying engine speeds, until the radiator fan starts. Then fill the system to MAX once more.
56. Test drive the car and check all functions. Check that the steering wheel stands straight when driving on a straight road. Adjust as necessary. Also check the oil level in the engine and gearbox.
57. Set the clock to the correct time. See owner's manual.

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1. Allow the engine to idle. Remove fuse 19. Turn off the ignition when the engine has stopped. Refit the fuse. Lay out wing covers, remove the battery cover and the intake manifold cover, drain the coolant and disconnect the negative battery lead. Raise the car and remove the lower engine cover.
2. Lower the car slightly and remove the front right wheel and disconnect the steering servo pipe from the subframe.
3. Drive in a «83 95 238 WEDGE»(ref-274819-S35534301612007122400000) between the oil sump and subframe on the right-hand side.
4. Remove the right-hand engine mounting with yoke and the bracket for the servo pump pipe.
5. Remove the mass air flow sensor with rubber gaiter. Unplug the connectors for the mass air flow sensor and turbo wastegate.
6. Remove the crankcase breather pipe.
7. Remove the front lifting eye from the engine and pull it out of the rubber.
8. Remove the charge air pipe, bypass valve and pressure/temperature sensor connector. Disconnect the bypass valve vacuum hose. Plug the throttle body and the hose by the charge air cooler.
9. Release the tension of the belt tensioner using «83 95 254 DRAWBAR HANDLE, HYDRAULIC BELT TENSIONER»(ref-274819-S29901584512007122400000) and insert a 3.5 mm allen key into the hole. Remove the poly-V-belt. IMPORTANT: Be careful so that the belt tensioner does not break at its end position!
10. Remove the belt tensioner, detach and move aside the generator. Remove the generator bracket.
11. Unplug the temperature sensor and ignition discharge module connectors.
12. Remove the coolant hoses from the cylinder head.
13. Remove the cover from the throttle body lever. Detach the accelerator cable, remove the dipstick with pipe and detach the fuel hoses using «83 95 261 TOOL, FUEL HOSE»(ref-274819-S20901671082007122400000) .
14. Remove the crankcase breather nipple from the timing cover.
15. Raise the car and remove the intake manifold steady bar.
16. Remove the turbocharger steady bar.
17. Lower the car to the floor.
18. Remove the heat shield from the turbocharger and exhaust manifold.
19. Remove the four retaining nuts between the exhaust manifold and the turbocharger. Heat the nuts carefully if they are stuck.
20. Remove the servo pump and suspend it from the radiator crossmember.
21. Remove the lower screw from the steering servo pump bracket.
22. Remove the bracket for the ignition discharge module connectors from the rear lifting eye and the bracket for the heat exchanger pipe.
23. Remove the intake manifold with partition. Move the manifold rearwards towards the bulkhead. The centre retaining bolts may be more easily accessible from underneath. Leave the intake manifold in the car.
24. Remove the ignition discharge module and spark plugs.
25. Remove the camshaft cover, line up the crankshaft pulley mark with the timing cover and check that the camshafts are in line with their timing marks.
26. Undo the camshaft sprocket bolts. Hold the end of the camshaft with an open-ended spanner to prevent it from turning.
27. Undo the bolt on the idler sprocket and remove the chain tensioner. Use a 27 mm socket after removing the plug with spring and pushrod.
28. Remove the camshaft sprockets and fit a rubber band between the chain guides.
29. Remove the cylinder head. Start with the bolts in the timing cover. Proceed in reverse order to fitting. Use a pair of pliers or a magnet to retrieve the bolts.
30. Wipe up any oil that has run out. Make sure that the timing chain does not obstruct its removal and then lift off the cylinder head.

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1. Fasten the inner gasket for the camshaft cover partition with 89 83 341 Ultra fast adhesive.
2. Position the gasket between the intake manifold and intermediate partition by means of two straps.
3. Carefully clean all sealing surfaces. Apply a 2 mm thick and 10-20 mm long bead of 93 21 795 Flange sealant to the inner part of the upper contact surface of the timing cover (against the cylinder head). Turn the engine in the stand, turning 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 locating sockets and that the chain is not trapped.
4. Fit the cylinder head Torx bolts and tighten to torque Tightening torque in three stages Step I: 40 Nm (30 lbf ft) Step II: 60 Nm (44 lbf ft) Step III: Tighten a further 90° Tightening sequence for the cylinder head bolts as shown.
5. Fit the two bolts between the timing cover and cylinder head. Tightening torque 22 Nm (16 lbf ft)
6. Check that the camshafts are in line with their timing marks and reset the crankshaft in line with the 0 mark.
7. Fit the camshaft sprockets and chain. Start with the camshaft on the exhaust side. Do not tighten the bolts yet!
8. Prepare the chain tensioner for fitting by pressing down the catch and pushing in the chain tensioner.
9. Fit the chain tensioner, using a 27 mm socket. Tightening torque 63 Nm (47 lbf ft)
10. Fit the chain tensioner plug with push rod and spring. Tightening torque 22 Nm (16 lbf ft)
11. Tighten the bolt on the idler pulley. Tighten the camshaft sprocket bolts. Hold the end of the camshaft with a spanner. Tightening torque 63 Nm (47 lbf ft)
12. 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.
13. Clean the sealing surface of the camshaft cover with benzene.
14. Coat the opening in the camshaft cover thinly with oil and fit the cover, starting at the opening. Make sure that the cables at the edge of the cover against the intake manifold do not get trapped. Then tighten the bolt located furthest to the front at the timing chain end. After that, continue all the way round on both the inside and outside. Tightening torque 15 Nm (11 lbf ft)
15. Fit the spark plugs. Tightening torque: 28 Nm (21 lbf ft) Fit the ignition discharge module. Tightening torque: 11 Nm (8 lbf ft)
16. Fit the intake manifold with intermediate partition but do not tighten until the straps are cut off and pulled away.
17. Tighten the intake manifold, using a torque wrench. Tightening torque 22 Nm (16 lbf ft)
18. Fit the generator bracket. Make sure that the adjuster sleeves in the generator bracket are tapped out approx. 1 mm to facilitate fitting. Fit the belt tensioner.
19. Tighten the bracket for the ignition discharge module connector in the rear lifting eye and the coolant pipe fitting.
20. Fit the bolt securing the coolant pipe to the thermostat housing cover.
21. Connect the coolant hoses to the cylinder head.
22. Plug in the ignition discharge module and temperature sensor connectors.
23. Fit the turbocharger retaining nuts between the exhaust manifold and the turbocharger and tighten to torque. Tightening torque: 25 Nm (19 lbf ft)
24. Fit the heat shield over the turbocharger.
25. Insert the dipstick tube.
26. Raise the car.
27. Tighten the turbocharger steady bar retaining bolts.
28. Tighten the intake manifold steady bar retaining bolts. Fit the dipstick tube correctly in position.
29. Lower the car to the floor.
30. Fit the fuel hoses and refit the rubber protectors.
31. Fit the crankcase ventilation nipple on the valve cover.
32. Tighten the dipstick tube, attach the throttle cable and adjust as necessary. Fit the ground connections to the cylinder head. Fit the cover over the throttle body spindle.
33. Fit the servo pump. Fit the multigroove belt and check the position of all pulleys. Tightening torque 20 Nm (15 lbf ft)
34. Release the tension of the belt tensioner using «83 95 254 DRAWBAR HANDLE, HYDRAULIC BELT TENSIONER»(ref-274819-S29901584512007122400000) and remove the allen key.
35. Fit the lifting eye, press the rubber in position and plug in the solenoid valve connector.
36. Fit the charge air pipe and bypass valve. Connect the bypass valve vacuum hose and the pressure/temperature sensor connector.
37. Fit and connect the mass air flow sensor's rubber gaiter.
38. Fit the engine mounting with yoke and the servo pump pipe bracket and tighten them, using a torque wrench. Tightening torque bolts 47 Nm (39 lbf ft) Tightening torque nut 105 Nm (78 lbf ft)
39. Remove the wedge and secure the servo pump pipe to the subframe.
40. «FIT THE RIGHT-HAND FRONT WHEEL»(ref-274828-S14401379102007122400000) .
41. Fit the crankcase breather pipe. Tightening torque banjo connection: 24 Nm (18 lbf ft) Tightening torque, mounting against camshaft cover 11 Nm (8 lbf ft)
42. Connect the negative battery cable. Check that the radiator's drain plug is properly tightened. Top up with coolant and check the system for leaks.
43. Check the coolant and oil levels. Top up if necessary.
44. Remove the protective covers from the wings and check that the engine bay is clean.
45. Lower the car to the floor.
46. Bleed the cooling system as follows.
47. Fill with coolant. Do not forget to shut the drain cock on the radiator first. Refer to «COOLANT»(ref-274824-S28480320972007122400000) for mixtures. Close the cap.
48. Start the engine and run it warm with the heater control on max.
49. Check the coolant level. Top up if necessary.
50. Check all functions. Test drive the car.
51. Reset the clock and radio code. See owner's manual.

