Basic Engine, V6: Other Saab 9-5 I рестайлинг

Matching in worn cylinder bore

Matching is carried out in the same way as with a new or rebored cylinder, but when matching in a worn cylinder bore the rings must be tested in the bottom dead centre position because the cylinder bores there have the smallest diameter.

Scheme 597

Use a piston ring clamp when fitting the rings in the piston. The lower compression ring should be turned so that the side marked "top" is uppermost. Test the piston rings by rotating them in their grooves. Also check the clearance at several places.

I = Front marking on piston crown, arrow points to timing end.

1. = Upper compression ring
2. = Lower compression ring
3. = Steel strip ring (upper oil scraper ring)
4. = Middle ring (oil scraper ring)
5. = Steel strip ring (lower scraper ring)

Oil the piston and rings before fitting. Turn the compression rings so that their gaps are staggered 180°, placing them in line with the ends of the gudgeon pins. Ensure also that the spring gaps in the top and bottom rings of the three-piece oil scraper ring are placed opposite each other.

Scheme 598

Matching of pistons

When matching pistons in the cylinder bores, use a 1/2" wide feeler gauge. For measurement, the cylinder bore should be lightly oiled and the piston, without rings, should be placed in the bore where it is to work. Hook a spring balance to the feeler gauge and insert the gauge between piston and 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 carried out at several different levels. In regard to piston clearance, See Pistons .

Scheme 599

Pistons, to fit (in car)

(Cylinder head removed)

Scheme 600

Pistons are stocked as spare parts in standard sizes and oversizes. In the case of oversize pistons, the cylinder must be rebored to achieve the correct piston clearance.

Regarding piston clearances, See Pistons .

Scheme 601

Scheme 602

Scheme 603

1. Assemble piston and connecting rod by tapping the gudgeon pin in with a plastic mallet and drift. Make sure that the marking on the piston points to the timing end of the engine and that the protuberance on the connecting rod points to the flywheel end.
2. Fit the gudgeon pin circlip. WARNING: It is extremely important to fit the circlip with its opening upwards.
3. Place the bearing shells in place in the connecting rods.
4. Oil the piston rings, bearings and cylinders.
5. Fit the pistons using fitting ring 83 95 113.
6. Fit the bearing cap with bearing shell. Tightening torque: 35 Nm (26 lbf ft) +45° +15° IMPORTANT: The contact surfaces of the connecting rod and big-end bearing cap must be clean and in perfect condition. If the contact surfaces are damaged in any way, the connecting rod must be changed as an accurate fit cannot then be assured. Clean the contact surfaces with compressed air.
7. Check that there are no impurities in the sump and clean the mating surfaces. Use benzine.
8. Seal all partition joints with part No. (10) 81 52 381.
9. Fit a new gasket and fit the antislosh baffle plate, the oil strainer and the sump. Apply part No. (10) 74 96 268 to the bolts. Tightening torque: Antislosh baffle plate: 8 Nm (6 lbf ft) Oil strainer: 8 Nm (6 lbf ft) Sump: 15 Nm (11 lbf ft)
10. Tighten the drain plug. Tightening torque: 25 Nm (18.5 lbf ft)
11. Lower the car.

Valve gear, to fit

(Cylinder head removed)

Scheme 604

Scheme 605

1. Fit the valves, washers and valve springs.
2. Use valve spring compressor «83 95 246 Valve spring compressor»(ref-212208-S01194638132005122300000) to fit the spring caps and tappets.
3. Remove the protective sleeves and refit the tappets.
4. Coat the cylinder head contact surfaces of the front bearing caps sparingly with part No. (10) 74 96 268, see illustration below. Fit the camshafts, stuffing boxes and bearing caps, starting where the cams point downwards and press on the tappets.

Cylinders 1-3-5 (rear)

The locating pins for the camshafts should point to the inside bolts for the camshaft bearing caps.

Cylinders 2-4-6 (front)

The locating pins for the intake camshaft should be in line (downwards) with the inside bolts for the camshaft bearing caps.

The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head.

Tightening torque: 8 Nm (6 lbf ft)

Scheme 606

Scheme 607

Scheme 608

Scheme 609

Scheme 610

Scheme 611

Scheme 612

Scheme 613

Scheme 614

Scheme 615

Scheme 616

Scheme 617

1. Drape the wing protectors over the wings and remove the engine cover.
2. Disconnect the negative cable from the battery.
3. Open the cap on the expansion tank and release the pressure.
4. Raise the car.
5. Remove the lower spoiler sections.
6. Drain the coolant from the radiator.
7. Insert two «83 95 238»(ref-212208-S14859113752005122300000) Wedges, between the oil sump and subframe and between the gearbox and subframe.
8. Lower the car to the floor.
9. Remove the mass air flow sensor with hose.
10. Detach the power steering hose from the holder.
11. Remove the right-hand engine attachment with bracket and engine mount.
12. Undo the retaining bolts from the coolant pump pulley and power steering pump pulley
13. Release the multigroove belt from tension.
14. Remove the coolant pump pulley and power steering pump pulley.
15. Remove the belt tensioner and generator air intake.
16. Remove the timing cover.
17. Remove the crankshaft pulley.
18. Unhook the throttle cable.
19. Remove the vacuum hoses and unplug the pressure sensor's connector from the upper intake manifold.
20. Detach the vacuum hose and the two water hoses from the throttle. Remove the turbo pressure hose with charge air bypass pipe. Unplug the throttle's connector and detach the venting-valve hose from the underside of the throttle.
21. Unplug the connectors for the ignition discharge module and injectors.
22. Detach the fuel lines.
23. Undo the upper intake manifold and move it aside.
24. Remove the middle intake manifold.
25. Remove the lower intake manifold. Plug the holes with paper or the like.
26. Zero the engine. The markings on the camshaft sprockets and the timing cover must be aligned, use Adjustment tool for camshaft sprockets and timing belt KM-800-20, as must the crankshaft marking. Fit the locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and locking tool KM-800-10 for the crankshaft.
27. Detach the tensioning pulley and the adjuster roller. Remove the guide roller. Use 83 94 983 Adjustment wrench, timing belt, V6 as counterstay on the adjuster rollers.
28. Mark the direction of rotation on the item to be refitted. In order to facilitate fitting the belt can be marked with each camshaft marking as well as with the crankshaft marking. Remove the tool KM-800-10 from the crankshaft. Remove the camshaft belt.
29. Remove the bracket with tensioning roller and the upper adjuster roller.
30. Rotate the crankshaft to 60° BTDC. Note the marking.
31. Remove the camshaft sprockets.
32. Remove the coolant pump.
33. Remove the inner timing cover.
34. Remove the ignition discharge module.
35. Remove the camshaft cover. Make sure that the O-rings are in place and that they do not fall into the engine.
36. Undo and remove the camshafts. Undo the bolts in stages, 1/2 to 1 turn at a time. Note the marking on the bearing caps. It is important to conclude removal at the bearing cap where the tappets are under load. Remove the stuffing boxes.
37. Lift out the tappets using tool 83 91 401.
38. Fit Protective collarspart no. 83 95 022 round the valve springs to protect the sealing surfaces of the tappets.
39. Rotate the crankshaft so the piston in the cylinder is in the upper stop position. Lock the engine with 83 94 868 Flywheel locking attachment and unscrew the spark plug for the cylinder. Use Spark plug socket part no. 83 95 485 and install the 83 94 173 compressed air adapter for spark plug hole. Connect compressed air and place the piston and valves under pressure.
40. Depress the valve heads using valve spring compressor 83 95 246 and remove the tappets.
41. Lift the spring cap and the valve spring and remove the valve stem seal with 83 94 157 Pliers for removing valve stem seal

