Basic Engine, 4-CYLINDER Petrol: Other Saab 9-5 I рестайлинг

Removing the power train

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1. Lay out wing covers, remove the battery covers 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 «83 94 744 ADAPTER, FUEL PRESSURE TESTING»(ref-212206-S23832364392005122200000) and plug them. NOTE: If necessary, cut a groove in the rubber seal. Exercise care when doing this so that it can be reused 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 it.
17. Unplug the connector for the radiator fan or fans. Remove the fan cowl 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 it.
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 «85 80 144 Puller windscreen wiper arm»(ref-212206-S39875536152005122200000) NOTE: The plastic hooks go under the windscreen. The cover panel must first be pulled forwards.
24. Undo the control module connector's retaining nuts. 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 «83 95 238 WEDGE»(ref-212206-S22330348352005122200000) 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 «83 95 212 Strap»(ref-212206-S27554981292005122200000) . 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's 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 belt tensioner pressure using a ratchet handle extension 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. (aut.) Remove quick-release couplings to gearbox oil cooler and plug. Use «83 95 261 FUEL LINE TOOL»(ref-212206-S27697855352005122200000) . Mark the hoses to tell them apart.
40. Raise the car higher.
41. Remove the steering swivel joint's three 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 «89 96 696 PULLER»(ref-212206-S09152224062005122200000)
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 «83 95 311 TROLLEY LIFT»(ref-212260-S14164380882005122300000) with assembly fixture 83 95 196 under the car. Align the fixture with adjusting feet 83 95 170 under the subframe with the locating dowels 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 have 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 bushing in 38 mm inner sleeve.
49. Lower the lifting trolley approx. 25 cm and thus also the subframe and power train. Make sure that the spindles 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 to the rear 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 dowels in their positions at front left and rear right. Make sure that the steering gear fits in place in the bulkhead partition.
4. Fit the drive shafts and screw on the three steering swivel joint retaining nuts. Tightening torque 30 Nm (22.5 lbf ft) +90.
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 have 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 bushing in 38 mm inner sleeve.
6. Fit the exhaust pipe, temperature sensor and air cleaner in the subframe.
7. Fit the track rod ends and anti-roll bar support to the suspension strut. Hold with a open wrench or hold the hexagonal pin with a socket. 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-212206-S41078081672005122200000) (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 partition.
21. Refit 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 pressures, 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 also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.
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 and tighten the wheel bolts, using a torque wrench. Tightening torque: 110 Nm (80 lbf ft). IMPORTANT: The wheels must be hanging freely when the wheel bolts are tightened.
49. Lower the car to the floor and retighten the hub nuts, using a torque wrench. Tightening torque 290 Nm (215 lbf ft) Tightening torque, nuts with top groove 170 Nm +45° (126 lbf ft + 45°)
50. Fit the battery tray, battery, cover over the intake manifold, the battery cover and remove the wing covers. Fit the vacuum hose to the heat exchanger shut-off valve, (for 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 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 AC 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. Also check the oil level in the engine and gearbox.
57. Set the clock to the correct time. Calibrate the ACC.

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1. Cover the wings and remove the top engine cover.
2. Fit «83 94 850 LIFTING BEAM»(ref-212206-S21504477522005122200000) 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.

Scheme 179

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 bolt on the torque arm.
3. Undo the bolts on the gearbox bracket so that the rear torque arm bolt can be removed.
4. Lift out the torque arm.

Scheme 181

1. Position the torque arm with through bolts.
2. Tighten the bolts on the gearbox bracket. Tightening torque 47 Nm (35 lbf ft)
3. Tighten the through bolt on the subframe. Tightening torque 121 Nm (90 lbf ft)
4. Tighten the bolt securing the torque arm to the bracket. Tightening torque 47 Nm (35 lbf ft)

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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 vent hose and remove the battery and battery tray.
3. Relieve the weight on the engine with «83 94 850 LIFTING BEAM»(ref-212206-S21504477522005122200000) .
4. Undo the center nut and bolts on the engine pad.
5. Remove the engine pad.
6. Detach the clutch hydraulic hose from its fastening.
7. Remove the engine mounting.

