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

To assemble the engine

Wash all sealing surfaces with benzine, making sure that they are perfectly clean.

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1. Fit the piston cooling nozzles. Place all main bearings in their correct positions and coat them with oil. Tightening torque: 18 Nm (13 lbf ft). IMPORTANT: Observe the utmost care when handling the slotted ring.
2. Fit the slotted ring, place the crankshaft in position and fit the two thrust washers at the main bearing between the No. 2 and No. 3 cylinders. Fit the washers with the embossed side facing towards the main bearing so that the bearing surface is the right way round.
3. Lubricate and fit all main bearing caps in their correct places, making sure that they are the right way round. Tightening torque 20 Nm + 70 (15 lbf ft + 70).
4. Turn the compression rings so that the gaps in the rings are moved 180 and located directly opposite the gudgeon pin ends. Also make sure that the upper and lower spring gap on the three-piece oil scraper ring are not lined up opposite each other.
5. Fit Protective collars «75 19 531 Protective collar (type 10)»(ref-212206-S41071964082005122200000) to the crankshaft studs, oil the pistons and rings, then fit the pistons in their respective cylinders. The arrow markings on the piston crowns should be turned towards the engine's timing chain end. Use «78 62 287 PISTON FITTING TOOL»(ref-212206-S02794003052005122200000) and carefully tap down the pistons in the bores.
6. Lubricate and fit all big-end bearing caps in their original positions, making sure that they are the right way round (number to number, groove in shell to groove in shell). Tightening torque with nut 20 Nm + 70 (15 lbf ft + 70) Tightening torque with bolt 25 Nm + 100 (18 lbf ft + 100)
7. Apply a bead of Loctite 518 about 1 mm thick on the end plate's mating surface and fit the plate in place. Mind the seal.
8. Align the crankshaft with the wedge straight up (corresponding to the 0 mark on the crankshaft pulley).
9. Fit the flywheel or the driven plate, using Loctite 270D on the bolts.
10. Fit «83 94 868 FLYWHEEL LOCKING ATTACHMENT»(ref-212206-S33849643872005122200000) and tighten the bolts. Tightening torque, flywheel and drive plate 20 Nm +50° (15 lbf ft +50°)
11. Lubricate the bearing surfaces on the balancer shafts and in the bearing housings and insert the balancer shafts into their respective tunnels, taking the utmost care to avoid damaging the bearing shells inside. IMPORTANT: The shaft with the smaller thrust ring marked INL should be mounted on the inlet side and the shaft with the larger thrust ring marked EXH should be mounted on the exhaust side.
12. Check the timing chain and fit the sprocket and chain onto the crankshaft end, marking to marking, and bolt the safety plate in place.
13. First fit the fixed chain guide, which is common to the timing chain and balancer-shaft chain, and then the pivoted chain guides for the timing and balancer-shaft chains.
14. Fit the balancer-shaft sprocket and the oil-pump driver onto the crankshaft end.
15. Cock the chain tensioner and insert a paper clip or similar object through the hole in the cylinder to prevent triggering of the tensioner. Before this, check that the plunger is turned to the position where it really is pressed out by the spring.
16. Fit the chain tensioner. Tightening torque: 10 Nm (7 lbf ft). WARNING: It is extremely important for the function that the correct torque is applied when fitting.
17. Inspect the balancer-shaft chain and fit it and the idler sprocket so that the upper setting marks behind the balancer-shaft sprocket and bearing housing are in line with each other. Tauten the chain between the crankshaft and balancer shafts. Fit the idler sprocket last. Hold the bolt in place with your thumb, mesh the teeth of the sprocket with the chain and roll it along the chain into position.
18. Check the marking on the balancer-shaft sprocket and remove the flywheel locking segment.
19. Setting: Fit the timing cover using two bolts only and do not tighten them. Mount the crankshaft pulley. Rotate the pulley one revolution. Reset the crankshaft relative to the timing cover. Remove the timing cover and crankshaft pulley carefully, making sure that the crankshaft does not move, and check the settings of the balancer shafts.
20. Check that the timing cover joint face is perfectly clean. Apply Loctite 518 in an approx. 1 mm bead on the timing cover. Apply the bead in the middle of the mating faces.
21. Fit the timing cover. Tightening torque 22 Nm (16 lbf ft).
22. Fit the oil pump, flywheel locking segment and crankshaft pulley. Remove the flywheel locking segment. Tightening torque 175 Nm (130 lbf ft).
23. Fit the oil pump pressure pipe and check that there are no impurities or other foreign matter in the oil sump.
24. Fit the adapter housing and oil filter.
25. Check that the mating surface of the oil sump is perfectly clean and apply an even coating of Loctite 518 along it. Turn the engine to a suitable position and fit the oil sump. Tightening torque 22 Nm (16 lbf ft).
26. Carefully clean all sealing surfaces. Apply a 2 mm thick and 10-20 mm long bead of Loctite 518, part No. 93 21 795, 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 fit the cylinder head using a new gasket. Check that it is correctly seated on the locating sleeves and that the chain runs freely. Tighten the cylinder head bolts in three stages: Step I: 40 Nm (30 lbf ft) Step II: 60 Nm (44 lbf ft) Step III: Tighten a further 90 Tighten the bolts in the order shown in the illustration.
27. Fit the two screws between the timing cover and the cylinder head. Tightening torque 22 Nm (16 lbf ft).
28. Remove the rubber band and check that the camshafts are in alignment with their setting marks and turn the crankshaft back to the 0 mark.
29. Fit the camshaft sprockets and chain. Start with the camshaft on the exhaust side. The marking on the sprockets should be in the center of the chain markings (only when the engine is fully zeroed, i.e. crankshaft aligned with the 0 mark). Do not tighten the bolts yet.
30. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.
31. Fit the chain tensioner, using a 27 mm socket. Tightening torque 63 Nm (47 lbf ft).
32. Fit the chain tensioner plug with push rod and spring. Tightening torque 22 Nm (16 lbf ft).
33. 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.
34. Tighten the camshaft sprocket bolts. Tightening torque 63 Nm (47 lbf ft).
35. Fit the spark plugs. Tightening torque 28 Nm (21 lbf ft).
36. Clean the sealing surface of the camshaft cover with benzine.
37. Apply oil to the camshaft cover's opening and fit the cover, starting at the opening. 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).
38. Fit the ignition discharge module. Tightening torque 11 Nm (8 lbf ft).
39. Fit the crankshaft position sensor.
40. Check the coolant pump O-rings, and replace 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. Grease the O-rings with acid-free petroleum jelly and fit the coolant pump and coolant pipes from the expansion tank and heat exchanger. Fit the clips for the crankshaft position sensor cable at the same time.
41. Fit a new gasket for the exhaust manifold.
42. Fit the turbocharger with exhaust manifold and steady bar. Tightening torque 25 Nm (19 lbf ft).
43. Fit the crankcase breather pipe together with the intake manifold. Mind the O-ring.
44. Connect the coolant and oil pipes. IMPORTANT: The rubber seals should be placed against the adapter housing, or water pump and cylinder head.
45. Fit the power steering pump with bracket and fit the turbo wastegate.
46. Fit the A/C compressor bracket.
47. Fit the heat shield over the turbocharger.
48. Clean all gasket surfaces between the intake manifold and cylinder head.
49. Align the intake manifold gasket with the aid of the outer retaining bolts and fit the intake manifold. Tightening torque 22 Nm (16 lbf ft).
50. Reconnect the hoses from the throttle body.
51. Plug in all electric connectors between the intake manifold and the remainder of the power train and fit its bracket in the lifting lug.
52. Fit the pressure pipe between the throttle body and charge air cooler.
53. Connect the crankcase breather pipe to the turbocharger's inlet pipe and plug in the wiring.
54. Fit the oil filler pipe with bracket.
55. Check that the torque converter bottoms in the transmission casing and that the locking screw is fitted (aut.). Fit the automatic transmission in place and tighten the bolts.
56. Fit the torque converter bolts (aut.). Apply Loctite 270D to the threads. Turning torque 60 Nm (44 lbf ft).
57. Fit the flywheel cover.
58. Fit a lifting sling to the engine and lift it off the stand.
59. Remove the holder and fit the rear engine mounting bracket and gearbox retaining bolt.
60. Position the engine on the subframe and fit the rear engine mounting, tightening it with a torque wrench. Tightening torque 50 Nm (37 lbf ft).
61. Fit the front exhaust pipe with sensor. Fit the gearbox steady bar and tighten it, using a torque wrench.
62. Fit the bearing bracket with intermediate shaft and inboard drive-shaft joint.
63. Fit the oil trap and connect its hoses.
64. Fit the intake manifold steady bar.
65. Fit and connect the generator, starter motor and belt tensioner.
66. Check that the oil plug is properly tightened. The power train is now ready for fitting in the car. Tightening torque 25 Nm (19 lbf ft).