Scheme 618

Scheme 619

Scheme 620

Scheme 621

Scheme 622

Scheme 623

Scheme 624

Scheme 625

Scheme 626

Scheme 627

Scheme 628

Scheme 629

Scheme 630

Scheme 631

Scheme 632

Scheme 633

1. Fit the valve stem seal to the valve. Use Assembly tool for valve stem sealpart no. 83 95 071 and a plastic mallet to carefully tap the seal into position.
2. Fit the spring and spring cap and place the collets in the spring cap groove.
3. Fit the valve cones with Valve spring compressor, part no. 83 95 246.
4. Disconnect the compressed air, remove the air nipple and the flywheel locking segment.
5. Fit the spark plugs using spark plug socket 83 95 485. Tightening torque: 25 Nm (18.5 lbf ft).
6. Remove the protective sleeves and fit the valve tappets.
7. Rotate the crankshaft to 60° BTDC
8. Place the camshafts in position and fit the stuffing boxes and bearing caps. Start where the cams point downwards and load the tappets. Coat the cylinder head contact surfaces of the front bearing caps sparingly with part No. (10) 74 96 268, see illustration below. Cylinders 1-3-5 (rear) The locating pin on the camshafts should point towards the inside bolts for the camshaft bearing caps. Cylinders 2-4-6 (front) The locating pin for the intake camshaft should be in line (downwards) with the inside bolts for the camshaft bearing caps. The guide pin for the exhaust camshaft should point straight up from the plane of the cylinder head. Tightening torque: 8 Nm (6 lbf ft) IMPORTANT: Tighten the bolts in stages - 1/2 to 1 turn at a time. The markings on the camshaft bearing caps and the cylinder head must match. The caps marked L1 - L8 are for the cylinder head with cylinders 1 - 3 - 5 and the caps marked R1 - R8 are for the cylinder head with cylinder 2-4-6. The camshaft bearing seats in each cylinder head are numbered 1 -8.
9. Check that the O-rings are in place in the camshaft cover and wipe clean. Lubricate with a soap solution and place part No. (10) 81 52 381 in the corners at the camshaft bearing caps. Fit the camshaft cover. Tightening torque: 8 Nm (6 lbf ft)
10. Fit the ignition discharge module.
11. Fit the inner (rear) timing cover.
12. Fit the camshaft sprockets correctly in relation to the locating pins. Tightening torque: 50 Nm (37 lbf ft) + 60°
13. Fit the coolant pump. Tightening torque: 25 Nm (18.5 lbf ft).
14. Fit the bracket with tensioning roller and the upper adjuster roller.
15. Fit Adjustment tools for camshaft sprockets and timing belt KM-800-1 on no. 1 and no. 2 camshaft sprockets and KM-800-2 on no. 3 and no. 4 camshaft sprockets.
16. Rotate the crankshaft to just before the 0° mark and fit tool KM-800-10. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump flange and remove the tool.
17. Fit the camshaft belt according to the markings on the belt and the marked direction of rotation. Use Adjustment tool for camshaft sprockets and timing belt KM-800-30 to keep the belt in place. Fit the guide roller. Make sure that the washer is in place. Carefully check that the markings on the timing belt are aligned with the corresponding markings on the camshaft sprocket. Raise the car and check the marking on the crankshaft. Lower the car and remove the tool KM-800-30. Fit the locking tool KM-800-10. Tightening torque, guide roller, 40 Nm (30 lbf ft)
18. Ensure the adjusting nut on the upper adjusting roller rotates freely and is not tight. Adjust the tensioning pulley with a 5 mm Allen key until the two lines on the tensioning pulley correspond with each other. Tighten. Tightening torque: 20 Nm (15 lbf ft) Remove the locking tool for camshaft sprockets 1 and 2. Fit tool KM-800-20. Then, adjust the upper adjusting roller anticlockwise with tool 83 94 983 until the markings on the camshaft sprockets are aligned with the corresponding markings on KM-800-20. Tighten. Use tool 83 94 983 as a counterstay. Tightening torque: 40 Nm (30 lbf ft) Remove KM-800-20 and the other locking tools
19. Rotate the engine two revolutions in the direction of rotation until just before the zero mark and fit locking tool KM-800-10 on the crankshaft. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump and tighten it. Fit tool KM-800-20 and ensure the markings on the camshaft sprockets are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprockets. IMPORTANT: Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.
20. Fit the lower intake manifold with new gaskets. Tightening torque: 20 Nm (15 lbf ft)
21. Fit the middle intake manifold. Tightening torque: 20 Nm (15 lbf ft)
22. Fit the upper intake manifold with a new gasket. Tightening torque: 20 Nm (15 lbf ft)
23. Connect the fuel lines.
24. Plug in the connectors for the ignition discharge module and injectors.
25. Connect the vacuum hose and the two water hoses to the throttle. Fit the turbo pressure hose with charge air bypass pipe. Plug in the throttle connector and connect the hose to the venting valve on the underside of the throttle. Tightening torques: Bypass pipe 8 Nm (6 lbf ft)
26. Connect the vacuum hoses and plug in the pressure sensor's connector to the upper intake manifold.
27. Refit the throttle cable.
28. Fit the crankshaft pulley. Tightening torque: 20 Nm (15 lbf ft)
29. Fit the timing cover. Tightening torque: 8 Nm (6 lbf ft)
30. Fit the belt tensioner and the generator air intake.
31. Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.
32. Fit the multigroove belt.
33. Tighten the retaining bolts on the pulleys. Tightening torques: Belt pulley/coolant pump: 8 Nm (6 lbf ft) Belt pulley/power steering pump: 20 Nm (15 lbf ft)
34. Fit the right-hand engine attachment with bracket and engine mount. Tightening torques: To body 63 Nm (46.5 lbf ft)
35. Fit the power steering hose in the holder
36. Fit the mass air flow sensor with hose.
37. Raise the car.
38. Lower the engine by carefully removing the wedges.
39. Lower the car to the floor.
40. Reconnect the negative cable to the battery.
41. Fill up with coolant. Do not forget to close the radiator drain cock first. Screw on the expansion tank filler cap.
42. Bleed the cooling system as follows: Fill the system up to the MAX level, close the expansion tank filler cap, start the engine and warm it up (by running it at varying rpm) until the radiator fan starts. Unscrew the expansion tank filler cap and top up again to the MAX level. Close the filler cap and run the engine at varying rpm until the radiator fan starts three more times. Switch off the engine and top up as necessary to the MAX level. NOTE: The A/C should be OFF.
43. Raise the car.
44. Check for leakage.
45. Fit the lower spoiler sections.
46. Lower the car to the floor.
47. Fit the engine cover and remove the wing protectors.
48. Reset the clock and the radio, if fitted.

