Basic Engine, 4-CYLINDER Petrol: Removal & Installation Saab 9-5 I рестайлинг

Removal of pistons (in situ)

The method requires cylinder head removal, see CYLINDER HEAD

Scheme 13

Scheme 14

1. Remove any burrs or carbon deposits from the tops of the cylinders.
2. Fit «83 94 850 LIFTING BEAM»(ref-212206-S21504477522005122200000) to keep the engine raised.
3. Remove subframe and oil sump, see «OIL SUMP (IN CAR)»(ref-212206-S01005113872005122200000)
4. Wipe up any dripping oil.
5. Remove the big-end caps and fit Protective collars «75 19 531 Protective collar (type 10)»(ref-212206-S41071964082005122200000) on the studs. Push the pistons and connecting rods out of the cylinder bores. Note the markings on the pistons and connecting rods so that they can be refitted in their original positions. Loosely fit the bearing shells and caps on the connecting rods so that each set is kept separate and the parts are not mixed. IMPORTANT: If one connecting rod is to be changed to a newer type (part no. 91 97 617), all the connecting rods must be changed or the difference in weight will become too great.
6. Remove the gudgeon pin circlips and drive out the gudgeon pins, using a plastic mallet and drift.

Scheme 15

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

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

Example cylinder classification A piston type A.

Scheme 16

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

To remove

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

Scheme 17

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

Scheme 18

1. Raise the car and place a receptacle under the engine to collect the oil.
2. Remove the lower banjo screw from the oil pipe to the turbocharger by the oil filter intermediate piece and allow the engine oil to drain.
3. Connect the banjo screw on the gauge equipment, 8395576, (included in Pressure gauge equipment, fuel pressure 83 93 852) and tighten it. Connect the hose with pressure gauge included in the pressure gauge equipment to the outlet on the banjo screw.
4. Lower the car to the floor.
5. Position the pressure gauge so that it can be read from inside the car. IMPORTANT: Make sure the pressure gauge hose is not resting against warm or sharp details.
6. Start the engine and read off the oil pressure. See «OIL PRESSURES»(ref-212206-S19888455642005122200000)
7. Leave the engine idling to reduce the turbo speed. Turn off the engine.
8. Raise the car.
9. Remove the pressure gauge equipment.
10. Fit the oil pipe banjo screw with new seals. Wipe of any oil spill
11. Lower the car, check the oil level and adjust as necessary.

For timing chain removal

86 12 822 Toolboard T3 Engine

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

Group: Engine

CHAIN LOCK SPECIFICATION

Scheme 19

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

Group: Engine

TIMING CHAIN SPECIFICATION

Scheme 20

Group: Engine

ADAPTER FUEL PRESSURE TESTING

Scheme 21

Group: Engine, Manual gearbox

BEAM SPECIFICATION

Scheme 22

86 12 798 Toolboard T1 Service

Group: Engine

FLYWHEEL LOCKING ATTACHMENT SPECIFICATION

Scheme 23