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1. Remove the blanking-off washer.
2. Insert press tool «83 94 470»(ref-212206-S00570477812005122200000) from the flywheel side and connect the pull rod with a nut.
3. Carefully remove the bearing by slowly tightening the nut.

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1. Clean the bearing surface in the cylinder block.
2. Fit the bearing on press tool «83 94 470»(ref-212206-S00570477812005122200000) .
3. Insert the fitting tool from the flywheel end and connect the pull rod with nut.
4. Tighten the nut until the mark on the tool is 5 mm from the edge of the hole for the blanking-off washer. The bearing is now in the correct position.
5. Dismantle and remove the tool.
6. Check that the oil passage is open by blowing compressed air through the center main bearing.
7. Fit a new blanking-off washer.

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1. Run the engine at idling speed. 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 right front wheel and disconnect the steering servo pipe from the subframe.
3. Drive in a «83 95 238 WEDGE»(ref-212206-S22330348352005122200000) 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. Take the strain off the belt tensioner with Drawbar handle, hydraulic belt tensioner «83 95 254»(ref-212206-S26192481942005122200000) and insert a 3.5 mm Allen key in the hole. Remove the multigroove belt. IMPORTANT: Be careful so that the belt tensioner does not crack at its end position!
10. Remove the belt tensioner. Loosen 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. Remove the throttle cable and the dipstick with tube, and undo the fuel hoses using tool 83 94 702.
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 form the turbocharger and exhaust manifold.
19. Remove the four retaining nuts between the exhaust manifold and the turbocharger. Heat the nuts carefully if they stick.
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's 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 lower/center 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's 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. Fit the inner gasket for the camshaft cover partition with gasket adhesive, part no. 46 20 084.
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 Loctite 518, part no. 93 21 795, 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 push 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 is 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. Relieve the belt tensioner with Reliever «83 95 254»(ref-212206-S26192481942005122200000) and remove the Allen key.
35. Fit the lifting eye, press the rubber in position and plug in the solenoid valve's 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. Tightening torque 110 Nm (80 lbf ft) Important The wheels must be hanging freely when the wheel bolts are tightened.
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 valve on the radiator first. Refer to «COOLANT»(ref-212206-S17652870372005122200000) 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. Reset the clock and radio code. Calibrate the ACC.

Crankshaft assembly

The crankshaft is a forging and has ground journals, which are surface-treated by induction hardening. This produces a hard surface finish which is highly resistant to wear. There are five main bearings, with the middle one also serving to locate the crankshaft axially. Oilways are drilled in the crankshaft for lubrication. All main bearing shells are replaceable.

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