Scheme 634

Scheme 635

Scheme 636

Scheme 637

Scheme 638

Scheme 639

Scheme 640

Scheme 641

Scheme 642

Scheme 643

1. Drape wing protectors over the wings and raise the car.
2. Remove the lower spoiler sections.
3. Insert two «83 95 238»(ref-212208-S14859113752005122300000) Wedges, between the oil sump and subframe and between the gearbox and subframe.
4. Lower the car.
5. Remove the mass air flow sensor with hose.
6. Detach the power steering hose from the holder.
7. Remove the right-hand engine attachment with bracket and engine mount.
8. Undo the retaining bolts from the coolant pump pulley and power steering pump pulley
9. Release the multigroove belt from tension.
10. Remove the coolant pump pulley and power steering pump pulley.
11. Remove the belt tensioner and generator air intake.
12. Remove the timing cover.
13. Remove the crankshaft pulley.
14. Turn the crankshaft in the direction of engine rotation until just before the zero mark. The grooves on the camshaft sprockets should be just in front of the marks on the inner (rear) timing cover. IMPORTANT: The crankshaft should always be carefully turned in the direction of engine rotation - never against the direction of engine rotation.
15. Fit locking tool KM-800-10 on the crankshaft. Carefully turn the crankshaft in the direction of engine rotation until the arm abuts against the coolant pump flange and tighten it. NOTE: The camshaft sprockets for cylinders 1 - 3 - 5 have the numbers 1 and 2 and the camshaft sprockets for cylinders 2-4-6 have the numbers 3 and 4. These numbers are right next to the groove markings.
16. Place gauge KM-800-20 on camshaft sprockets 3 and 4. The markings on these sprockets must be exactly aligned with the markings on the gauge. Place gauge KM-800-20 on camshaft sprockets 1 and 2. The markings on these sprockets must be exactly aligned with the markings on the gauge.
17. Fit the crankshaft pulley. Tightening torque: 20 Nm (15 lbf ft)
18. Fit the timing cover. Tightening torque: 8 Nm (6 lbf ft)
19. Fit the belt tensioner and the generator air intake.
20. Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.
21. Fit the multigroove belt.
22. Tighten the retaining bolts on the pulleys. Tightening torque: Belt pulley/coolant pump: 8 Nm (6 lbf ft) Belt pulley/power steering pump: 20 Nm (15 lbf ft)
23. Fit the right-hand engine attachment with bracket and engine mount. Tightening torque: To body 63 Nm (46.5 lbf ft)
24. Fit the power steering hose in the holder
25. Fit the mass air flow sensor with hose.
26. Raise the car.
27. Lower the engine by carefully removing the wedges.
28. Fit the lower spoiler sections.
29. Lower the car and remove the wing protectors.

Valve stem seals, to fit

(Cylinder head removed, camshafts and tappets removed)

Scheme 644

1. Fit the seals with tool «83 95 071 Fitting tool, valve stem gasket»(ref-212208-S20282439742005122300000) . Place the seal in the tool and then insert the tool in the valve guide. If the valve is fitted in place, use the valve stem as a guide.
2. Tap the seal into position using a plastic mallet and remove the plastic sleeves.

Valve guides

The valve guides cannot be changed but must be reamed to oversize and the valve then has to be changed for one of corresponding size.

Scheme 645

Use valve guide reamer, part No. 83 95 089 Valve guide reamer, 6mm .

Valve seats

Use a milling kit with T-wrench, locating shaft for valve seat cutter part no. 83 95 097 Locating shaft for valve seat cutter, 6 mm , cutters part no. ( 78 61 040 VALVE SEAT CUTTER, 11° AND 45° , part no. 83 93 936 VALVE SEAT CUTTERS, 60° , and part no. 83 95 105 VALVE SEAT CUTTER, 70° .

Scheme 646

Scheme 647

1. Exhaust valve
2. Inlet valve

Valve seat angle

45°

Regrinding angle

60° (exhaust)

71° (intake)

Valve seat width

1.4 -1.8 mm (exhaust)

1.0 -1.4 mm (intake)

Scheme 648

Scheme 649

Scheme 650

Scheme 651

Scheme 652

Scheme 653

1. Drape wing protectors over the wings and raise the car.
2. Remove the lower spoiler sections.
3. Insert two «83 95 238»(ref-212208-S14859113752005122300000) Wedges, between the oil sump and subframe and between the gearbox and subframe.
4. Lower the car to the floor.
5. Remove the mass air flow sensor with hose.
6. Detach the power steering hose from the holder.
7. Remove the right-hand engine attachment with bracket and engine mount.
8. Undo the retaining bolts from the coolant pump pulley and power steering pump pulley
9. Release the multigroove belt from tension.
10. Remove the coolant pump pulley and power steering pump pulley.
11. Remove the belt tensioner and generator air intake.
12. Remove the timing cover.
13. Raise the car and remove the crankshaft pulley from the flange (6 bolts).
14. Lower the car and zero the engine. The markings on the camshaft sprockets and the timing cover must be aligned, use Adjustment tool for camshaft sprockets and timing belt KM-800-20, as must the crankshaft marking. Fit the locking tools KM-800-1 and KM-800-2 for the camshaft sprockets and note the "TOP" marking. Fit the locking tool KM-800-10 for the crankshaft.
15. Detach the tensioning pulley and the adjuster roller. Remove the guide roller. Use 83 94 983 Adjustment wrench, timing belt, V6 as counterstay on the adjuster rollers.
16. Mark the direction of rotation on the item to be refitted. In order to facilitate fitting the belt can be marked with each camshaft marking as well as with the crankshaft marking. Remove the tool KM-800-10 from the crankshaft. Remove the camshaft belt.

Scheme 654

Scheme 655

Scheme 656

Scheme 657

Scheme 658

Scheme 659

1. Fit the camshaft belt according to the markings on the belt and the marked direction of rotation. Use Adjustment tool for camshaft sprockets and timing belt KM-800-30 to keep the belt in place. Fit the guide roller. Make sure that the washer is in place. Carefully check that the markings on the timing belt are aligned with the corresponding markings on the camshaft sprocket. Raise the car and check the marking on the crankshaft. Lower the car and remove the tool KM-800-30. Fit the locking tool KM-800-10. Tightening torque, guide roller, 40 Nm (30 lbf ft)
2. Ensure the adjusting nut on the upper adjusting roller rotates freely and is not tight. Adjust the tensioning pulley with a 5 mm Allen key until the two lines on the tensioning pulley correspond with each other. Tightening torque: 20 Nm (15 lbf ft) Remove the locking tool for camshaft sprockets 1 and 2. Fit tool KM-800-20 on the rear camshaft sprockets. Then, adjust the upper adjusting roller anticlockwise using 83 94 983 Adjustment wrench, timing belt, V6 until the markings on the camshaft sprockets are aligned with the corresponding markings on KM-800-20. Tighten. Use wrench 83 94 983 as a counterstay. Tightening torque 40 Nm (30 lbf ft) Remove KM-800-20 and the other locking tools.
3. Rotate the engine two revolutions in the direction of rotation until just before the zero mark and fit locking tool KM-800-10 on the crankshaft. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump and tighten it. Fit tool KM-800-20 and ensure the markings on the camshaft sprockets are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprockets. IMPORTANT: Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.
4. Raise the car and fit the crankshaft pulley. Tightening torque: 20 Nm (15 lbf ft)
5. Lower the car and fit the timing cover. Tightening torque: 8 Nm (6 lbf ft)
6. Fit the belt tensioner and the generator air intake.
7. Fit the coolant pump belt pulley and the power steering pump belt pulley. Use Thread locking adhesive, Loctite 270. Do not tighten the bolts!
8. Fit the multigroove belt.
9. Tighten the retaining bolts on the pulleys. Tightening torques Belt pulley/coolant pump: 8 Nm (6 lbf ft) Belt pulley/power steering pump: 20 Nm (15 lbf ft)
10. Fit the right-hand engine attachment with bracket and engine mount. Tightening torques To body 63 Nm (47 lbf ft)
11. Fit the power steering hose in the holder
12. Fit the mass air flow sensor with hose.
13. Raise the car.
14. Lower the engine by carefully removing the wedges.
15. Fit the lower spoiler sections.
16. Lower the car and remove the wing protectors.