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This method presupposes that the cylinder head has been removed.

Check and adjust the valve clearance relative to the working range of the tappet.

The tolerances for valve clearance are 19.5±0.05 mm minimum and 20.5±0.05 mm maximum.

The valve clearance settings are 20.0 mm minimum and 20.4 mm maximum, with a nominal clearance of 20.2 mm.

Valve clearance is equivalent to the distance between the end of the valve stem and the camshaft bearing seat.

Before valve clearances can be checked, the camshafts and valve tappets must first be removed.

The valve clearance is checked with VALVE CLEARANCE GAUGE 83 93 753 as follows

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1. Place valve clearance gauge across two of the camshaft bearing seats with the depth gauge against the end of the valve stem.
2. Check that the maximum gauge depth of 20.5 mm actually reaches down to the end of the valve stem (noticed by the valve clearance gauge not bottoming against the bearing seat closest to the depth gauge).
3. Then check that the min depth 19.5 mm does not reach the end of the valve stem spindle. Correct valve position should be between the depth measurement min and max values. If the valve position deviates from the given measurements, adjustments are done on the valve spindle or valve seat. The valve spindle is shortened if measurement is below the min value and the valve seat is machined if the max value is exceeded. When adjusting the valve position, set this at nominal value 20.2 mm.

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The method for dismantled power train mounted in fixture has been discontinued.

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1. Remove the dipstick.
2. Remove power steering pump and bracket with lifting eye.
3. Remove water pump and sleeve with O-rings.
4. Remove guard plate and oil sump. Leave the guide sleeve in place in the cylinder block. Wipe clean from dripping oil.
5. Use «FLYWHEEL LOCKING ATTACHMENT 83 94 868»(ref-274819-S08616750162007122400000) . Remove the crankshaft pulley.
6. Disconnect the crankcase breather hose from the oil sump.
7. Remove guide pins from timing cover by cutting an internal thread with a 3/8" UNC screw tap and pull them out with «SLIDING HAMMER 83 90 270»(ref-274819-S02698422542007122400000) .
8. Remove all bolts from timing cover.
9. Pull the cover loose at the bottom first.
10. Then lift the cover out/down so that the gasket is not damaged on the cylinder head.

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1. Thoroughly clean away all the sealant residue on all surfaces. Wash with benzine.
2. Apply Loctite 518 in a 1 mm thick bead onto sealing surfaces.
3. Fit the timing cover by carefully twisting it in place. Tighten retaining bolts loosely and knock in guide pins.
4. Torque tighten the timing cover. Tightening torque 22 Nm (16 lbf ft).
5. Check the water pump O-rings and renew as necessary. Clean the hole in the block and tighten the sleeve, using a torque wrench, with its large wing pointing horizontally towards the flywheel end. Lubricate O-rings with acid-free Vaseline and fit the water pump.
6. Fit the crankshaft pulley. Use «FLYWHEEL LOCKING ATTACHMENT 83 94 868»(ref-274819-S08616750162007122400000) . Tightening torque 175 Nm (130 lbf ft).
7. Check that there are no impurities or other foreign matter in the sump and clean the sealing surfaces.
8. Apply an even bead of Loctite 518 on the oil sump's sealing surface and fit the oil sump in place. Tightening torque 22 Nm (16 lbf ft).
9. Fit the guard plate, plug in the oil level sensor and press the cable back into its clamps.
10. Check that the oil plug is tight and connect cables to oil pressure sensor, generator and starter motor. Tightening torque 25 Nm (19 lbf ft).

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1. Remove the upper engine cover.
2. Remove the dipstick and place a rag in the tube. Remove the oxygen sensor cables.
3. Remove the turbo bypass pipe and the heat shield over the exhaust manifold.
4. Undo the two upper nuts on the exhaust pipe.
5. Raise the car and remove the lower engine cover.
6. Remove the remaining mountings and remove the front exhaust pipe.
7. Remove the cover plate from the gearbox.
8. Drain the engine oil.
9. Disconnect the crankcase ventilation hose from the oil sump.
10. Remove the bolts on the oil sump and lower the sump.

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1. If the sump is changed, transfer the splash guard and pipe to the new sump. Use new O-rings.
2. Ensure the oil sump contains no dirt or contaminants. Clean the sealing surfaces on the engine and sump with a gasket scraper and benzene.
3. Apply an even, 2 mm thick bead of flange sealant, part no. 93 21 795, to the sealing surfaces of the oil sump.
4. Check that the pipe to the oil adapter is securely in place and that it positioned correctly in the oil sump. Change the O-rings if necessary.
5. Lift up and position the oil sump. Thread all the bolts.
6. Tighten the oil sump bolts. Tightening torque 22 Nm (16 lbf ft)
7. Fit the crankcase ventilation hose.
8. Fit the gearbox cover plate.
9. Clean the joints, grease the studs of the turbocharger with Molycote 1000, part no. 30 20 971, and fit the exhaust pipe.
10. Check that the oil plug has been tightened and lower the car.
11. Tighten the upper bolts on the exhaust pipe.
12. Plug in the oxygen sensor cables.
13. Fit the heat shield over the exhaust manifold and turbo bypass pipe. Tightening torque, nut, heat shield 20 Nm (14 lbf ft)
14. Fill with engine oil and put back the dipstick.
15. Fit the upper engine cover.
16. Run the engine until warm, raise the car and check the integrity around the sealing surfaces.
17. Fit the lower engine cover.
18. Lower the car, check the oil level and top up as necessary.

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1. Raise the car, remove the cover and detach the oil filter.
2. Detach the oil hoses from the adapter housing and disconnect the turbocharger's oil pipe.
3. Remove the adapter housing.

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1. Clean and inspect the sealing surfaces.
2. Change the O-ring.
3. Lubricate the seal and fit the adapter housing to the engine block, using Loctite 518.
4. Connect the oil hoses and the turbocharger pipe.
5. Check that the oil plug is properly tightened, fit the oil filter and cover and lower the car.
6. Fill up with motor oil, warm up the engine and check for leaks.

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1. Cover the wings and remove the top engine cover.
2. Fit «83 94 850 LIFTING BEAM»(ref-274819-S33109733222007122400000) and take up the weight of the engine via the lifting eye.
3. Detach the power steering hose from the clip under the engine mounting.
4. Remove the engine mounting.
5. Remove the engine pad.

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1. Fit the engine pad. Tightening torque: 47 Nm (35 lbf ft).
2. Secure the power steering hose with the clip
3. Tighten the bolts and nuts on the engine mounting to torque Tightening torque 47 Nm (36 lbf ft).
4. Lower the engine and remove the lifting beam
5. Move the engine back and forth sideways until it is balanced and not under strain.
6. Tighten the engine mounting nuts. Tightening torque 105 Nm (78 lbf ft)

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1. Raise the car.
2. Remove the screws to the torque arm.
3. Loosen the screws on the gearbox bracket so the torque arm's rear screw can be removed.
4. Remove the torque arm.

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1. Fit the torque arm with through bolts.
2. Tighten the gearbox bracket screws. Tightening torque up to and including Vehicle Identification Number 73514478: 47 Nm (35 lbf ft) Tightening torque from and including Vehicle Identification Number 73514479: 38 Nm (28 lbf ft)
3. Tighten the through bolt to the subframe. Tightening torque: 90 Nm + 90° (66 lbf ft + 90°)
4. Tighten the bolt holding the torque arm to the bracket. Tightening torque: 70 Nm + 90° (52 lbf ft + 90°)

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Scheme 218

1. Cover the wings and remove the cover over the battery. Note the radio code where applicable. Remove the top engine cover.
2. Detach the battery and battery tray. Loosen the fuse box and move it to the side.
3. Relieve the weight on the engine with «83 94 850 LIFTING BEAM»(ref-274819-S33109733222007122400000) .
4. Undo the centre nut and bolts on the engine pad.
5. Remove the engine mounting (and the steady bar's screw, manual only).
6. Detach the clutch hydraulic hose from its fastening.
7. Remove the engine mounting.

Scheme 219

Scheme 220

Scheme 221

1. Fit the engine mounting (and brace screw, manual only). Tightening torque, man. 47 Nm (35 lbf ft) Tightening torque, aut. 84 Nm (62 lbf ft) Tightening torque, engine mounting brace 63 Nm (46 lbf ft)
2. Fit the clutch hydraulic hose to its fastening.
3. Fit the engine pad locating bolt and make sure the centre bolt is in the centre of the engine pad without being pulled to one side.
4. Tighten the remaining bolts and the centre nut Tightening torque bolts 40 Nm +45° (35 lbf ft +45°) Tightening torque, nut, up to and including Vehicle Identification Number 73514478: 84 Nm (62 lbf ft) Tightening torque, nut, from and including Vehicle Identification Number 73514479: 74 Nm (55 lbf ft)
5. Take the weight off the engine and remove the lifting beam.
6. Replace the fuse box, battery and battery tray. Set the correct time on the clock. See owner's manual.