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1. Refit the engine mounting. Tightening torque, man. 47 Nm (35 lbf ft) Tightening torque, aut. 84 Nm (62 lbf ft)
2. Fit the clutch hydraulic hose to its fastening.
3. Fit the engine pad locating bolt and make sure the center bolt is in the center of the engine pad without being pulled to one side.
4. Tighten the remaining bolts and the center nut Tightening torque bolts 40 Nm +45° (35 lbf ft +45°) Tightening torque, nut 84 Nm (62 lbf ft)
5. Take the weight off the engine and remove the lifting beam.
6. Fit the battery with tray and the battery vent hose. Set the correct time on the clock. Calibrate the ACC.

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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 attachment of the bypass pipe to the turbo intake pipe.
6. Remove the exhaust manifold 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-212206-S21504477522005122200000) .
9. Undo the two upper nuts on the turbo/front exhaust system joint.
10. Raise the car.
11. Undo the third nut on the turbo/front exhaust system joint.
12. Undo the upper bolt on the stay securing the catalytic converter to the engine.
13. Undo the pipe joint between the front and rear exhaust systems.
14. Remove the clips and carefully pull off the rubber mountings.
15. Lift off 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.

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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 turbo unit.
6. Fit the stay securing the front pipe to the engine. Tightening torque 25 Nm (19 lbf ft)
7. Feed 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. Take hold of 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.
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. Calibrate the ACC. Set the clock and radio code where applicable.

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Place the dismantled engine on a lifting trolley.

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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 «87 92 665 Protective plug, drive shaft hole»(ref-212206-S04950981402005122200000) 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-212206-S22313497162005122200000) to the engine and lift over the power train to «78 74 878 FLOOR STAND»(ref-212206-S36032422062005122200000) .
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-212206-S01243674062005122200000) .
12. Lift away the gearbox. Use «87 92 442 LIFTING CABLE»(ref-212206-S05682245362005122200000) .
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 «83 94 868 FLYWHEEL LOCKING ATTACHMENT»(ref-212206-S33849643872005122200000) 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-212206-S41071964082005122200000) 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.

Piston rings

Fitting in a new or rebored cylinder

Scheme 210

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. If necessary, the gap can be increased with a special file. For measurement information, see «PISTONS»(ref-212206-S12938547032005122200000) .

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.

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Scheme 212

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.

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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-212206-S41071964082005122200000) over the connecting rod studs and oil the piston rings, bearings and cylinder.
5. Fit the piston using piston fitting tool 78 62 287. 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-212206-S01005113872005122200000) .
8. Place a «83 95 238 WEDGE»(ref-212206-S22330348352005122200000) between the subframe and oil sump and remove the lifting beam.

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This method presupposes that the cylinder head has been removed.

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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 «83 93 787 VALVE STAND»(ref-212206-S08558754612005122200000) .
3. Fit the «83 93 746 PROTECTIVE COLLAR»(ref-212206-S30288789632005122200000) .
4. Use «83 93 761 Valve spring tool»(ref-212206-S33173055162005122200000) and Valve spring depressor «83 93 779»(ref-212206-S29134600892005122200000) 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-212206-S17678287052005122200000) .
6. Remove the valves. Keep them in «83 93 787 VALVE STAND»(ref-212206-S08558754612005122200000) .

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1. Fit the washer with valve stem seal using Tong for removing valve guide seal «83 94 157»(ref-212206-S17678287052005122200000) .
2. Fit the valves and springs.
3. Use valve spring compressor «83 93 761 Valve spring tool»(ref-212206-S33173055162005122200000) 83 93 761 and Valve spring depressor «83 93 779»(ref-212206-S29134600892005122200000) to refit the collets.
4. Place Valve clearance gauge «83 93 753»(ref-212206-S40919584852005122200000) 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-212206-S04533876662005122200000) .
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 center, 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.