Scheme 660

Place the dial gauge, part No. 87 92 194 Dial gauge kit , with holder 87 90 727 Bracket, dial gauge , on the end of the cylinder block with its tip resting on the crankshaft.

Push the crankshaft lengthwise (axially).

Maximum permissible clearance is 0.1-0.76 mm.

Remove the dial gauge.

Scheme 661

Place the dial gauge, part No. 87 92 194, with holder 87 90 727, on the cylinder block with its tip resting on the main bearing journal.

Rotate the crankshaft steadily. Maximum permissible rotational deviation is 0.05 mm. Remove the dial gauge.

Scheme 662

Clean the crankshaft and measure the crankpins with a micrometer. Measurements should be taken at several points round the circumference. The out-of-round (ovality) of the main journals must not exceed 0.003 mm. If the measurements are close to or in excess of this wear, the crankshaft should be ground down to the specified undersize.

Scheme 663

Main bearings

Measure clearances with (45) 30 06 558 Plastigage

Scheme 664

Scheme 665

1. Position the engine with the cylinder head surface downwards so that the weight of the crankshaft will not affect the measurements.
2. Clean the parts that are to be measured. Place a strip of Plastigage along the shaft.
3. Fit the bearing cap. Tightening torque: 50 Nm (37 lbf ft) + 60° + 15° The crankshaft must not be rotated during measurement.
4. Remove the bearing cap. The strip of Plastigage should now have adhered to either the bearing cap or the main journal.
5. Measure the width of the Plastigage strip using the scale printed on the packaging and read off the clearance. One side of the packaging gives the measurement in millimetres, the other side in thousandths of an inch. Measure the strip at the widest point and take care not to touch it with your fingers. Permissible main bearing clearance is 0.014-0.043 mm.

Big-end bearings

Measure clearances with (45) 30 06 558 Plastigage

Scheme 666

Scheme 667

Scheme 668

1. Clean the parts that are to be measured. Place a strip of Plastigage along the shaft.
2. Fit the bearing cap. Tightening torque: 35 Nm (26 lbf ft) + 45° + 15° The crankshaft must not be rotated during measurement.
3. Remove the bearing cap. The strip of Plastigage should now have adhered to either the bearing cap or the main journal.
4. Measure the width of the Plastigage strip using the scale printed on the packaging and read off the clearance. One side of the packaging gives the measurement in millimetres, the other side in thousandths of an inch. Measure the strip at the widest point and take care not to touch it with your fingers. Permissible big-end bearing clearance: 0.013-0.061 mm.

Scheme 669

Scheme 670

Scheme 671

Scheme 672

Scheme 673

1. Drape wing protectors over the wings and raise the car.
2. Remove the lower spoiler sections.
3. Insert two «83 95 238»(ref-212208-S14859113752005122300000) Wedges, between the oil sump and subframe and between the gearbox and subframe.
4. Lower the car.
5. Remove the mass air flow sensor with hose.
6. Detach the power steering hose from the holder.
7. Remove the right-hand engine attachment with bracket and engine mount.
8. Undo the retaining bolts from the coolant pump pulley and power steering pump pulley
9. Release the multigroove belt from tension.
10. Remove the coolant pump pulley and power steering pump pulley.
11. Remove the belt tensioner and generator air intake.
12. Remove the timing cover.
13. Remove the crankshaft pulley.
14. Zero the engine. The markings on the camshaft sprockets and the timing cover must be aligned, use Installation tool for camshaft sprockets and camshaft drive belt KM-800-20, as must the crankshaft marking. Fit the locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and locking tool KM-800-10 for the crankshaft.
15. Undo the tensioning pulley and adjusting rollers. Use tool 83 94 983 as a counterstay on the adjusting rollers.
16. Mark the direction of rotation on the belt. The belt can also be marked with the respective camshaft markings and crankshaft marking to facilitate refitting. Remove tool KM-800-10 from the crankshaft. Let locking tools KM-800-1 and KM-800-2 remain. Remove the lower adjusting roller. Ensure the washer behind the roller is also removed. Remove the timing belt.
17. Rotate the crankshaft to 60° BTDC
18. Raise the car.
19. Fit the Counterstay, part no. «83 95 063»(ref-212208-S02545993922005122300000) and remove the crankshaft's timing belt sprocket and spacer ring.
20. Use a screwdriver to prise out the old seal, taking care not to damage the sealing surface.

Scheme 674

Scheme 675

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

1. Fit the inner part of Assembly tool for front crankshaft seal part no. 83 94 942, to the crankshaft with the taper outward. Lubricate the seal and place it on the shaft. Tap in the seal with the outer part of the tool.
2. Fit the spacer ring. Place part no. (10) 93 21 795 on the back of the crankshaft timing belt sprocket and fit it in place. Use Counterstay, part no. 83 95 063. Remove the counterstay. Tightening torque: 250 Nm (184.5 lbf ft) + 45°
3. Lower the car.
4. Fit locking tool KM-800-1 on No. 1 and No. 2 camshaft sprockets and locking tool KM-800-2 on No. 3 and No. 4 camshaft sprockets.
5. Rotate the crankshaft to just before the 0° mark and fit tool KM-800-10. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump flange and remove the tool.
6. Put on the camshaft belt according to the markings on the belt and the marked direction of rotation. Use Setting tool for camshaft sprocket and camshaft belt KM-800-30 to keep the belt in place. Fit the lower tensioning pulley loosely. Make sure the washer is in place. Adjust the tensioning pulley by hand so that the belt does not jump. Adjust anticlockwise. Make sure the markings on the camshaft belt and the corresponding markings on the camshaft sprocket and crankshaft are aligned. Remove the tool KM-800-30. Fit locking tool KM-800-10, position a piece of camshaft belt and fit Belt-tension meter part no. 83 93 985 to measure the belt tension. Tighten the centre bolts of the adjuster rollers lightly. Adjust the lower adjuster roller anticlockwise until a tension of 275-300 Nm is obtained. Use tool 83 94 983. Tighten the adjuster roller's bolt. Use tool 83 94 983 as a counterstay. Check the belt tension again and adjust as necessary. Tightening torque: 40 Nm (30 lbf ft) Remove the belt-tension meter and piece of the toothed belt. IMPORTANT: Adjustment of belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.
7. Ensure the adjusting nut on the upper adjusting roller rotates freely and is not tight. Adjust the tensioning pulley with a 5 mm Allen key until the two lines on the tensioning pulley correspond with each other. Tighten. Tightening torque: 20 Nm (15 lbf ft) Remove the locking tool for camshaft sprockets 1 and 2. Fit tool KM-800-20. Then, adjust the upper adjusting roller anticlockwise with tool 83 94 983 until the markings on the camshaft sprocket are aligned with the corresponding markings on KM-800-20. Tighten. Use tool 83 94 983 as a counterstay. Tightening torque: 40 Nm (30 lbf ft) Remove KM-800-20 and the other locking tools
8. Rotate the engine two revolutions in the direction of rotation until just before the zero mark and fit locking tool KM-800-10 on the crankshaft. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump and tighten it. Fit tool KM-800-20 and ensure the markings on the camshaft sprocket are opposite the markings on the tool and that the edge of the belt is aligned with the edge of the sprocket. IMPORTANT: Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.
9. Fit the crankshaft pulley. Tightening torque: 20 Nm (15 lbf ft)
10. Fit the timing cover. Tightening torque: 8 Nm (6 lbf ft)
11. Fit the belt tensioner and the generator air intake.
12. Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.
13. Fit the multigroove belt.
14. Tighten the retaining bolts on the pulleys. Tightening torque: Belt pulley/coolant pump: 8 Nm (6 lbf ft) Belt pulley/power steering pump: 20 Nm (15 lbf ft)
15. Fit the right-hand engine attachment with bracket and engine mount. Tightening torque: To body 63 Nm (46.5 lbf ft)
16. Fit the power steering hose in the holder
17. Fit the mass air flow sensor with hose.
18. Raise the car.
19. Lower the engine by carefully removing the wedges.
20. Fit the lower spoiler sections.
21. Lower the car and remove the wing protectors.