Scheme 222

Scheme 223

Scheme 224

Scheme 225

Scheme 226

Scheme 227

1. Cover the wings and remove the top engine cover and the battery cover. Note the radio code, where applicable.
2. Disconnect the negative battery cable.
3. (man) Remove the stay for the gear-changing linkage from the rear engine mounting's bracket.
4. Remove the engine mounting's upper retaining nut and the bolts securing it to the subframe.
5. Remove the bypass pipe and valve. NOTE: There is an O-ring at the bypass pipe's attachment to the turbo intake pipe.
6. Remove the exhaust manifold's heat shield.
7. Unplug the oxygen sensor connectors. Cut the cable tie and pull out the cables.
8. Fit «83 94 850 LIFTING BEAM»(ref-274819-S33109733222007122400000) .
9. Loosen the two upper nuts at the connection between the turbo/front exhaust system.
10. Raise the car.
11. Loosen the third nut at the connection between the turbo/front exhaust system.
12. Undo the upper bolt on the stay securing the catalytic converter to the engine.
13. Separate the pipe joint between the front and rear exhaust systems.
14. Remove the clips and carefully pull off the rubber mountings.
15. Lower the front exhaust system. NOTE: The flexible section on the front of the exhaust system must not be bent more than 5° from its neutral line, i.e. if the front exhaust system is left suspended, it must not be bent to a greater degree than is caused by its own weight. Excessive strain on the pipe will cause permanent deformation of the components. This can result in noise and leaks, and eventually to breakage.
16. Remove the engine mounting from the gearbox.
17. Remove the engine pad.

Scheme 228

Scheme 229

Scheme 230

Scheme 231

Scheme 232

1. Position the engine pad and insert the retaining bolts for the engine mounting.
2. Fit the engine mounting to the gearbox. Tightening torque: 84 Nm (62 lbf ft)
3. Fit the front pipe with rubber mountings and clips.
4. Fit the nuts on the rear pipe joints. Tightening torque 22 Nm (16 lbf ft)
5. Fit the lower nut on the turbocharger.
6. Fit the stay securing the front pipe to the engine. Tightening torque: 25 Nm (19 lbf ft)
7. Lift up the oxygen sensor cables and lower the car.
8. Release the strain on the lifting beam and remove it.
9. Tighten the engine mounting's retaining bolts, using a torque wrench. Tightening torque: 26 Nm (19 lbf ft).
10. Fit the gear linkage to the engine mounting.
11. Fit the engine mounting's upper retaining nut. Tightening torque: 47 Nm (35 lbf ft).
12. Fit the two upper nuts on the exhaust system. Tightening torque 24 Nm (18 lbf ft)
13. Lay out the oxygen sensor cables and plug in the connectors.
14. Secure the cables with a cable tie.
15. Fit the top engine cover and the heat shield over the exhaust manifold. Tightening torque, nut, heat shield 20 Nm (15 lbf ft)
16. Lubricate the O-ring on the bypass pipe with acid-free petroleum jelly and fit the pipe with the valve and vacuum hose. Tightening torque: 8 Nm (6 lbf ft)
17. Connect the negative battery cable and fit the cover over the battery. Set the clock and radio code where applicable. See owner' s manual.

Scheme 233

Place the dismantled engine on a lifting trolley.

Scheme 234

Scheme 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

Scheme 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

1. Remove the starter motor.
2. Remove the belt tensioner and generator. Remove the support bearing bracket with intermediate shaft and inboard drive-shaft joint. Plug the gearbox with protective plugs 87 92 244.
3. Remove the generator bracket and crankcase breather's oil trap complete with hoses.
4. Remove the intake manifold's steady bar and remove the rear engine mounting.
5. Remove the gearbox retaining bolts. Disconnect the exhaust pipe from the turbocharger and unplug the oxygen sensor connectors.
6. Remove the gearbox stay. Remove the servo pump and put it on the subframe.
7. Lift the power train and roll away the table with the subframe. Remove the bracket, engine mounting and bolts lower, rear on the engine to the gearbox.
8. «FIT ENGINE HOLDER 83 95 220»(ref-274819-S32917214052007122400000) to the engine and lift over the power train to «78 74 878 FLOOR STAND»(ref-274819-S42922041072007122400000) .
9. Drain off the oil.
10. Remove the protective plate and undo the torque converter retaining bolts (aut.). Gradually withdraw the torque converter while rotating the crankshaft pulley.
11. Prevent the torque converter from moving by means of Converter «HOLDER 87 92 574»(ref-274819-S10554236812007122400000) .
12. Lift away the gearbox. Use «LIFTING CABLE 87 92 442»(ref-274819-S01403697422007122400000) .
13. Remove the oil filler pipe from its bracket and disconnect the preheating hoses from the throttle body.
14. Remove the bracket for the electric leads from the cylinder head.
15. Unplug all electric connectors between the intake manifold and engine.
16. Remove the crankcase breather nipple.
17. Remove the delivery pipe between the charge air cooler and throttle body.
18. Disconnect the crankcase breather pipe from the turbocharger's inlet pipe.
19. Remove the heat shield from above the turbocharger.
20. Remove the power steering pump and power steering bracket by means of the lifting eyebolt.
21. Remove the A/C compressor bracket.
22. Remove the turbocharger steady bar, disconnect the coolant and oil hoses, and remove the turbocharger complete with exhaust manifold. Heat it carefully if it sticks.
23. Remove the throttle body preheating hose.
24. Remove the bolts retaining the intake manifold. Lift it away from the power train.
25. Disconnect the filler hose from the expansion tank.
26. Remove the pipe from the heat exchanger and the hose from the cylinder head.
27. Remove the thermostat housing's cover complete with thermostat.
28. Remove the coolant pump with filler pipe, and the sleeve with the O-rings.
29. Remove the oil filter and the adapter housing.
30. Remove the crankshaft position sensor.
31. Align the 0 mark on the crankshaft pulley with the mark on the transmission casing.
32. Fit «FLYWHEEL LOCKING ATTACHMENT 83 94 868»(ref-274819-S08616750162007122400000) and remove the crankshaft pulley.
33. Remove the flywheel, pressure plate and linings or driven plate and remove the flywheel locking segment.
34. Remove the ignition discharge module.
35. Remove the spark plugs and remove the camshaft cover.
36. Remove the chain tensioner. First remove the plug, then use a 27 mm socket.
37. Remove the camshaft sprockets, holding each camshaft steady with a spanner applied to the end of it.
38. Fit a rubber band round the chain guides and remove the cylinder head. Start with the bolts in the timing cover and then continue in reverse order to assembly. Collect the bolts with a magnet.
39. Turn the engine into a suitable working position and remove the oil sump and the pipe running to the oil filter. Leave the guide sleeve in the cylinder block.
40. Remove the oil pump and timing cover.
41. Remove the top chain guide and chain tensioner for the balancer-shaft chain.
42. Remove the idler sprocket and balancer-shaft chain.
43. Remove the oil pump driver and sprocket from the crankshaft.
44. Remove the balancer-shaft and camshaft chain guides.
45. Remove the timing chain guard and remove the chain complete with sprocket. IMPORTANT: Turn the balancer shafts 180 so that the weights point up and remove them with great care so that the inner bearing bushings are not damaged.
46. Remove the balancer shafts complete with sprockets and bearing housings.
47. Remove the end plate. IMPORTANT: When dismantling bearing caps and shells, store them carefully and in the right order so that they can be reassembled in their original positions.
48. Remove any carbon deposits from the edges, turn the engine into a convenient position and remove all big-end bearing caps. NOTE: Use a 12 point 14 mm socket.
49. Fit «PROTECTIVE SLEEVE 75 19 531»(ref-274819-S05500282362007122400000) on the studs and press or carefully tap the pistons out of the cylinders.
50. Remove all main bearing caps and lift out the crankshaft. IMPORTANT: Observe the utmost care when handling the slotted ring.
51. Remove the slotted ring.
52. Remove all the bearing shells for both the main bearings and big-end bearings. Also remove the two thrust washers from main bearing no. 3.
53. Remove the piston cooling nozzles.

Fitting in a worn cylinder

Piston rings for a worn cylinder should be matched in the same way as for a new or rebored cylinder, but they must be tried at the lower limit of piston travel because the bore is narrowest at this point.

In connection with piston ring replacement, the cylinder bore should be honed before the rings are fitted.

Scheme 245

Scheme 246

1. Use a piston ring clamp to fit the rings on the piston.
2. The lower compression ring should be fitted with the side marked "top" facing up.
3. Check the fit of the piston rings in their grooves by rolling them round the grooves. Also measure the clearance at several points.
4. Oil the piston and rings before assembly. Turn the compression rings so that their gaps are roughly 180 to each other and position each of them above one of the gudgeon pin holes.
5. Make sure that the gaps in the top and bottom rings of the three-part scraper ring are staggered round the piston and not in line with each other.