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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.
3. Lift out the tappets, using magnetic tool 83 91 401.
4. Fit «83 93 746 PROTECTIVE COLLAR»(ref-212206-S30288789632005122200000) 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 center. Lock the engine using «83 94 868 FLYWHEEL LOCKING ATTACHMENT»(ref-212206-S33849643872005122200000) and fit the air nipple for spark plug hole «83 94 173»(ref-212206-S13636159882005122200000) . Connect compressed air and pressurize the piston and valves.
6. 'Press down the valve disc with Valve spring compressor 83 95 246 and remove the collets.
7. Lift out the spring cap and valve spring and remove the washer with valve guide seal using pliers for removing valve guide seals 83 94 157.

Scheme 227

Scheme 228

Scheme 229

Scheme 230

Scheme 231

1. Fit the washer with valve seal using pliers for removing valve guide seals «83 94 157»(ref-212206-S17678287052005122200000) .
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 232

Use a cutter set with T-wrench 83 95 204 , 83 93 936 VALVE SEAT CUTTERS, 60° and 78 61 040 VALVE SEAT CUTTER, 11° AND 45° o/34.5 mm .

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-212206-S15944449872005122200000)
4. If the valves leak, clean and recut the valve seats and grind with paste. Check the valve clearances, see «CHECKING VALVE CLEARANCES»(ref-212206-S04533876662005122200000) .

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 233

Fitting of previously used chain tensioner

Scheme 234

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 right-hand 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 235

Scheme 236

Scheme 237

Scheme 238

Scheme 239

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 240

Scheme 241

Scheme 242

Scheme 243

Scheme 244

Scheme 245

Scheme 246

Scheme 247

Scheme 248

Scheme 249

Scheme 250

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 the tool kit for timing chain replacement «83 94 637»(ref-212206-S25593889942005122200000) and then remove the link using pliers. Attach a cable tie to the end of the old chain.
3. Connect the new chain to the old one with the link in the tool kit for timing chain replacement «83 94 660»(ref-212206-S00891380062005122200000) . Be careful to make sure that the chain does not fall down!
4. Make sure that the new chain lies over the camshaft sprockets on the intake side.
5. Fit the chain support from the tool kit for timing chain replacement «83 94 652»(ref-212206-S38055662412005122200000) and remove the cloth and cable ties from 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 PHY 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 251

Method excluded for power train removed and mounted in fixture.

Scheme 252

Scheme 253

1. Remove the dipstick.
2. Remove the idler pulley.
3. Remove the power steering pump and its bracket with the lifting eye.
4. Remove the water pump and the sleeve with O-rings.
5. Remove the protective plate and oil sump. Leave the guide sleeve in the cylinder block. Wipe up any oil that has dripped out.
6. Use «83 94 868 FLYWHEEL LOCKING ATTACHMENT»(ref-212206-S33849643872005122200000) . Remove the crankshaft pulley.
7. Disconnect the crankcase breather hose from the oil sump.
8. Remove the locating pins in the timing cover by cutting an internal thread in them using a 3/8" UNC thread tap and withdraw them with sliding hammer «83 90 270 Sliding hammer»(ref-212206-S22152391202005122200000) .
9. Remove all timing cover retaining bolts.
10. Pull the timing cover away, starting at the bottom.
11. Then lift the cover outwards/downwards to avoid damaging the gasket at the cylinder head.

Scheme 254

Scheme 255

Scheme 256

1. Thoroughly remove all remains of sealant on all surfaces. Wash clean with benzine.
2. Apply a bead of Loctite 518 about 1 mm thick along the middle of the sealing surfaces.
3. Fit the timing cover, carefully turning it into position. Fit the retaining bolts but do not tighten them. Tap the locating pins in place.
4. Tighten the timing cover, using a torque wrench. Tightening torque 22 Nm (16 lbf ft).
5. Inspect the water pump's O-rings and change them if 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 the O-rings with petroleum jelly (Vaseline) and fit the water pump.
6. Fit the crankshaft pulley. Use «83 94 868 FLYWHEEL LOCKING ATTACHMENT»(ref-212206-S33849643872005122200000) . Tightening torque 175 Nm (130 lbf ft).
7. Make sure that there are no impurities or other foreign matter in the oil sump and clean its sealing surface.
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 protective plate, plug in the oil level sensor connector and press the cable back into its clamps.
10. Check that the oil plug is properly tightened and connect the cables to the oil pressure sensor, generator and starter motor. Tightening torque 25 Nm (19 lbf ft).