Scheme 681

Scheme 682

Scheme 683

1. Remove the gearbox, see «AUTOMATIC TRANSMISSION»(ref-212247) .
2. Remove the drive plate.
3. Use a screwdriver to prise out the old crankshaft seal with care. IMPORTANT: The sealing surface must not be damaged.
4. Lubricate the sealing lips.
5. Fit tools «83 94 967 Assembly tool, rear crankshaft seal, V6»(ref-212208-S08420430982005122300000) and «83 94 975 Fitting tools, rear crankshaft seal»(ref-212208-S09579846052005122300000) and then the seal. Use tools 83 94 967 and 83 94 975 to tap the seal in place. Make sure that the sealing lips are fitted correctly on the crankshaft.
6. Fit the drive plate, Coat the bolts with part No. (10) 74 96 292. Tightening torque: 65 Nm (48 lbf ft) + 30 °
7. Fit the gearbox, see «AUTOMATIC TRANSMISSION»(ref-212247) .

Scheme 684

Scheme 685

Scheme 686

Scheme 687

1. Drape wing protectors over the wings and raise the car.
2. Remove the lower spoiler sections.
3. Insert two «83 95 238»(ref-212208-S14859113752005122300000) Wedges, between the oil sump and subframe and between the gearbox and subframe.
4. Lower the car.
5. Remove the mass air flow sensor with hose.
6. Detach the power steering hose from the holder.
7. Remove the right-hand engine attachment with bracket and engine mount.
8. Release the multigroove belt from tension.

To fit

1. Fit the multigroove belt.
2. Fit the right-hand engine mounting with bracket and engine pad. Tightening torque: To body 63 Nm (46.5 lbf ft)
3. Fit the power steering hose to the holder.
4. Fit the mass air flow sensor with hose.
5. Raise the car.
6. Lower the engine by carefully removing the wedges.
7. Fit the lower spoiler sections.
8. Lower the car and remove the wing protectors.

Scheme 688

1. Remove the drive belt. See «Drive belt for auxiliaries»(ref-212208-S26411874382005122300000) .
2. Remove the belt tensioner.

Scheme 689

1. Fit the belt tensioner. Tightening torque: 47 Nm (30 lbf ft)
2. Fit the drive belt. See «To fit»(ref-212208-S09506247542005122300000) .

Scheme 690

Scheme 691

Scheme 692

Scheme 693

Scheme 694

Scheme 695

Scheme 696

1. Drape the wing protectors over the wings and remove the engine cover.
2. Disconnect the negative cable from the battery.
3. Open the cap on the expansion tank and release the pressure.
4. Raise the car.
5. Remove the lower spoiler sections.
6. Drain the coolant from the radiator.
7. Lower the car.
8. Unhook the throttle cable. Unplug the throttle's connector.
9. Remove the vacuum hoses and unplug the pressure sensor's connector from the upper intake manifold.
10. Detach the vacuum hose and the two water hoses from the throttle. Remove the turbo pressure hose with charge air bypass pipe. Detach the venting-valve hose from the underside of the throttle.
11. Unplug the connector for the injectors.
12. Detach the fuel lines.
13. Undo the upper intake manifold and move it aside.
14. Remove the middle intake manifold.
15. Remove the lower intake manifold. Plug the holes with paper or the like.
16. Undo the coolant bridge and move it aside. Mind the gaskets.
17. Undo the clamp holding the oil pipes.
18. Raise the car. Remove the crankshaft position sensor.
19. Detach the heat exchanger's oil pipes from the oil filter adapter and cylinder block.
20. Lower the car and remove the heat exchanger oil pipes. Remove the two heat exchanger retaining nuts.
21. Remove the cover and lift out the heat exchanger.

Scheme 697

Scheme 698

Scheme 699

Scheme 700

Scheme 701

Scheme 702

1. Fit new O-rings on the two pipe connections and mount the heat exchanger.
2. Clean the heat exchanger's cover with benzine and place part No. (10) 81 52 381 in the groove. Position a new gasket and fit the cover in place. Tighten the bolts clockwise, starting in the middle. Tightening torque: 20 Nm (15 lbf ft)
3. Screw on the two heat exchanger retaining nuts. Position the heat exchanger's oil pipes and connect them to the heat exchanger. Do not tighten the bolts.
4. Fit the clamp for the oil pipes.
5. Raise the car.
6. Connect the oil pipes to the oil filter adapter and cylinder block. Tightening torque: 25 Nm (18.5 lbf ft).
7. Fit the crankshaft position sensor.
8. Lower the car.
9. Tighten the retaining nuts and the oil pipe to the heat exchanger. Tightening torque, retaining nuts 35 Nm (26 lbf ft) Tightening torque, oil pipe 30 Nm (22 lbf ft)
10. Fit the coolant bridge. Coat the bolts with part No. (10) 74 96 284. Tightening torque: 30 Nm (22 lbf ft).
11. Fit the lower intake manifold with new gaskets. Tightening torque: 20 Nm (15 lbf ft)
12. Fit the middle intake manifold. Tightening torque: 20 Nm (15 lbf ft)
13. Fit the upper intake manifold with a new gasket. Tightening torque: 20 Nm (15 lbf ft)
14. Connect the fuel lines.
15. Plug in the connector for the injectors.
16. Connect the vacuum hose and the two water hoses to the throttle. Fit the turbo pressure hose with charge air bypass pipe. Connect the hose to the venting valve on the underside of the throttle and plug in the throttle's connector. Tightening torque: Bypass pipe 8 Nm (6 lbf ft)
17. Connect the vacuum hoses and plug in the pressure sensor's connector to the upper intake manifold.
18. Refit the throttle cable.
19. Reconnect the negative cable to the battery.
20. Fill up with coolant. Do not forget to close the radiator drain cock first. Screw on the expansion tank filler cap.
21. Bleed the cooling system as follows: Fill the system up to the MAX level, close the expansion tank filler cap, start the engine and warm it up (by running it at varying rpm) until the radiator fan starts. Unscrew the expansion tank filler cap and top up again to the MAX level. Close the filler cap and run the engine at varying rpm until the radiator fan starts three more times. Switch off the engine and top up as necessary to the MAX level. NOTE: The A/C should be OFF.
22. Raise the car.
23. Check for leakage.
24. Fit the lower spoiler sections.
25. Lower the car.
26. Fit the engine cover and remove the wing protectors.
27. Reset the clock and the radio, if fitted.