Scheme 247

Scheme 248

Scheme 249

1. Assemble piston and connecting rod by driving in the gudgeon pin, using a plastic mallet and drift. Make sure that the mark on the piston crown faces the timing cover and that the numbers on the connecting rods face the exhaust side. IMPORTANT: If one connecting rod is to be changed to a newer type (part no. 91 97 617), all the connecting rods must be changed or the difference in weight will become too great.
2. Fit the gudgeon pin lock ring. WARNING: It is extremely important to fit the lock ring with its opening upwards.
3. Place the bearing halves in place in the connecting rods.
4. Fit «PROTECTIVE COLLARS 75 19 531»(ref-274819-S05500282362007122400000) over the connecting rod studs and oil the piston rings, bearings and cylinder.
5. Fit the piston using «PISTON FITTING TOOL 78 62 287»(ref-274819-S13913916302007122400000) . IMPORTANT: Pistons of different makes must not be used in the same engine. The name of the manufacturer is cast inside the piston.
6. Fit the big-end bearing caps with bearing halves (connecting rod numbers facing in the same direction). Tightening torque, with nut 20 Nm +70° (15 lbf ft +70°) Tightening torque, with bolt 25 Nm +100° (18 lbf ft +100°)
7. Fit the subframe and oil sump, see «OIL SUMP (IN CAR)»(ref-274819-S05459067672007122400000) .
8. Place a «WEDGE 83 95 238»(ref-274819-S35534301612007122400000) between the subframe and oil sump and remove the lifting beam.

Scheme 250

This method presupposes that the cylinder head has been removed.

Scheme 251

Scheme 252

1. Remove the camshaft bearing caps, it is important to finish removal of the bearing cap where the tappets are under load, and lift out the camshafts.
2. Remove the tappets and keep them in the «VALVE STAND 83 93 787»(ref-274819-S41365892962007122400000) .
3. Fit the «PROTECTIVE COLLARS 83 93 746»(ref-274819-S11617677182007122400000) .
4. Use «VALVE SPRING COMPRESSOR 83 93 761»(ref-274819-S12019480192007122400000) and «VALVE SPRING DEPRESSOR 83 93 779»(ref-274819-S41299441802007122400000) to remove the collets.
5. Lift out the valve discs and valve springs. Lift out the washer with guide seals with Tong for removing «VALVE GUIDE SEALS 83 94 157»(ref-274819-S29265770982007122400000) .
6. Remove the valves. Keep them in «VALVE STAND 83 93 787»(ref-274819-S41365892962007122400000) .

Scheme 253

Scheme 254

Scheme 255

1. Fit the washer with valve stem seal using Tong for removing «VALVE GUIDE SEAL 83 94 157»(ref-274819-S29265770982007122400000) .
2. Fit the valves and springs.
3. Use «VALVE SPRING COMPRESSOR 83 93 761»(ref-274819-S12019480192007122400000) and «VALVE SPRING DEPRESSOR 83 93 779»(ref-274819-S41299441802007122400000) to refit the collets.
4. «PLACE VALVE CLEARANCE GAUGE 83 93 753»(ref-274819-S11565194182007122400000) across two of the camshaft bearing seats with the depth gauge against the end of the valve stem.
5. Check that the maximum depth of 20.5 mm reaches down to the end of the valve stem (valve clearance gauge does not bottom in the bearing seat closest to the depth gauge), see «CHECKING VALVE CLEARANCES»(ref-274819-S41366919892007122400000) .
6. Then check that the minimum gauge depth of 19.5 mm does not reach down to the end of the valve stem. The correct valve clearance is between the minimum and maximum gauge depths. If the clearance is less than the minimum, the valve stem must be shortened and if it is greater than the maximum the valve seat must be reground.
7. Remove the protective sleeves and fit the valve tappets.
8. Fit the camshafts and bearing caps, starting where the cams point downwards and press on the tappets. Bearing caps marked 1-5 for the inlet side, 6-10 for the exhaust side. Tightening torque 15 Nm (11 lbf ft). IMPORTANT: The black bolts have an oilway and should be fitted on the spark plug side.
9. Line up the marks on the camshafts with their timing marks.

Valve-Gear Timing

When the pistons in cylinders no. 1 and no. 4 are at top dead centre, the mark on the crankshaft pulley should be in line with the setting mark on the timing cover. When the timing marks on the camshafts are in line with those on the bearing caps, the inlet and exhaust valves for cylinder no. 1 are closed. As the valves open, they extend beyond the face of the cylinder head and into the zone where the pistons change direction. If the setting of the crankshaft and valve gear is altered, the valves and other vital parts of the engine will be damaged.

Scheme 256

Scheme 257

Scheme 258

Scheme 259

Scheme 260

1. Remove the upper engine cover. Unplug the electrical connection and remove the ignition discharge module and the spark plug. Undo the screw of the crankcase ventilation pipe on the camshaft cover and remove the banjo nipple for crankcase ventilation and the vacuum hose from the camshaft cover. Remove the camshaft cover.
2. Rotate the crankshaft to the 0 mark, remove the chain tensioner and the camshafts. Cover the space for the sprockets and timing chain to prevent collets and seals from dropping down inside. IMPORTANT: Keep all dismantled valve gear parts in «VALVE STAND 83 93 787»(ref-274819-S41365892962007122400000) .
3. Lift out the tappets, using «83 91 401 MAGNETIC TOOL»(ref-274819-S24054039802007122400000) .
4. Fit «83 93 746 PROTECTIVE COLLAR»(ref-274819-S11617677182007122400000) around the valve springs to protect the tappet sliding surfaces. Note the position of the collar.
5. Rotate the crankshaft until the piston in the cylinder concerned is at top dead centre. Lock the engine using «83 94 868 FLYWHEEL LOCKING SEGMENT»(ref-274819-S08616750162007122400000) and fit «83 94 173 AIR NIPPLE»(ref-274819-S35064590382007122400000) . Connect the compressed air and pressurize the piston and valves.
6. Press down the valve disc with «83 95 246 VALVE SPRING COMPRESSOR»(ref-274819-S13522614012007122400000) and remove the collets.
7. Lift out the spring cap and valve spring and remove the washer with valve guide seal using «83 94 157 PLIERS, VALVE GUIDE SEAL»(ref-274819-S29265770982007122400000) .

Scheme 261

Scheme 262

Scheme 263

Scheme 264

Scheme 265

1. Fit the washer with valve seal using «83 94 157 PLIERS, VALVE GUIDE SEAL»(ref-274819-S29265770982007122400000)
2. Fit the spring and spring cap and fit the collets in the spring cap's groove.
3. Disconnect the compressed air, remove the air nipple and the flywheel locking segment.
4. Turn the crankshaft to the 0 marking and then 45°.
5. Remove the protective sleeves and fit the valve tappets.
6. Fit the camshafts and bearing caps, starting where the cams point downwards and press on the tappets. Bearing caps marked 1-5 for the inlet side, 6-10 for the exhaust side. Tightening torque 15 Nm (11 lbf ft) IMPORTANT: The black bolts have an oilway and should be fitted on the spark plug side.
7. Line up the marks on the camshaft with their timing marks and turn the crankshaft back to the 0 mark.
8. Fit the camshaft sprockets and chain. Start with the inlet side camshaft. Do not tighten the bolts yet!
9. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.
10. Fit the chain tensioner, using a 27 mm socket. Tightening torque 63 Nm (47 lbf ft)
11. Fit the chain tensioner plug with push rod and spring. Tightening torque: 22 Nm (16 lbf ft)
12. Check that the chain runs correctly on the chain guides. Rotate the crankshaft two turns and check the settings of the flywheel and camshafts. Tighten the camshaft sprocket bolts. Tightening torque 63 Nm (47 lbf ft)
13. Clean the sealing surface of the camshaft cover with benzene.
14. Apply a soap solution to the opening in the camshaft cover and fit the cover, starting at the opening end. Then continue all the way round, on both the inside and outside. Tightening torque 15 Nm (11 lbf ft)
15. Fit the nipple for crankcase ventilation and vacuum for the camshaft cover. Refit the bolt securing the crankcase breather pipe on the camshaft cover.
16. Fit the spark plugs. Tightening torque: 28 Nm (21 lbf ft)
17. Fit the ignition discharge module. Tightening torque: 11 Nm (8 lbf ft)
18. Plug in the ignition discharge module's connector.

Scheme 266

Use a CUTTER SET WITH T-WRENCH 83 95 204 , VALVE SEAT CUTTER 83 93 936 (60°) and VALVE SEAT CUTTER 78 61 040 (45) .

Valve seat angles, inlet and exhaust valves: 45°.

Regrinding angle: 60°.

Valve seat width: Inlet valve 1.0-1.5 mm.

Outlet valve 1.5-2.0 mm

Press home the guide spindle into the valve guide from the valve seat side. Cut clean the valve seats in the cylinder head with a 45° cutter. It may be necessary to remove the hard surface on the exhaust valve seat with an abrasive cloth. In most cases, the valve seat width will be too great after cutting and must be reduced. Use a 60° correction cutter to reduce the width.