Scheme 257

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 258

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 259

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

Scheme 260

Scheme 261

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»(ref-212206-S05137803222005122200000) regarding dimensions.

Scheme 262

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 263

Scheme 264

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»(ref-212206-S05137803222005122200000) regarding dimensions.

Scheme 265

Scheme 266

Scheme 267

Scheme 268

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 «83 95 238 WEDGE»(ref-212206-S22330348352005122200000) 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 «83 94 868 FLYWHEEL LOCKING ATTACHMENT»(ref-212206-S33849643872005122200000) .
6. Remove the crankshaft pulley.
7. Use a screwdriver to prise out the old seal, taking care not to damage the sealing surface.

Scheme 269

Scheme 270

Scheme 271

Scheme 272

1. Fit a new seal using fitting tool for crankshaft seal, timing chain end «83 94 876 FITTING TOOL, CRANKSHAFT SEAL»(ref-212206-S31748745692005122200000) .
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 right-hand 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 273

1. (man.) Remove the gearbox, see «TO REMOVE»(ref-212206-S19012290132005122200000) under Manual gearbox. (aut.) Remove the gearbox, see " «COMPLETE AUTOMATIC TRANSMISSION»(ref-212247-S15185553412005122300000) " under Automatic transmission.
2. Remove the clutch and pressure plate, see «CHANGING THE COMPLETE CLUTCH»(ref-212248-S25619514562005122300000) .
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 274

1. Grease the gasket and place it on fitting tool for crankshaft seal, flywheel end «83 94 884»(ref-212206-S27602724302005122200000) 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 flywheel 80 Nm (59 lbf ft) driven plate 95 Nm (70 lbf ft).
3. Fit the clutch and pressure plate, see «CHANGING THE COMPLETE CLUTCH»(ref-212248-S25619514562005122300000) .
4. (man.) Fit the gearbox, see «TO FIT»(ref-212206-S12057024752005122200000) under manual gearbox. (aut.) Fit the gearbox, see " «COMPLETE AUTOMATIC TRANSMISSION»(ref-212247-S15185553412005122300000) ".

Scheme 275

Scheme 276

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 «83 95 238 WEDGE»(ref-212206-S22330348352005122200000) 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 277

Scheme 278

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 279

Scheme 280

Scheme 281

1. Remove the cover over the intake manifold.
2. Raise the car. Remove the right-hand front wheel and detach the power steering pump from the subframe.
3. Insert a «83 95 238 WEDGE»(ref-212206-S22330348352005122200000) between the oil sump and subframe so that it can later be driven in to raise the engine on assembly.
4. Remove the right-hand engine mounting with yoke.
5. 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, as shown. IMPORTANT: Exercise the utmost care to ensure that the belt tensioner does not break at its end position!
6. Remove the flywheel cover plate and fit «83 94 868 FLYWHEEL LOCKING ATTACHMENT»(ref-212206-S33849643872005122200000)
7. Remove the crankshaft pulley. Remove and clean the oil sump circlip. Use circlip pliers 82 93 086 Lift off the pump cover with large multigrip pliers. Remove the pump gears. NOTE: Two bent welding rods can be used to assist in the removal of the outer pump gear.

Scheme 282

Scheme 283

Scheme 284

Scheme 285

Scheme 286

1. Make sure that the marking on the oil pump ring gear is facing out and the pump gear with flange facing in. Check the position and condition of the O-ring, lubricate with vaseline.
2. Oil and fit the pump gears, fit the pump cover in correct position using the locating arrows.
3. Fit the circlip with the chamfer facing outwards and the opening downwards.
4. Fit the crankshaft pulley. Tightening torque 175 Nm (130 lbf ft).
5. Remove the flywheel locking segment and fit the flywheel cover plate.
6. Drive in the wedge to raise the engine.
7. Fit the drive belt, check its position on all the pulleys and remove the strain-relieving hexagon key.
8. Fit the right-hand engine mounting. Tightening torque 50 Nm (37 lbf ft).
9. Remove the wedge and fit the power steering pump pipe.
10. Fit the wheel. Tightening torque: 110 Nm (80 lbf ft). IMPORTANT: The wheels must be hanging freely when the wheel bolts are tightened.
11. Start the engine and run it at idling speed for a while.
12. Switch off the engine and check that the belt is correctly positioned.
13. Fit the cover over the intake manifold.