Scheme 703

Scheme 704

1. Unplug the heated oxygen sensor connector and snip the cable tie securing the oxygen sensor's lead. Note the run of the wiring and lower the cable. Also undo the two upper nuts securing the front exhaust pipe at the turbo. IMPORTANT: The cables must not be twisted. Twisted cables exposed to vibration can break.
2. Raise the car.
3. Remove the lower, rear spoiler section.
4. Remove the front exhaust pipe.
5. Drain the engine oil.
6. Undo the oil sump's retaining bolts and remove the sump.
7. Remove the oil suction pipe. Note the oil suction pipe's O-ring.
8. Remove the antislosh baffle.

Scheme 705

Scheme 706

Scheme 707

Scheme 708

1. Apply part No. (10) 81 52 381 to the joints in the mating surface. The surface should be free from all oil and grease.
2. Fit the antislosh baffle. Apply part No. (10) 74 96 268 to the bolts. Tightening torque: 8 Nm (6 lbf ft)
3. Fit the oil suction pipe. Note the O-ring. Apply part No. (10) 74 96 268 to the bolts. Tightening torque: 8 Nm (6 lbf ft)
4. Position the gasket and fit the oil sump. Apply part No. (10) 74 96 268 to the bolts. Tightening torque: 15 Nm (11 lbf ft)
5. Tighten the drain plug. Tightening torque: 25 Nm (18.5 lbf ft)
6. Fit the front exhaust pipe. Tightening torque: Front/rear exhaust system: 22 Nm (16 lbf ft) Front pipe/rear exhaust manifold 40 Nm (29.5 lbf ft) Front pipe/turbo: 24 Nm (18 lbf ft)
7. Carefully run the heated oxygen sensor's lead back to the connector. Secure the lead with a cable tie. IMPORTANT: The cables must not be twisted. Twisted cables exposed to vibration can break.
8. Fit the lower, rear spoiler section.
9. Lower the car and fill up with motor oil. Tighten the two upper nuts for the front exhaust pipe at the turbo. Tightening torque: Front pipe/turbo: 24 Nm (18 lbf ft)
10. Plug in the heated oxygen sensor's connector.

Scheme 709

Scheme 710

Scheme 711

Scheme 712

Scheme 713

Scheme 714

Scheme 715

Scheme 716

Scheme 717

Scheme 718

Scheme 719

Scheme 720

1. Drape wing protectors over the wings and remove the engine cover. Disconnect the negative cable from the battery.
2. Open the cap on the expansion tank and release the pressure.
3. Raise the car and remove the right-hand front wheel.
4. Remove the lower spoiler sections.
5. Drain the coolant from the radiator.
6. Lower the car to the floor.
7. Attach a lifting eye to the front cylinder head. Use the 83 94 850 Lifting beam and hang the engine in the lifting eye.
8. Remove the mass air flow sensor with hose.
9. Detach the power steering hose from the holder.
10. Remove the right-hand engine attachment with bracket and engine mount.
11. Remove the front exhaust manifold's heat shield.
12. Detach the crankcase breather pipe from the turbo intake pipe. Note the gasket. Move the pipe aside.
13. Remove the turbo intake pipe. Also detach the hose connected to the venting valve.
14. Undo the retaining bolts from the coolant pump pulley and power steering pump pulley
15. Release the multigroove belt from tension.
16. Remove the coolant pump pulley and power steering pump pulley.
17. Remove the belt tensioner and generator air intake.
18. Remove the timing cover.
19. Remove the crankshaft pulley.
20. Zero the engine. The markings on the camshaft sprockets and timing cover should be in alignment as also should the marking on the crankshaft. Fit locking tools KM-800-1 and KM-800-2 for the camshaft sprockets and KM-800-10 for the crankshaft.
21. Detach the tensioning pulley and the adjuster roller. Remove the guide roller. Use 83 94 983 Adjustment wrench, timing belt, V6as counterstay on the adjuster rollers.
22. Mark the direction of rotation on the item to be refitted. In order to facilitate fitting the belt can be marked with each camshaft marking as well as with the crankshaft marking. Remove the tool KM-800-10 from the crankshaft. Remove the camshaft belt.
23. Remove the bracket with the upper adjuster roller and tensioning roller. Also remove the lower adjuster roller.
24. Rotate the crankshaft to 60° BTDC. Note the marking.
25. Lock the camshaft sprockets with locking tools KM-800-1 and KM-800-2 and remove the sprockets.
26. Remove the coolant pump.
27. Remove the inner timing cover.
28. Fit counterstay «83 95 063»(ref-212208-S02545993922005122300000) and remove the crankshaft timing belt pulley.
29. Disconnect the lead for the oil pressure switch.
30. Remove the generator.
31. Raise the car.
32. Remove the front exhaust pipe.
33. Drain the engine oil.
34. Remove the oil sump and oil strainer.
35. Undo the A/C compressor and bracket. Move aside.
36. Lower the car to the floor.
37. Remove the oil pump housing.
38. Remove the cover and take out the two pump wheels (impellers).
39. If necessary, check the oil pressure release valve and oil pressure control valve.