Apply a thin layer of grinding paste on the valve seat and insert the valve into the cylinder head. The grinding paste must not come in contact with the valve stem. Rotate with the grinding tool a few times. Clean off the grinding paste thoroughly and check the contact surface with e.g. marking ink. Repeat the grinding where required and recut if necessary.

Checking Valve Tightness

1. Clean the combustion chamber and valve seats. Use a rotating wire brush for example. Wash the cylinder head.
2. Refit the intake valves and fit new exhaust valves. Fill the intake and exhaust chambers with methanol. Do not spill.
3. Check all valves for leaks. The fluid may dampen but not run out. If the valves are tight, fit the cylinder head, see «FITTING OF CYLINDER HEAD (IN CAR)»(ref-274819-S39268659022007122400000)
4. If the valves leak, clean and recut the valve seats and grind with paste. Check the valve clearances, see «CHECKING VALVE CLEARANCES»(ref-274819-S41366919892007122400000) .

New tensioner

A new chain tensioner is delivered with the spring tensioned. Remove the pin and plug, spring and push rod. Then follow the instructions for fitting of a previously used chain tensioner.

Scheme 267

Scheme 268

1. Prepare the chain tensioner for fitting by pressing down the catch and pushing in the chain tensioner.
2. Fit the chain tensioner, using a 27 mm socket. Tightening torque 63 Nm (47 lbf ft).
3. Fit the chain tensioner plug with push rod and spring. Tightening torque 22 Nm (16 lbf ft). As the plug is screwed in, the spring pushes the tensioning arm out and so tautens the chain.
4. Fit the idler pulley.
5. Fit the drive belt, check the position of all belt pulleys and tension the multigroove belt.
6. Fit the RH engine mounting. Tightening torque: 50 Nm (36 lbf ft).
7. Remove the wedge and mount the power steering pump pipe on the subframe.
8. Start the engine and run it at idling speed for a while. Switch off the engine and check that the belt is positioned correctly.

Scheme 269

Scheme 270

Scheme 271

Scheme 272

Scheme 273

1. Raise the care and remove the belt circuit cover.
2. Lower the car and remove the upper engine cover.
3. Remove the ignition discharge module and spark plugs.
4. Remove the crankcase ventilation pipe and hose. Cut the cable tie on the check valve. Unplug the solenoid valve connector and remove the camshaft cover.
5. Align the crankshaft and camshafts with their respective setting marks by turning the crankshaft clockwise.
6. Relieve the tension from the multigroove belt and undo the idler sprocket so that the chain tensioner sleeve is freed.
7. Check chain wear by removing the chain tensioner plug, spring and pushrod, and removing the chain tensioner without altering the position of the pistons. The protruding part of the chain tensioner must not be longer than 15 mm. If it is, the chain must be changed.
8. Check the wear on chain sprockets and chain guide. Chain guide wear must not be so great that the chain acts on the surface between the outer tracks. If the surface between the outer tracks shows signs of wear, they must also be replaced and the chain changed in the usual manner.

Scheme 274

Scheme 275

Scheme 276

Scheme 277

Scheme 278

Scheme 279

Scheme 280

Scheme 281

Scheme 282

Scheme 283

Scheme 284

1. Cover the area round the chain with a cloth and also secure the chain with cable ties on both sides.
2. Split the chain by pressing out a link using «83 94 637 REMOVAL TOOL»(ref-274819-S26614620782007122400000) and then removing the link with a pair of pliers. Attach a cable tie to the end of the old chain.
3. Couple together the new chain with the old one using «83 94 660 CHAIN LOCKING LINK»(ref-274819-S23154406342007122400000) . Take care not to let the chain fall down!
4. Make sure that the new chain lies over the camshaft sprockets on the intake side.
5. Fit the chain support in «83 94 652 FIXTURE»(ref-274819-S29495907602007122400000) and remove the cloth and the cable tie on the camshaft sprocket.
6. With the old chain in your hand and the new one resting over your hand, carefully feed in the new chain while a helper turns the crankshaft. IMPORTANT: Be sure to keep the old chain under tension as it is fed forward. It might otherwise fold itself double down at the crankshaft.
7. When the new chain has been fed forward to such an extent that only a few links still remain on the inlet side's camshaft sprocket, cover the area round the chain with a cloth once again. Secure the chain with a cable tie, and remove the chain link and the old chain.
8. Connect the ends of the new chain together with a chain link and remove the cable tie and cloth. Pull the chain round until the link is midway between the shanks of the chain support.
9. Cover the opening with a cloth, remove the chain link and fit a new chain lock. Check that the inserts marked 2 are mounted in the tool. Then place the chain link's plate in the tool and align it over the link on the chain. Press the plate in place with a force of 10 Nm (7 lbf ft).
10. Reverse the insert in the tool and position the tool with the V notch directly over one of the shanks of the link. Rivet the shanks with a force of 15 Nm (11 lbf ft). Repeat for the other shank.
11. Check the riveting by checking the compressed shank diameter with a vernier caliper. The correct diameter is Ø 3.4-3.6 mm.
12. Remove the cloth and shank support.
13. Reassemble and fit the chain tensioner using a new washer. Fit the plug with a new O-ring sparingly greased with vaseline. Tightening torque, chain tensioner 63 Nm (46 lbf ft) Tightening torque, plug 22 Nm (16 lbf ft)
14. Tighten the chain tensioner bolt and make sure the multigroove belt is correctly positioned on all pulleys. Tightening torque 63 Nm (47 lbf ft)
15. Turn the engine over two turns and check the 0 marks of the camshafts and crankshaft.
16. Wash the cylinder head gasket surface with benzene and oil the four recesses with engine oil.
17. Fit the camshaft cover as shown in the illustration. Tightening torque 15 Nm (11 lbf ft)
18. Fit the spark plugs. Tightening torque: 28 Nm (21 lbf ft)
19. Fit the ignition discharge module and connector. Tightening torque: 11 Nm (8 lbf ft)
20. Fit the crankcase ventilation hose and pipe. Secure the check valve with a cable tie.
21. Raise the care and fit the belt circuit cover.
22. Lower the car and fit the upper engine cover.

Scheme 285

Clean the crankshaft and use a micrometer to measure the crankpins and main journals. Measurements should be taken at several points round the circumference. Main journal and crankpin out-of-round (ovality) should not exceed 0.05 mm. If the measurements are close to or in excess of this limit, the crankshaft should be ground down to the specified undersize. Crankpins can be ground down to the first undersize using a straight grinding wheel. If they are ground down beyond that, a grinding wheel capable of grinding radii must be used since undercutting only suffices to the first undersize. Check that the shaft is straight to within 0.10 mm, using a dial gauge. Place the shaft with crankpins No. 1 and No. 5 in V-blocks on a flat and level bench. Apply a dial gauge to the middle crankpin and rotate the shaft.

Scheme 286

Main bearings

Before the bearing clearance is checked in connection with fitting new bearings, the crankshaft journals ovality and taper must be checked. The clearances are checked with PLASTIGAUGE, PART NUMBER 30 06 558 , available in three dimensions. Type PG-1 (green) must be used.

Scheme 287

Measure ovality with a micrometer at two positions 90 degrees from each other. Use Plastigauge to measure clearance as follows

Scheme 288

Scheme 289

1. Turn the engine upside down on the stand so that the weight of the crankshaft will not affect the measurements.
2. Clean the parts to be measured so that they are dry and free from oil and dirt. Place a strip of Plastigauge along the shaft.
3. Fit the bearing cap. Tightening torque 20 Nm + 70° (15 lbf ft + 70°). The crankshaft must remain absolutely still while measurement is in progress.
4. Remove the bearing cap. The strip of Plastigauge should now have adhered to either the bearing cap or the main journal.
5. Measure the width of the Plastigauge strip using the scale that is printed on the packaging to measure the clearance. One side of the packaging gives measurements in mm and the other in 1000ths of inches. Measure the strip at its widest point. Do not touch the strip with your fingers. See «CRANKSHAFT REGARDING DIMENSIONS»(ref-274819-S24218376332007122400000) .

Scheme 290

Before the bearing clearance is checked in connection with fitting of new bearings, the crankshaft journals ovality and taper must be checked. The clearances are checked with PLASTIGAUGE, PART NUMBER 30 06 558 , available in three dimensions. Type PG-1 (green) must be used.

Measure ovality with a micrometer in two positions 90 degrees from each other. Clearance can be checked with a Plastigauge as follows

Scheme 291

Scheme 292

1. Clean the parts to be measured so that they are dry and free from oil and dirt. Place a strip of Plastigauge along the shaft.
2. Fit the bearing cap. Tightening torque 20 Nm + 70 (15 lbf ft + 70) The crankshaft must remain absolutely still while measurement is in progress.
3. Remove the bearing cap. The strip of Plastigauge should now have adhered to either the bearing cap or the main journal.
4. Measure the width of the Plastigauge strip using the scale that is printed on the packaging to measure the clearance. One side of the packaging gives measurements in mm and the other in 1000ths of inches. Measure the strip at its widest point. Do not touch the strip with your fingers. See «CRANKSHAFT REGARDING DIMENSIONS»(ref-274819-S24218376332007122400000) .