Scheme 287

Scheme 288

Scheme 289

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 breather hose from the oil sump.
10. Remove the bolts on the oil sump and lower the sump.

Scheme 290

Scheme 291

Scheme 292

Scheme 293

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.
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.

Scheme 294

Scheme 295

Scheme 296

Scheme 297

Scheme 298

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 breather 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 PHY 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 299

Scheme 300

Scheme 301

Scheme 302

Scheme 303

Scheme 304

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 breather 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.
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 305

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.

Scheme 306

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.

Scheme 307

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 308

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-212206-S33680839722005122200000) .
4. Lower the car, fit the cover and check the oil level. Top up 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 309

1. Remove the cylinder head and the cylinder head gasket, see «CYLINDER HEAD»(ref-212206-S36619655502005122200000) 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-212206-S36619655502005122200000) .

Conditions

The following conditions apply for this fault symptom

The fault symptoms may be caused by clogged pipes in the camshaft cover, which can produce excess pressure in the crankcase.

Scheme 310

Scheme 311

1. Remove the ignition discharge module.
2. Remove the camshaft cover.
3. Clean the two crankcase ventilation pipes. Use a 6 mm fuel hose connected to compressed air. If necessary, use a piece of wire.
4. Fit the camshaft cover as described under Cylinder head, " «Fitting of cylinder head (in car)»(ref-212206-S15944449872005122200000) For fitting cylinder heads (in situ)", steps 13-14.
5. Fit the ignition discharge module.

Scheme 312

Check the level while the engine is still warm, 2-5 minutes after switching off.

Top up with oil to the MAX mark on the dipstick. The distance between the MAX and MIN marks corresponds to 1 litre (1.05 qts).

Oil type

See supplemental information in owners manual.

Scheme 313

Scheme 314

Apply the handbrake. Start the engine and run it at idling speed. Select D and wait at least 15 seconds. Then select R and wait another 15 seconds. Repeat in position P.

Check the fluid level (engine running at idling speed and selector lever in P). Top up as necessary.

Oil type

Texaco Texamatic Dexron III automatic transmission fluid (mineral oil based) (7045 EU, TL 1863 US).

Scheme 315

Check the level and top up as necessary. If the fluid level is low, investigate the cause.

Oil type

Power steering fluid CHF 11S, part no. 30 32 380.

Spark plugs

SPARK PLUG SPECIFICATION

MOTOR DESIGNATION

Tightening torque: B205E/B235E/B235R: 28 Nm (21 lbf ft) - B308E: 27 Nm (20 lbf ft) Electrode gap

Measure electrode gap with a wire gauge

Scheme 316

Scheme 317

Checking for oil leaks

Check that no oil leaks from the top or bottom of the engine and gearbox or the power steering's hydraulic system.

If there is an oil leak on the auxiliaries side of the engine, it is recommended that the drive belt is inspected and replaced if necessary.

Scheme 318

Change the oil. Fill to the MAX mark. The distance between the MAX and MIN marks is equivalent to 1 litre (1.05 qts).

Check the level while the engine is warm, 2-5 minutes after it has been turned off.

See owners manual.

Tightening torque, drain plug

B205E, B235E, B308E: 25 Nm (19 lbf ft)

Check the oil level after changing the engine oil and oil filter.

Scheme 319

Scheme 320

Scheme 321

1. Slacken the oil filter with the filter wrench and unscrew it. Clean the sealing surface on the engine.
2. Oil in the new oil filter's rubber gasket and fit it in place. Tighten the filter by hand.
3. Start the engine and check the filter for leaks.

SPARK PLUG SPECIFICATION

ENGINE DESIGNATION

Tightening torque: B205E/B235E/B235R: 28 Nm (21lbf ft) - B308E: 27 Nm (20 lbf ft) Electrode gap

Spark plugs should be checked with a wire gauge.