Scheme 721

Scheme 722

Scheme 723

Scheme 724

Scheme 725

Scheme 726

Scheme 727

Scheme 728

Scheme 729

Scheme 730

Scheme 731

Scheme 732

Scheme 733

Scheme 734

Scheme 735

1. Position the pump wheels (impellers) in the housing and fit the cover. Apply part No. (10) 74 96 268 to the bolts. Tightening torque: 6 Nm (4.5 lbf ft). IMPORTANT: The marks on the pump wheels (impellers) should face outwards when fitting.
2. Fit a new gasket. Coat it with part No. (10) 93 21 795 and fit the pump housing. Tightening torque: 6 Nm (4.5 lbf ft).
3. Fit the A/C compressor and bracket. Fit the right-hand front wheel.
4. Raise the car.
5. Seal the joints in the oil sump mating surface with part No. (10) 81 52 381.
6. Fit the oil strainer and oil sump. Tightening torques: Oil strainer: 8 Nm (6 lbf ft) Oil sump: 15 Nm (11 lbf ft)
7. Fit the front exhaust pipe. Tightening torques: Front/rear exhaust system: 22 Nm (16 lbf ft) Front pipe/rear exhaust manifold 40 Nm (29.5 lbf ft) Front pipe/turbo: 24 Nm (18 lbf ft)
8. Lower the car to the floor.
9. Fit the generator.
10. Connect the lead for the oil pressure switch.
11. Use counterstay «83 95 063»(ref-212208-S02545993922005122300000) and fit the crankshaft timing belt pulley. Tightening torques: 250 Nm (184.5 lbf ft) + 45°
12. Fit the inner (rear) timing cover.
13. Fit the coolant pump. Tightening torque: 25 Nm (18.5 lbf ft).
14. Fit the bracket with tensioning roller and the upper adjuster roller. Also fit the lower adjuster roller.
15. Fit the camshaft sprockets correctly in relation to the locating pins. Tightening torque: 50 Nm (37 lbf ft) + 60°
16. Fit locking tool KM-800-1 on No. 1 and No. 2 camshaft sprockets and locking tool KM-800-2 on No. 3 and No. 4 camshaft sprockets.
17. Rotate the crankshaft to just before the mark and fit tool KM-800-10 on the crankshaft. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump flange and remove the tool.
18. Fit the camshaft belt according to the markings on the belt and the marked direction of rotation. Use 83 95 006 Adjustment tools for camshaft sprockets and timing belt, V6 KM-800-30 to keep the belt in place. Fit the guide roller. Make sure that the washer is in place. Carefully check that the markings on the timing belt are aligned with the corresponding markings on the camshaft sprocket. Raise the car and check the marking on the crankshaft. Lower the car and remove the tool KM-800-30. Tightening torque, guide roller, 40 Nm (30 lbf ft)
19. Adjust the tensioning roller by means of an Allen key until the two lines on it are in alignment. Tighten. Tightening torque: 20 Nm (15 lbf ft) Remove the locking tool for camshaft sprockets 1 and 2. Then adjust the upper adjuster roller anticlockwise until sprocket No. 2 moves 1-2 mm clockwise. Tightening torque: 40 Nm (30 lbf ft) Remove the other locking tools.
20. Turn the crankshaft two revolutions until just before the zero mark and fit locking tool KM-800-10 on it. Carefully turn the crankshaft in the engine's direction of rotation until the arm abuts against the coolant pump flange and tighten it. Fit tool KM-800-20 and check that the markings on the camshaft sprockets are opposite the markings on the tool and that the edge of the belt coincides with the edge of the sprockets. IMPORTANT: Check that marking A is about 2 mm above marking B. If this distance is smaller, adjustment must be carried out afresh.
21. Fit the crankshaft pulley. Tightening torque: 20 Nm (15 lbf ft)
22. Fit the timing cover. Tightening torque: 8 Nm (6 lbf ft)
23. Fit the belt tensioner and the generator air intake.
24. Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.
25. Fit the multigroove belt.
26. Tighten the retaining bolts on the pulleys. Tightening torques: Belt pulley/coolant pump: 8 Nm (6 lbf ft) Belt pulley/power steering pump: 20 Nm (15 lbf ft)
27. Fit the right-hand engine attachment with bracket and engine mount. Tightening torques: To body 63 Nm (46.5 lbf ft)
28. Fit the power steering hose in the holder
29. Fit the mass air flow sensor with hose.
30. Remove the lifting beam and lifting eye.
31. Connect the hose to the venting valve and fit the turbo intake pipe. Tightening torques: V-clamp 3 Nm (2 lbf ft) U-clamp cylinder head 14 Nm (10 lbf ft)
32. Fit the crankcase breather pipe to the turbo intake pipe. Tightening torque: 24 Nm (18 lbf ft)
33. Fit the front exhaust manifold's heat shield. Tightening torque: 24 Nm (18 lbf ft)
34. Reconnect the negative cable to the battery.
35. Fill up with coolant. Do not forget to close the radiator drain cock first. Screw on the expansion tank filler cap.
36. Bleed the cooling system as follows: Fill the system up to the MAX level, close the expansion tank filler cap, start the engine and warm it up (by running it at varying rpm) until the radiator fan starts. Unscrew the expansion tank filler cap and top up again to the MAX level. Close the filler cap and run the engine at varying rpm until the radiator fan starts three more times. Switch off the engine and top up as necessary to the MAX level. NOTE: The A/C should be OFF.
37. Raise the car.
38. Check for leakage.
39. Fit the lower spoiler sections.
40. Lower the car, fit the engine cover and remove the wing protectors.
41. Reset the clock and the radio, if fitted.

Pressure release valve

(Oil pump removed)

Scheme 736

1. Loosen the screw and lift the spring and valve. Use the 83 91 401 Magnetic tool

Scheme 737

1. Fit the valve and spring and tighten the bolt.

Scheme 738

Scheme 739

Scheme 740

Scheme 741

1. Raise the car.
2. Remove the lower front cover.
3. Insert two «83 95 238»(ref-212208-S14859113752005122300000) Wedges, between the oil sump and subframe and between the gearbox and subframe.
4. Lower the car.
5. Remove the mass air flow sensor with hose.
6. Detach the power steering hose from the holder.
7. Remove the right-hand engine attachment with bracket and engine mount.
8. Undo the retaining bolts from the coolant pump pulley and power steering pump pulley
9. Release the multigroove belt from tension.
10. Remove the coolant pump pulley and power steering pump pulley.
11. Remove the belt tensioner and generator air intake.
12. Remove the timing cover.
13. Loosen the screw and lift the spring and valve. Use the 83 91 401 Magnetic tool

Scheme 742

Scheme 743

Scheme 744

Scheme 745

1. Position the spring and piston and tighten the bolt with a new sealing ring.
2. Fit the timing cover. Tightening torque: 8 Nm (6 lbf ft)
3. Fit the belt tensioner and the generator air intake.
4. Fit the coolant pump pulley and the power steering pump pulley. Use Loctite, part No. 74 96 292. Do not tighten the bolts.
5. Fit the multigroove belt.
6. Tighten the retaining bolts on the pulleys. Tightening torque: Belt pulley/coolant pump: 8 Nm (6 lbf ft) Belt pulley/power steering pump: 20 Nm (15 lbf ft)
7. Fit the right-hand engine attachment with bracket and engine mount.
8. Fit the power steering hose in the holder
9. Fit the mass air flow sensor with hose.
10. Raise the car.
11. Lower the engine by carefully removing the wedges.
12. Fit the lower front cover.
13. Lower the car.

Scheme 746

1. Raise the car and drain the engine oil.
2. Remove the cover.
3. Cut threads, using an M10 (step 3) screw tap, in the end plate. Screw in an M10 bolt and pull out the bypass valve. IMPORTANT: Make sure that no metal cuttings are left inside.

Scheme 747

1. Oil the bypass valve and tap it home. Use a phi 15 mm drift.
2. Fit the cover with a new seal.
3. Lower the car and fill up with motor oil.
4. Start the engine and check for leakage.