Scheme 293

Scheme 294

Scheme 295

Scheme 296

1. Raise the car. Remove the right-hand front wheel and detach the power steering pump from the subframe.
2. Remove the cover for the belt circuit. Fit a «WEDGE 83 95 238»(ref-274819-S35534301612007122400000) between the oil sump and the subframe so that it can be driven in to raise the engine for fitting.
3. Remove the right-hand engine mounting with yoke.
4. Take the strain off the belt tensioner with the aid of a ratchet handle extension and insert a 3 mm hexagon key in the hole. IMPORTANT: Exercise the utmost care to ensure that the belt tensioner does not break at its end position!
5. Remove the flywheel cover plate and fit «FLYWHEEL LOCKING SEGMENT 83 94 868»(ref-274819-S08616750162007122400000) .
6. Remove the crankshaft pulley.
7. Use a screwdriver to prise out the old seal, taking care not to damage the sealing surface.

Scheme 297

Scheme 298

Scheme 299

Scheme 300

1. Fit a new seal using «FITTING TOOL FOR CRANKSHAFT SEAL, TIMING CHAIN END 83 94 876»(ref-274819-S36682801132007122400000) .
2. Fit the crankshaft pulley. Tightening torque 175 Nm (130 lbf ft).
3. Remove the flywheel locking segment and fit the flywheel cover plate.
4. Drive in the wedge to raise the engine.
5. Fit the drive belt, check its position on all the pulleys and remove the strain-relieving hexagon key.
6. Fit the RH engine mounting. Tightening torque 50 Nm (37 lbf ft).
7. Remove the wedge and fit the power steering pump pipe.
8. Fit the belt circuit cover and the wheel. Tightening torque: 110 Nm (80 lbf ft). IMPORTANT: The wheels must be hanging freely when the wheel bolts are tightened.
9. Start the engine and run it at idling speed for a while.
10. Switch off the engine and check that the belt is correctly positioned.

Scheme 301

1. (man.) Remove the gearbox, see «TO REMOVE»(ref-274820-S42602635282007122400000) under Manual gearbox. (aut.) Remove the gearbox, see " «COMPLETE AUTOMATIC TRANSMISSION»(ref-274822-S25086022652007122400000) " under Automatic transmission.
2. Remove the clutch and pressure plate, see «CHANGING THE COMPLETE CLUTCH»(ref-274823-S09403881682007122400000)
3. Remove the flywheel or driven plate.
4. Use a screwdriver to prise out the old seal, taking care not to damage the sealing surface.

Scheme 302

1. Grease the gasket and place it on fitting tool for «CRANKSHAFT SEAL, FLYWHEEL END 83 94 884»(ref-274819-S04639872632007122400000) and screw it onto the crankshaft. Press in the gasket by screwing together the tool. The gasket is correctly positioned when the tool bottoms out.
2. Fit the flywheel or driven plate. Tightening torques, see «Tightening Torques»(ref-274819-S27047293572007122400000)
3. Fit the clutch and pressure plate, see «CHANGING THE COMPLETE CLUTCH»(ref-274823-S09403881682007122400000) .
4. (man.) Fit the gearbox, see «TO FIT»(ref-274820-S35986821842007122400000) under manual gearbox. (aut.) Fit the gearbox, see " «COMPLETE AUTOMATIC TRANSMISSION»(ref-274822-S25086022652007122400000) ".

Scheme 303

Scheme 304

1. Drape protective sheets over the wings and remove the cover over the intake manifold.
2. Raise the car, turn the right-hand front wheel outwards and disconnect the power steering pump pipe from the subframe.
3. Drive in «WEDGE 83 95 238»(ref-274819-S35534301612007122400000) between the oil sump and subframe.
4. Disconnect the mass air flow sensor's rubber gaiter and move it aside.
5. Remove the right-hand engine mounting with yoke.
6. Take the strain off the belt tensioner with the aid of a ratchet handle extension and insert a 3 mm hexagon key in the hole. IMPORTANT: Exercise the utmost care to ensure that the belt tensioner does not break at its end position!
7. Remove the drive belt from the pulleys.

Scheme 305

Scheme 306

1. Fit the drive belt round the pulleys, check its position on all the pulleys and tension it.
2. Fit the right-hand engine mounting with yoke. Tightening torque: 50 Nm (36 lbf ft).
3. Fit the rubber gaiter.
4. Remove the wedge and attach the pipe to the subframe.
5. Lower the car to the floor.
6. Start the engine and run it at idling speed for a while. Switch off the engine and check that the belt is positioned correctly.

Scheme 307

Scheme 308

Scheme 309

1. Remove the upper engine cover.
2. Remove the dipstick and place a cloth in the tube. Remove the heated oxygen sensor cables.
3. Remove the turbo bypass pipe and the heat shield on the exhaust manifold.
4. Loosen the upper two nuts on the exhaust pipe.
5. Raise the car and remove the lower engine cover.
6. Remove the remaining mountings and the lower nut on the exhaust pipe. Lower the front of the exhaust pipe.
7. Drain the engine oil.
8. Disconnect the crankcase ventilation hose from the oil sump.
9. Make a punch mark 35 mm from the edge as in the illustration to mark the drilling point.
10. Predrill with a smaller drill. Drill with a drift punch Ø 30 mm at a ca. 45° degree angle to enable access to the hidden oil sump screws. From engine number Y062148-, the motor is equipped with an oil sump that has notchings for the holes. Tap these out with a ball hammer.
11. Remove the cover plate and the oil sump screws.
12. Carefully prise open with a crowbar according to the illustration in order to remove the oil sump.
13. Clean off all oil and filings. Thoroughly clean all surfaces.

Scheme 310

Scheme 311

Scheme 312

Scheme 313

Scheme 314

Scheme 315

1. Transfer the splashguard and pipes to the new oil sump. Use new O-rings.
2. Tap out the holes in the new sump with a ball hammer. Deburr the holes and remove any filings.
3. Check that there are no impurities in the sump and clean the mating surfaces on the engine and gearbox with a gasket scraper and benzine.
4. Apply an approximately 2 mm thick bead of flange sealant, part No. 93 21 795 to the oil sump seals.
5. Check that the pipe to the oil adapter is firmly attached and that it is directed straight into the oil sump. Replace O-rings if necessary.
6. Install the access panel.
7. Prise laterally somewhat with a crowbar and fit the oil sump. Replace all screws. Tighten the screws to the access panel. Tightening torque: 7 Nm (5 lbf ft)
8. Moderately tighten the screws to the engine block. Tighten the three screws to the gearbox and the oil sump's other screws. Finish by tightening the screws in the reinforcements. Replace the cover. Tightening torque, oil sump 22 Nm (16 lbf ft) Tightening torques, gearbox screws 47 Nm (35 lbf ft)
9. Connect the crankcase ventilation hose.
10. Clean the joints, grease the turbocharger studs with Molycote 1000, part No. 30 20 971 and replace the exhaust pipe.
11. Check that the oil plug is tightened and lower the car to the floor.
12. Tighten the other exhaust pipe nuts. Tightening torque: 25 Nm (18 lbf ft)
13. Connect the heated oxygen sensor cables.
14. Fit the heat shield over the exhaust manifold and the turbo bypass pipe. Tightening torque, nut, heat shield 20 Nm (14 lbf ft)
15. Add the engine oil and replace the dipstick.
16. Replace the upper engine cover.
17. Run the engine to normal temperature and check the mating surfaces.
18. Replace the bottom engine cover.
19. Lower the car, check the oil level and add oil if necessary.

Scheme 316

1. Raise the car, remove the cover and unscrew the plug.
2. Remove the adapter housing or loosen the A/C-compressor slightly.
3. Extract the spring and thermostat.

Scheme 317

1. Fit the thermostat and spring. Make sure that the thermostat rests on the flange before it bottoms in the thermostat housing.
2. Check the seal and sealing face and fit the plug. Turning torque 60 Nm (44 lbf ft).
3. Fit the adapter housing or A/C compressor, see «OIL FILTER ADAPTER HOUSING»(ref-274819-S32585788632007122400000) .
4. Lower the car, fit the cover and check the oil level. Top up as necessary.

Scheme 318

1. Raise the car and remove the cover.
2. Unscrew the plug and extract the spring and reducing valve.

Scheme 319

1. Fit the reducing valve and spring. Make sure that the reducing valve is an easy fit.
2. Check the seal and sealing surface and screw in the plug. Tightening torque 25 Nm (19 lbf ft).
3. Fit the cover and lower the car.
4. Check the oil level and top up as necessary.