Scheme 322

Scheme 323

Check that the marking on the moving part of the belt tensioner is between the two markings on the fixed part.

Check also the operation and condition of the belt tensioner by pressing against the belt. The belt should become taut again smoothly.

Check value for drive belt: Min 170 N (40 lbf).

Use 83 93 985 Belt tension meter.

Checking condition of belt

The belt must not be cracked or flaking.

If there are any cracks or other defects on the belt profile or back, it must be replaced with a new one.

Drive belts, change (4-cyl.)

When changing the drive belts, see CYLINDER HEAD .

Scheme 324

Coolant

Check the level and top up as necessary with equal amounts of SAAB Original Coolant and water (half and half).

This mixture also provides effective corrosion protection.

Avoid mixing different types of coolant.

Do not fill up above the MAX mark.

In the event of coolant loss, investigate the cause.

Scheme 325

Check the level and top up as necessary.

Brake fluid

Grade to DOT 4 specification.

Scheme 326

(Only B205E engine with tuning kit)

Change to NGK BCP R6 ES-11 spark plugs.

Electrode gap: 1.0-1.1 mm (0.039-0.043 in).

Scheme 327

The ejector kit is supplied with the car.

1. Undo the 4 rear bolts securing the center spoiler shield.
2. Fit the ejector with the bolts included in the kit.

Scheme 328

86 12 798 Toolboard T1 Service

Used together with 30 05 477 Cooling system tester

Group: Engine

ADAPTER COOLING SYSTEM TESTER SPECIFICATION

Scheme 329

Used for coolant, washer fluid and battery acid.

86 12 798 Toolboard T1 Service

Group: Engine

TOOLBOARD T1 SERVICE SPECIFICATION

Scheme 330

Group: Engine

PLASTIGAUGE SPECIFICATION

Scheme 331

86 12 822 Toolboard T3 Engine

Group: Engine

TOOLBOARD T3 ENGINE SPECIFICATION

Scheme 332

Group: Engine

DIAL GAUGE SPECIFICATION

Scheme 333

Used together with 78 74 878 FLOOR STAND

Group: Automatic gearbox

AUTOMATIC GEARBOX SPECIFICATION

Scheme 334

86 12 822 Toolboard T3 Engine

Group: Engine

TOOLBOARD T3 ENGINE SPECIFICATION

Scheme 335

86 12 822 Toolboard T3 Engine

Group: Engine

TOOLBOARD T3 ENGINE

Scheme 336

Group: Engine

PISTON FITTING TOOL SPECIFICATION

78 74 878 Floor stand

Group: Engine, Manual gearbox

Used together with 83 94 751 Holder, engine

FLOOR STAND SPECIFICATION

Scheme 337

For chain tensioner, 4 cyl.. FACOM 427 NSB

Help tools (not included on toolboard)

Group: Other tools

Scheme 338

Help tools (not included on toolboard)

Group: Misc.

TEMPLATE SPECIFICATION

Scheme 339

Reading for bearing preload

86 12 855 Toolboard T5 Automatic Transmission

Group: Engine

TOOLBOARD T5 AUTOMATIC TRANSMISSION SPECIFICATION

Scheme 340

86 12 830 Toolboard T4 Manual Gearbox

Use with 83 90 858 Pin

Group: Manual gearbox

TOOLBOARD T4 MANUAL GEARBOX SPECIFICATION

Scheme 341

Used together with 78 74 878 FLOOR STAND .

