Basic Engine: Removal & Installation Saab 9-5 I рестайлинг 2

Removal of pistons (in situ)

The method requires cylinder head removal, see CYLINDER HEAD

Scheme 2

Scheme 3

1. Remove any burrs or carbon deposits from the tops of the cylinders.
2. Fit «83 94 850 LIFTING BEAM»(ref-274819-S33109733222007122400000) to keep the engine raised.
3. Remove subframe and oil sump, see «OIL SUMP (IN CAR)»(ref-274819-S05459067672007122400000)
4. Wipe up any dripping oil.
5. Remove the big-end caps and fit «PROTECTIVE COLLARS 75 19 531»(ref-274819-S05500282362007122400000) on the studs. Push the pistons and connecting rods out of the cylinder bores. Note the markings on the pistons and connecting rods so that they can be refitted in their original positions. Loosely fit the bearing shells and caps on the connecting rods so that each set is kept separate and the parts are not mixed. 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.
6. Remove the gudgeon pin circlips and drive out the gudgeon pins, using a plastic mallet and drift.

Scheme 4

Spare pistons are stocked in both standard and oversize diameters. Where the latter are used, the cylinder bore must be honed or rebored to obtained the correct piston clearance.

When matching pistons in the cylinder bores, use a 1/2" wide feeler gauge. The cylinder bore should be lightly oiled during measuring and the piston, without rings, should be placed in its corresponding bore. Hook a spring balance to the feeler gauge and insert the gauge between the piston and the bore at right angles to the gudgeon pin. When the pulling force is 8-12 N (1.8-2.7 lbf), the mean value of the clearance coincides with the thickness of the feeler gauge. The test should be performed at several different levels. For piston clearance information, see PISTONS

Scheme 5

When the piston clearances are measured in the engine by means of a 0.05 mm feeler gauge, no measurable force will be recorded on the spring balance when withdrawing the feeler gauge from the No. 2 and No. 3 cylinders. This means that the piston clearance in these cylinders is greater than 0.05 mm and the maximum bore in them is therefore judged to be 90.020 mm. Since the pistons may have bedded-in to a certain extent, giving a further +0.003 mm, it may be assumed that the bore is 90.023 mm. Assuming a standard class B piston, the theoretical piston clearance will be 0.034 0.052 mm and this lies within the clearance limits which for class A piston/class A cylinder is 0.031-0.069 mm, and for class B piston/class B cylinder is also 0.031-0.069 mm. In No. 1 and No. 4 cylinders, the pistons cannot be fitted into the cylinder bores with a 0.05 mm or 0.04 mm feeler gauge inserted. With a 0.03 mm feeler gauge inserted the force necessary to withdraw it will be 20 N (4.6 lbf) and with a 0.02 mm feeler gauge it will be 6 N (1.4 lbf). We can therefore assume a piston clearance of 0.024 mm in the No. 1 and No. 4 cylinders and the pistons in these cylinders will therefore not need to be replaced.

Scheme 6

1. Push the piston rings down into the cylinder one by one, using a piston to position them correctly.
2. Measure the ring gap with a feeler gauge, see illustration. If necessary, the gap can be increased with a special file. For measurement information, see «PISTONS»(ref-274819-S14055534882007122400000) .

83 94 678 Timing Chain Removal Kit, 16 Valve

For timing chain removal

1. 83 94 652 Support for chain (over camshaft sprockets)
2. 83 94 637 Chain link removal tool
3. 83 94 645 Tool for riveting chain links
4. 83 94 660 Chain link

Group: Engine

TOOL REFERENCE

Scheme 7

Group: Engine

TOOL REFERENCE

Scheme 8

86 12 863 Toolboard T6 Tool Holders

Used together with 78 74 878 FLOOR STAND

Group: Engine

TOOL REFERENCE

Scheme 9

Used together with 83 95 311 TROLLEY LIFT

Group: Miscellaneous

TOOL REFERENCE

Scheme 10

Group: Engine, Manual gearbox

TOOL REFERENCE

Scheme 11

86 12 798 Toolboard T1 Service

Group: Engine

TOOL REFERENCE

Scheme 12

Timing end

Group: Engine

86 12 798 Toolboard T1 Service

TOOL REFERENCE

Scheme 13

Flywheel end

86 12 798 Toolboard T1 Service

Group: Engine

TOOL REFERENCE

Scheme 14

4-cyl, V6

86 12 822 Toolboard T3 Engine

Group: Engine

TOOL REFERENCE

Scheme 15

Test pressurising radiator cap

86 12 798 Toolboard T1 Service

Group: Engine

TOOL REFERENCE

Scheme 16

Used together with 83 95 311 LIFTING TROLLEY and 83 94 801 PARENT FIXTURE

Group: Miscellaneous

TOOL REFERENCE

Quantity: 4

Scheme 17

Used together with 83 95 311 TROLLEY LIFT and 83 94 801 PARENT FIXTURE

Group: Miscellaneous

TOOL REFERENCE

Scheme 18

86 12 822 Toolboard T3 Engine

Group: Engine

TOOL REFERENCE

Scheme 19

Group: Engine

TOOL REFERENCE

Scheme 20

86 12 863 Toolboard T6 Tool Holders

Used together with 78 74 878 FLOOR STAND .

Group: Engine

TOOL REFERENCE

Scheme 21

Group: Body, Engine

TOOL REFERENCE

Qty: 5 pcs

Scheme 22

86 12 822 Toolboard T3 Engine

Group: Engine

TOOL REFERENCE

Scheme 23

For unloading the belt tensioner

86 12 798 Toolboard T1 Service

Group: Engine

TOOL REFERENCE

Scheme 24

For parting the fuel line and tank ventilation

Group: Engine

TOOL REFERENCE

Scheme 25

Group: Miscellaneous

TOOL REFERENCE

Scheme 26

86 12 871 Toolboard T7 Diesel 4-cyl

Group: Engine

TOOL REFERENCE

Scheme 27

86 12 871 Toolboard T7 Diesel 4-cyl

Group: Engine

TOOL REFERENCE

Scheme 28

86 12 871 Toolboard T7 Diesel 4-cyl

Group: Engine

Reference: KM-977

TOOL REFERENCE

Scheme 29

86 12 871 Toolboard T7 Diesel 4-cyl

Used together with 87 91 360 PULLER

Group: Engine

TOOL REFERENCE

Scheme 30

86 12 798 Toolboard T1 Service

Group: Body

TOOL REFERENCE

Scheme 31

Securing injectors

86 12 871 Toolboard T7 Diesel 4-cyl

Group: Engine

TOOL REFERENCE

Qty: 4 pcs

Scheme 32

86 12 871 Toolboard T7 Diesel 4-cyl

Group: Engine

TOOL REFERENCE

Scheme 33

86 12 830 Toolboard T4 Manual Gearbox

Group: Automatic transmission

TOOL REFERENCE

Scheme 34

86 12 830 Toolboard T4 Manual Gearbox

Group: Manual gearbox

TOOL REFERENCE

Scheme 35

86 12 798 Toolboard T1 Service

Group: Manual gearbox, Automatic transmission

TOOL REFERENCE

Scheme 36

For torque converter

Group: Automatic transmission

Scheme 37

(9-3 Viggen)

86 12 830 Toolboard T4 Manual Gearbox

Group: Automatic transmission, Manual gearbox

TOOL REFERENCE

Scheme 38

86 12 798 Toolboard T1 Service

Group: Manual gearbox

TOOL REFERENCE