Scheme 320

1. Raise the car and place a receptacle under the engine to collect the oil.
2. Remove the lower banjo screw from the oil pipe to the turbocharger by the oil filter intermediate piece and allow the engine oil to drain.
3. Connect the banjo screw on the gauge equipment, 8395576, (included in Pressure gauge equipment, fuel pressure 8393852) and tighten it. Connect the hose with pressure gauge included in the pressure gauge equipment to the outlet on the banjo screw.
4. Lower the car to the floor.
5. Position the pressure gauge so that it can be read from inside the car. IMPORTANT: Make sure the pressure gauge hose is not resting against warm or sharp details.
6. Start the engine and read off the oil pressure. See «OIL PRESSURE»(ref-274819-S31372018742007122400000)
7. Leave the engine idling to reduce the turbo speed. Turn off the engine.
8. Raise the car.
9. Remove the pressure gauge equipment.
10. Fit the oil pipe banjo screw with new seals. Wipe of any oil spill
11. Lower the car, check the oil level and adjust as necessary.

Pitting in the surface sealing to the cylinder head

Under certain conditions, the cylinder block's surface sealing to the cylinder head can become pitted due to prolonged leaks in the cylinder head gasket. The pitting arises in the area around the engine coolant passageways.

Scheme 321

1. Remove the cylinder head and the cylinder head gasket, see «CYLINDER HEAD»(ref-274819-S19304414332007122400000) . Seal the oil and coolant passageways and cylinders. IMPORTANT: Make sure no repair compound or grindings enter the cylinders, coolant ducts or oil ways.
2. Clean the surface thoroughly. For maximum adhesion, the surface should be roughened slightly with course abrasive paper.
3. Use protective rubber gloves. Cut the desired amount of repair compound, Alustick, and remove the plastic casing from the compound. WARNING: Always use protective gloves when working with chemicals.
4. Knead the repair compound with your fingers until it has an even colour.
5. Apply the repair compound with pressure to the damaged area within 2 minutes. Thoroughly apply the compound in an even layer, making sure that the surface lies on top of the surrounding surface area for the cylinder block. To achieve the smoothest possible surface, excess repair compound should be removed immediately with a damp cloth.
6. Let the compound harden completely (1-2 hours) and smooth off the area with a grinding block so that the cylinder block surface is level and smooth. Make sure that no metal is removed from the surface of the cylinder block.
7. Fit the cylinder head and the cylinder head gasket, see «CYLINDER HEAD»(ref-274819-S19304414332007122400000) .

Scheme 322

All 4-cylinder engines are water-cooled in-line units with 4 valves per cylinder, 2 overhead camshafts and 2 balancer shafts incorporated in the cylinder block. The engines have fuel injection and are of crossflow type, i.e. with the inlet valves on one side and the exhaust valves on the other side of the combustion chambers. The balancer shafts are designed to overcome vibration and the forces generated by the moving parts of the engine and at the same time reduce the level of unwanted engine noise.

Scheme 323

Cylinder block

The cylinder block is a special one-piece casting with the cylinder bores drilled directly into the block. Special oilways for the lubricating system are also drilled into the block.

Two tunnels for the balancer shafts are incorporated in the block. The tunnels have press-fitted aluminium bearing shells in which the balancer shafts run. These bearing shells can be replaced without the need for subsequent machining.

Pistons

The pistons are made of light alloy and have grooves for two compression rings and one oil scraper ring.

The upper compression ring is flat and chrome or molybdenum plated. The lower compression ring acts as an oil scraper, is somewhat wider than the upper compression ring and has three sections. The pistons are internally reinforced and designed for trapezoid connecting rods. The pistons are tin plated and their upper parts hard anodized. The gudgeon pins are nitro-hardened. The compression ratio of the B205 is 8.8:1 and of the B235 9.3:1.

Connecting rods

The connecting rods are forged and incorporate bushings for the gudgeon pins. The gudgeon pin bushings and big-end bearing shells are replaceable.

The gudgeon pins have a floating fit in the pistons and connecting rods. The axial movement of the gudgeon pins is limited by circlips in the gudgeon pin holes. The engine's connecting rods are strong and have trapezoid small ends.

Scheme 324

Cylinder head

The cylinder head, a light alloy casting, is bolted to the cylinder block. The combustion chambers are hemispherical with 4 valves per cylinder. This design improves the flow of gases in the cylinders, ensuring effective combustion of the fuel air mixture and so higher efficiency.

Timing cover and end plate

The timing cover incorporates the oil pump. The timing cover and end plate are both sealed to the block by means of Loctite 518.

Scheme 325

Second-order forces acting vertically

Inertial forces are generated because the pistons are not at half their stroke at 90° and 270° but considerably lower down. This is due to the relationship between stroke and connecting rod length. The common centre of gravity of the ascending and descending masses is therefore much lower down at 90° and 270°, than at 0° and 180°. This gives rise to forces moving upwards and downwards which vary periodically twice per crankshaft revolution and cause the engine to vibrate in a vertical direction.

Second-order forces acting laterally

During the power stroke the piston is pressed against the cylinder wall due to the angle of the connecting rod relative to the cylinder. At higher engine speeds, however, the inertial force is much greater. It can then be said that the crankshaft pulls the piston down and due to the angle of the connecting rod relative to the cylinder the piston is pressed against the cylinder wall, but this time on the opposite side. The combined gas and inertial forces acting in a sideways direction vary periodically twice per crankshaft revolution and cause the engine to vibrate in a lateral direction.

Scheme 326

The Saab balancer shaft system

Saab has used the balancer-shaft principle to cancel out second-order inertial forces. Two balancer shafts positioned symmetrically on the sides of the engine block but at different heights above the crankshaft centreline are fitted with eccentrically mounted balance weights. The shafts are driven by a chain and rotate in opposite directions to each other at twice the crankshaft speed.

At 90° and 270° the common centre of gravity of the ascending and descending masses is situated lower down in the engine block than at 0° and 180°. The balancer shaft weights must therefore be directed upwards. At 0° and 180° the centre of gravity has moved upwards and the balancer shaft weights must therefore be directed downwards.

Since the balancer shafts are situated at different heights above the crankshaft centreline, they also cancel out lateral forces. The torque generated by the balancer shafts is designed to counteract the gas and inertial forces acting in a sideways direction.

The balancer shafts are of identical design and are supported by aluminium bushes in the middle (between cylinders 2 and 3). The bushes are a press fit in the block and are lubricated via separate oilways.

For the balancer shafts to perform as intended, it is absolutely essential for them to be precisely aligned on assembly. Sprocket assemblies of different design for the exhaust and inlet sides are therefore used on the shafts and marked with identifying text.

The balancer shaft, chain sprocket and bearing housing are assembled as a single unit before being mounted in the cylinder block. This unit is then fitted on the correct side of the engine as indicated by the marking on the bearing housing.

Scheme 327

Balancer shaft drive

The balancer shafts are driven by the crankshaft via a chain, where the gear ratio on the shafts drive gears is such that the balancer shafts speed is double that of the crankshaft. The shaft on the exhaust side rotates in opposite direction since an idler sprocket has been mounted in the chain circuit. The chain is partly guided by two fixed guides and also by a moveable chain guide acted on by a chain tensioner. The chain tensioner tensions the chain with a spring when the engine is not running. When the engine is running, the oil pressure reduces the chain tensioner's spring force to reduce wear and noise in the balancer shaft circuit. The chain noise is reduced by the thrust rings located on the shaft gear and idler sprocket. The thrust rings catch the chain at the ring gear and the chain is thus applied smoother and quieter operation is achieved. Due to the smaller dwell angle, the thrust rings are larger on the exhaust side than on the intake side.

Scheme 328

Camshaft and tappets

The engine has twin overhead camshafts driven by a timing chain equipped with a self-adjusting chain tensioner. The camshafts act directly on the valves via hydraulic tappets which adjust automatically to differences in valve clearances caused by temperature variations. They operate in an oil bath, with oil supplied via an oilway in the cylinder head. The valves are made of steel with chrome-plated stems. The heads of the exhaust valves are stellited.

Chain tensioner

Mounted in the cylinder head, the chain tensioner is easily accessible for service. Tensioning force is applied by a springloaded plunger which, via a guide bar pivoted at the bottom, keeps the slack side of the chain correctly tensioned. A ratchet with close-spaced teeth prevents the plunger, and with it the guide bar, from moving back.

Scheme 329

Oil sump

The oil sump is in cast aluminium. Apply sealing compound (Loctite 518) directly to the flat surface of the flange. The B235R/L with manual gearbox has a reinforcement piece on the left-hand side of the sump that bears against the gearbox.

Oil filter

The oil filter is mounted on the exhaust side of the cylinder block. An adapter housing is fitted between the oil filter and the block. Hoses run from the adapter housing to the engine oil cooler.

An overflow valve is mounted inside the filter. The valve opens if the pressure drop across the filter becomes excessive, as could happen if the filter is heavily soiled.