Group: Manual gearbox, Automatic gearbox, Engine

AXLE SPECIFICATION

Scheme 342

Used together with 83 90 270 SLIDING HAMMER

JOURNAL SPECIFICATION

Scheme 343

86 12 798 Toolboard T1 Service

Group: Engine

TOOLBOARD T1 SERVICE SPECIFICATION

Scheme 344

Group: Engine

LIFTING SLING SPECIFICATION

Scheme 345

Group: Engine

WRENCH SMALL OIL FILTER SPECIFICATION

Scheme 346

Group: Engine

WRENCH, KNOCK SENSOR AND OIL PRESSURE SWITCH SPECIFICATION

Scheme 347

Required number 16

86 12 822 Toolboard T3 Engine

Group: Engine

PROTECTIVE COLLAR SPECIFICATION

Scheme 348

86 12 822 Toolboard T3 Engine

Group: Engine

MEASURING BRIDGE VALVE POSITION SPECIFICATION

Scheme 349

86 12 822 Toolboard T3 Engine

Used together with 83 93 779 TAPPETS

Group: Engine

VALVE SPRING TOOL SPECIFICATION

Scheme 350

Used together with 83 93 761 Valve spring tool

Group: Engine

TAPPETS SPECIFICATION

Scheme 351

86 12 822 Toolboard T3 Engine

Group: Engine

VALVE STAND SPECIFICATION

Scheme 352

86 12 822 Toolboard T3 Engine

Used together with 78 61 040 Valve seat cutter, 11° and 45° o/34.5 mm

Group: Engine

VALVE SEAT CUTTERS SPECIFICATION

Scheme 353

86 12 822 Toolboard T3 Engine

Group: Engine

PLIERS VALVE GUIDE SEAL SPECIFICATION

Scheme 354

86 12 822 Toolboard T3 Engine

Used on 9-3 together with 83 94 207 FITTING TOOL and 83 94 181 Dismantling tool

Group: Engine

COMPRESSED AIR ADAPTER FOR SPARK PLUG HOLE SPECIFICATION

Scheme 355

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

REMOVAL TOOL SPECIFICATION

Scheme 356

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

FITTING TOOL SPECIFICATION

Scheme 357

86 12 822 Toolboard T3 Engine

Group: Engine

BALANCER SHAFT BEARING PRESS SPECIFICATION

Scheme 358

For adjusting basic charging pressure, Turbo

86 12 822 Toolboard T3 Engine

Use together with

Group: Engine

WRENCH LOCK NUT SPECIFICATION

Scheme 359

86 12 822 Toolboard T3 Engine

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

Group: Engine

REMOVAL TOOL SPECIFICATION

Scheme 360

86 12 822 Toolboard T3 Engine

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

Group: Engine

FITTING TOOL SPECIFICATION

Scheme 361

86 12 822 Toolboard T3 Engine

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

Group: Engine

FIXTURE SPECIFICATION

Scheme 362

Timing end

Group: Engine

86 12 798 Toolboard T1 Service

FITTING TOOL CRANKSHAFT SEAL SPECIFICATION

Scheme 363

Flywheel end

86 12 798 Toolboard T1 Service

Group: Engine

FITTING TOOL CRANKSHAFT SEAL SPECIFICATION

Scheme 364

4-cyl, V6

86 12 822 Toolboard T3 Engine

Group: Engine

FITTING TOOL VALVE STEM GASKET SPECIFICATION

Scheme 365

For unloading the belt tensioner

86 12 798 Toolboard T1 Service

Group: Engine

DRAWBAR HANDLE HYDRAULIC BELT TENSIONER SPECIFICATION

Scheme 366

For parting the fuel line and tank ventilation

Group: Engine

FUEL LINE TOOL

Scheme 367

For lifting the engine

86 12 798 Toolboard T1 Service

Group: Engine

HOLDER SPECIFICATION

Scheme 368

Group: Miscellaneous

TROLLEY LIFT SPECIFICATION

Scheme 369

Sensor for Motometer compression gauge

86 12 871 Toolboard T7 Diesel 4-cyl

Group: Engine

ADAPTER COMPRESSION PRESSURE SENSOR SPECIFICATION

Scheme 370

86 12 798 Toolboard T1 Service

Group: Engine

SPARK PLUG SOCKET ASSEMBLY WITH LOCATING SLEEVES SPECIFICATION

Scheme 371

For pressurizing cylinders, e.g. when changing valve seals

86 12 871 Toolboard T7 Diesel 4-cyl

Used together with 83 95 345 ADAPTER, COMPRESSION PRESSURE SENSOR

Group: Engine

AIR NIPPLE SPECIFICATION

Scheme 372

Spare part for lifting beam

Used together with 83 94 850 LIFTING BEAM

Group: Engine

BEAM SPECIFICATION

Scheme 373

Used together with 83 94 850 LIFTING BEAM

Group: Engine

BEAM SPECIFICATION

Scheme 374

86 12 798 Toolboard T1 Service

Group: Body

PULLER WINDSCREEN WIPER ARM SPECIFICATION

Scheme 375

Allows independent placement of floor stand.

Used together with 78 74 878 FLOOR STAND

Group: Engine

FLOOR STAND SPECIFICATION

Scheme 376

86 12 830 Toolboard T4 Manual Gearbox

Group: Automatic transmission

BRACKET DIAL GAUGE SPECIFICATION

Scheme 377

86 12 855 Toolboard T5 Automatic Transmission

Used together with 78 40 622 Dial indicator

Group: Engine

CONTACT POINTS SPECIFICATION

Scheme 378

Group: Manual gearbox

DIAL GAUGE KIT SPECIFICATION

Scheme 379

For adjusting gear lever position (x2)

86 12 798 Tool board T1 Service

Group: Manual gearbox

TOOL BOARD T1 SERVICE SPECIFICATION

Scheme 380

86 12 798 Toolboard T1 Service

Group: Manual gearbox, Automatic transmission

TOOLBOARD T1 SERVICE SPECIFICATION

Scheme 381

(9-3 Viggen)

86 12 830 Toolboard T4 Manual Gearbox

Group: Automatic transmission, Manual gearbox

TOOLBOARD T4 MANUAL GEARBOX SPECIFICATION

Scheme 382

Removing the ball joint and steering link

86 12 814 Toolboard T2 Chassis-Body

Group: Chassis

PULLER SPECIFICATION

Scheme 383

86 12 798 Toolboard T1 Service

Group: Manual gearbox

CENTERING DRIFT CLUTCH DISC, 6-SPEED TRANSMISSION SPECIFICATION

Scheme 384

GENERAL DATA

Scheme 385

Cylinder bore

ENGINE BLOCK SPECIFICATION

Scheme 386

CYLINDER HEAD SPECIFICATION

General data

GENERAL DATA

Control values, pressure

CONTROL VALUES PRESSURE

Scheme 387

Piston types

PRESSURE CONTROL VALUES SPECIFICATION

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 SPECIFICATION

Scheme 388

PISTON RINGS

Gudgeon pins

GUDGEON PINS SPECIFICATION

Scheme 389

CONNECTING RODS COMPONENTS

Scheme 390

GENERAL DATA SPECIFICATION

Scheme 391

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)

COLOUR CODING

Main journal diameter (2)

MAIN JOURNAL SPECIFICATION

Scheme 392

1. Exhaust valve
2. Inlet valve

VALVE GEAR SPECIFICATION

Valve guides

VALVE GUIDES

Maximum lateral clearance between valve stem and valve guide

VALVE GUIDES

Scheme 393

Valve springs (double springs)

VALVE SPRINGS SPECIFICATION

Tappets

TAPPETS

Scheme 394

GENERAL DATA

Valve timing

VALVE TIMING SPECIFICATION

Scheme 395

GENERAL DATA

Scheme 396

Scheme 397

DRIVE-BELT TENSION SPECIFICATION

Scheme 398

GENERAL DATA

Scheme 399

Oil pressures

OIL PRESSURES SPECIFICATION

Scheme 400

ENGINE SERIAL SPECIFICATION

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 aluminum 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 401

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 402

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 center 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 403

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 center 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 center 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 aluminum 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 404

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 405

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 spring-loaded 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 406

Oil sump

The oil sump is in cast aluminum. Apply sealing compound (Loctite 518) directly to the flat surface of the flange. The B235R with manual gearbox has a reinforcement piece on the left-hand side of the sump that rests 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 407

Scheme 408

Drive belt routing, with and without A/C compressor

1. Generator
2. Belt tensioner
3. Idler sprocket
4. Idler sprocket
5. Power steering pump
6. Water pump
7. A/C compressor
8. 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 409

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.