Scheme 330

Drive belt routing, with and without A/C compressor

1. Generator
2. Belt tensioner
3. Idler sprocket
4. Power steering pump
5. Water pump
6. A/C compressor
7. Crankshaft

The engine has only one belt drive for all the auxiliaries. The drive has an automatic, self-adjusting belt tensioner consisting of a powerful spring which maintains belt tension via a pulley.

Scheme 331

Background

The balancer shafts are most effective within the normal working range of the engine, from 1800 rpm and above. At slower engine speeds, from idling up to 1800 rpm, the balancer shafts are unable to counteract engine vibration. To provide effective damping of engine vibration at speeds below 1800 rpm, the rear and right-hand front engine mountings are of hydraulic type. They are designed to provide the maximum damping effect between idling speed and about 1800 rpm. Hydraulic engine mountings confer the following advantages

1. improved damping of horizontal engine movements during acceleration
2. improved damping of vertical engine movements on bumpy roads
3. Improved damping of engine movements when idling
4. Reduction of structure-borne noise between engine and body.

General data

PISTON DATA SPECIFICATION

Control values, pressure

COMPRESSION RATIOS

Scheme 332

Scheme 333

Piston types

PISTON DIAMETER

Classification of pistons and cylinder bores

The piston classification is stamped on the piston crown roof. The piston classes for service are B

First oversize (+0.5)

Second oversize (+1.0)

Piston classification

PISTON CLASSIFICATION

Piston diameter

Piston diameter is measured at right angles to the gudgeon pin holes, 11 mm from the bottom of the piston.

PISTON DIAMETER

Scheme 334

Piston rings

PISTON RINGS THICKNESS

Gudgeon pin

GUDGEON PIN DIAMETER

Scheme 335

CRANKSHAFT GENERAL DATA SPECIFICATION

Scheme 336

Colour coding of main bearing and big-end bearing shells

Standard bearing shells are Yellow - Yellow or Red - Blue.

Red shells are thinnest, yellow are 0.005 mm (0.0002 in) thicker than red, and blue shells are 0.005 mm (0.0002 in) thicker than yellow ones. Only yellow bearing shells are available as a spare part.

Crankshaft journal diameter (1)

CRANKSHAFT JOURNAL DIAMETER

Main journal diameter (2)

MAIN JOURNAL DIAMETER

Scheme 337

LUBRICATING GENERAL DATA SPECIFICATION

Scheme 338

Oil pressures

OIL PRESSURES SPECIFICATIONS

Scheme 339

Cylinder bore

CYLINDER BORE SPECIFICATION

Scheme 340

CYLINDER HEAD REFERENCE

CONNECTING ROD DIAMETER

Scheme 341

INLET AND EXHAUST VALVE DIMENSIONS

Valve guides

VALVE GUIDES DIAMETER

Maximum lateral clearance between valve stem and valve guide

MAXIMUM LATERAL CLEARANCE BETWEEN VALVE STEM AND VALVE GUIDE

Clearance is measured at the disc with the valve pulled out 3 mm from the seat.

Scheme 342

Valve springs (double springs)

VALVE SPRINGS DOUBLE SPRINGS

Tappets

TAPPETS DIAMETER

Scheme 343

CAMSHAFTS GENERAL DATA SPECIFICATION

Valve timing

VALVE TIMING REFERENCE

Scheme 344

BALANCER SHAFTS GENERAL DATA SPECIFICATION

Scheme 345

TENSION WHEN CHECKING

B235R

250 hp

Scheme 346

B205E

150 hp

Scheme 347

B235E

185 hp

Scheme 348

B235L

220 hp

Scheme 349

B205E BioPower

The values apply when only E85 is used.

180 hp/280Nm

B235E BioPower

The values apply when only E85 is used.

210 hp/310Nm

Scheme 350

TYPE OF ENGINE

Fuel Consumption

FUEL CONSUMPTION

Scheme 351

86 12 798 Toolboard T1 Service

Used together with 30 05 477 COOLING SYSTEM TESTER

Group: Engine

TOOL REFERENCE

Scheme 352

Used for coolant, washer fluid and battery fluid

86 12 798 Toolboard T1 Service

Group: Engine

TOOL REFERENCE

Scheme 353

Group: Engine

TOOL REFERENCE

Scheme 354

Prevents runoff from cooling system hoses

86 12 798 Toolboard T1 Service

Group: Engine

TOOL REFERENCE

Scheme 355

Group: Engine

TOOL REFERENCE

Scheme 356

86 12 822 Toolboard T3 Engine

Group: Engine

TOOL REFERENCE

Scheme 357

Group: Engine

TOOL REFERENCE

Scheme 358

Used together with 78 74 878 FLOOR STAND

Group: Automatic gearbox

TOOL REFERENCE

Scheme 359

86 12 822 Toolboard T3 Engine

Group: Engine

TOOL REFERENCE

Scheme 360

86 12 822 Toolboard T3 Engine

Group: Engine

TOOL REFERENCE

Scheme 361

Group: Engine

TOOL REFERENCE

Scheme 362

Group: Engine, Manual gearbox

Used together with 83 94 751 HOLDER, ENGINE

TOOL REFERENCE

Scheme 363

For chain tensioner, 4 cyl.. FACOM 427 NSB

Help tools (not included on toolboard)

Group: Other tools

Scheme 364

Help tools (not included on toolboard)

Group: Misc.

TOOL REFERENCE

Scheme 365

Reading for bearing preload

86 12 855 Toolboard T5 Automatic Transmission

Group: Engine

TOOL REFERENCE

Scheme 366

86 12 830 Toolboard T4 Manual Gearbox

Use with 83 90 858 PIN

Group: Manual gearbox

TOOL REFERENCE

Scheme 367

Used together with 78 74 878 FLOOR STAND .

Group: Manual gearbox, Automatic gearbox, Engine

TOOL REFERENCE

Scheme 368

Used together with 83 90 270 SLIDING HAMMER

TOOL REFERENCE

Scheme 369

86 12 798 Toolboard T1 Service

Group: Engine

TOOL REFERENCE

Scheme 370

Group: Engine

TOOL REFERENCE

Scheme 371

Group: Engine

TOOL REFERENCE

Scheme 372

Group: Engine

TOOL REFERENCE

Scheme 373

Required number 16

86 12 822 Toolboard T3 Engine

Group: Engine

TOOL REFERENCE

Scheme 374

86 12 822 Toolboard T3 Engine

Group: Engine

TOOL REFERENCE

Scheme 375

86 12 822 Toolboard T3 Engine

Used together with 83 93 779 TAPPETS

Group: Engine

TOOL REFERENCE

Scheme 376

Used together with 83 93 761 VALVE SPRING TOOL

Group: Engine

TOOL REFERENCE

Scheme 377

86 12 822 Toolboard T3 Engine

Group: Engine

TOOL REFERENCE

Scheme 378

86 12 822 Toolboard T3 Engine

Used together with 78 61 040 VALVE SEAT CUTTER, 11° AND 45° ø 34.5 MM

Group: Engine

TOOL REFERENCE

Scheme 379

Multigroove belt

Positive drive belt, camshaft drive V6

86 12 798 Toolboard T1 Service

Group: Engine

TOOL REFERENCE

Scheme 380

86 12 822 Toolboard T3 Engine

Group: Engine

TOOL REFERENCE

Scheme 381

86 12 822 Toolboard T3 Engine

Used on 9-3 together with 83 94 207 ASSEMBLY TOOL and 83 94 181 DISMANTLING TOOL

Group: Engine

TOOL REFERENCE

Scheme 382

86 12 822 Toolboard T3 Engine

Used together with 83 94 207 FITTING TOOL and 83 94 173 COMPRESSED AIR ADAPTER FOR SPARK PLUG HOLE

Group: Engine

TOOL REFERENCE

Scheme 383

86 12 822 Toolboard T3 Engine

Used together with 83 94 181 REMOVAL TOOL and 83 94 173 COMPRESSED AIR ADAPTER FOR SPARK PLUG HOLE

Group: Engine

TOOL REFERENCE

Scheme 384

86 12 822 Toolboard T3 Engine

Group: Engine

TOOL REFERENCE

Scheme 385

For adjusting basic charging pressure, Turbo

86 12 822 Toolboard T3 Engine

Use together with

Group: Engine

TOOL REFERENCE

Scheme 386

86 12 822 Toolboard T3 Engine

Used together with 83 94 678 TIMING CHAIN REMOVAL KIT, 16 VALVE

Group: Engine

TOOL REFERENCE

Scheme 387

86 12 822 Toolboard T3 Engine

Used together with 83 94 678 TIMING CHAIN REMOVAL KIT, 16 VALVE

Group: Engine

TOOL REFERENCE

Scheme 388

86 12 822 Toolboard T3 Engine

Used together with 83 94 678 TIMING CHAIN REMOVAL KIT, 16 VALVE

Group: Engine

TOOL REFERENCE

Scheme 389

For timing chain removal

86 12 822 Toolboard T3 Engine

Used together with 83 94 678 TIMING CHAIN REMOVAL KIT, 16 VALVE

Group: Engine

TOOL REFERENCE