Procedure

When an oil leak is detected, check the areas listed below

Scheme 748

Scheme 749

Scheme 750

Scheme 751

1. Oil patch by crankshaft position sensor. Remove the crankshaft position sensor. Clean the sealing surface and fit a new O-ring greased with Petrolatum, Kluber Syntheso Pro AA2. Fit the crankshaft position sensor
2. Oil patch by the oil cooler intake and outlet. A banjo screw (part no. 59 58 095) has been developed. This should be used with an aluminium washer (part no. 46 21 413). The new screw is fitted to all engines from engine number B308EE003723200.
3. Oil patch by the oil cooler seal with the cylinder block. Remove the oil cooler. Clean the sealing surfaces on the cylinder block and cooler cover and apply TB 1217F (part no. 47 73 594) to the sealing surfaces. This new seal was introduced into production from engine number B308EE003685986. It is difficult to detect the origin of leaks 2 and 3 without using an endoscope, using a tracing agent added to the oil or removing the intake manifold.
4. Oil patch by the cover on the cylinder block. Clean the sealing surface, fit a new O-ring (part no. 91 98 615). Use Vaseline, non-acidic to secure the O-ring and ensure it remains in its groove. The new O-ring was introduced as from B308EE002577279. Tighten the cover. Tightening torque 15 Nm (11 lbf ft) Check also that the tightening torque of the threaded pipe is correct. Tightening torque: 20 Nm (15 lbf ft)
5. Oil patch by the oil return pipe from the turbo to the oil pan. Two possible areas: The flange at the turbo outlet and the O-ring seal at the oil pan. If there is a leak, the entire oil return pipe must be changed along with the gasket and O-ring (part no. 91 85 455, 91 07 582 and 79 85 708). Check that the oil return pipe mates well with the oil pan. If not, slacken the hose clip, adjust the pipe and tighten the clip. The oil return pipe has been rectified for all cars since MY02. After remedial action, clean the engine from oil and dirt and test drive to check that the leak has been rectified.

Scheme 752

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (PLASTIGAUGE)

Scheme 753

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (OIL PAN STAND)

Scheme 754

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (VALVE SEAT CUTTER)

Scheme 755

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (FLOOR STAND)

Scheme 756

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (AXLE)

Scheme 757

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (MAGNETIC TOOL)

Scheme 758

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (LIFTING SLING)

Scheme 759

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (VALVE STAND)

Scheme 760

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (VALVE SEAT CUTTERS)

Scheme 761

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (BELT-TENSION METER)

Scheme 762

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (VALVE GUIDE SEAL PLIERS)

Scheme 763

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (COMPRESSED AIR ADAPTER)

Scheme 764

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (ENGINE HOLDER)

Scheme 765

Group: Engine, Manual gearbox

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (LIFTING BEAM)

Scheme 766

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (FLYWHEEL LOCKING ATTACHMENT)

Scheme 767

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (REAR CRANKSHAFT SEAL FITTING KIT)

Scheme 768

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (FRONT CRANKSHAFT SEAL ASSEMBLY TOOL)

Scheme 769

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (CAMSHAFT SEAL ASSEMBLY TOOL)

Scheme 770

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (REAR CRANKSHAFT SEAL ASSEMBLY TOOL)

Scheme 771

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (REAR CRANKSHAFT SEAL FITTING TOOLS)

Scheme 772

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (CAMSHAFT BELT ADJUSTING WRENCH)

Scheme 773

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (CAMSHAFT SPROCKETS AND DRIVE BELT ASSEMBLY KIT)

Scheme 774

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (PROTECTIVE COLLAR)

Quantity: 12

Scheme 775

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (CYLINDER HEAD FIXTURE)

Scheme 776

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (CRANKSHAFT BELT PULLEY COUNTERSTAY)

Scheme 777

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (VALVE STEM GASKET FITTING TOOL)

Scheme 778

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (VALVE GUIDE REAMER)

Scheme 779

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (VALVE SEAT CUTTER)

Scheme 780

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (VALVE SEAT CUTTER - 31MM)

Scheme 781

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (PISTON FITTING TOOL)

Scheme 782

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (STRAP)

Scheme 783

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (WEDGE)

Scheme 784

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (VALVE SPRING COMPRESSOR)

Scheme 785

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (HOLDER)

83 95 311 Trolley lift

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (TROLLEY LIFT)

Scheme 786

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (GUIDE SLEEVE)

Scheme 787

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (SPARK PLUG SOCKET ASSEMBLY)

Scheme 788

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (DIAL GAUGE BRACKET)

Scheme 789

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (DIAL GAUGE KIT)

Scheme 790

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (HOLDER)

Scheme 791

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (PULLER)

Scheme 792

ENGINE TECHNICAL SPECIFICATIONS

Scheme 793

Classification codes

CYLINDER BLOCK TECHNICAL SPECIFICATIONS

Scheme 794

CYLINDER HEAD TECHNICAL SPECIFICATIONS

General data

PISTON TECHNICAL SPECIFICATIONS (GENERAL)

Piston diameter

Piston diameter is measured at right angles to the gudgeon pin holes, 16 mm from the bottom of the piston.

PISTON TECHNICAL SPECIFICATIONS (CLASSIFICATION CODES)

Piston rings

PISTON RINGS TECHNICAL SPECIFICATIONS

Scheme 795

GUDGEON PIN TECHNICAL SPECIFICATIONS

Scheme 796

CONNECTING ROD TECHNICAL SPECIFICATIONS

Scheme 797

CRANKSHAFT TECHNICAL SPECIFICATIONS (GENERAL)

Big-end bearing journal diameter

CRANKSHAFT BIG-END BEARING JOURNAL DIAMETER TECHNICAL SPECIFICATIONS

Main bearing journal diameter

CRANKSHAFT Main bearing journal diameter technical SPECIFICATIONS

Standard size

CRANKSHAFT MAIN BEARINGS TECHNICAL SPECIFICATIONS (STANDARD SIZE)

Undersize -0.25

CRANKSHAFT MAIN BEARINGS TECHNICAL SPECIFICATIONS (UNDERSIZE - 0.25)

Undersize -0.50

CRANKSHAFT MAIN BEARINGS TECHNICAL SPECIFICATIONS (UNDERSIZE - 0.50)

CRANKSHAFT MAIN BEARINGS CLEARANCE SPECIFICATIONS

CRANKSHAFT BEARINGS THICKNESS SPECIFICATIONS

Scheme 798

The exhaust valve (1) is available in two oversizes

EXHAUST VALVE SPECIFICATIONS

Scheme 799

The inlet valve (2) is available in two oversizes

INLET VALVE SPECIFICATIONS

Scheme 800

VALVE SPRING SPECIFICATIONS

Scheme 801

CAMSHAFTS TECHNICAL SPECIFICATIONS (GENERAL)

INLET AND EXHAUST VALVE OPENING AND CLOSING TECHNICAL SPECIFICATIONS

Scheme 802

LUBRICATION SYSTEM TECHNICAL SPECIFICATIONS (GENERAL)

Note. The same oil filter as for the 4-cylinder SAAB 9-5 should be used.

Camshafts with tappets

Each cylinder head has double overhead camshafts with large diameter on the base circle, which allows large lifting with small stress. All four camshafts are driven by a toothed belt with self-adjusting belt tensioner. Two adjuster rollers are also included in the belt circuit.

The camshafts work via hydraulic tappets directly on the valves. The hydraulic tappets are automatically adjusted in accordance with the longitudinal change of the valves at different temperatures. They operate in an oil-bath and are supplied with oil via an oil duct in the cylinder head. The main advantages with hydraulic tappets are a very quiet operation and very high operational reliability. In addition, each cylinder head has two air vent nozzles to prevent noise in the tappets after starting.

The valves have chrome-plated spindles and the exhaust valves are sodium-cooled. The camshaft sprockets on the rear cylinder head and the camshaft sprockets on the front cylinder head are interchangeable amongst themselves.

Belt tensioner

The belt tensioner located on the slack side of the toothed belt is dynamic and adjustable. After the belt tensioner has been adjusted in the belt tensions continuously and compensates for belt wear.

There are also two adjuster rollers in the belt circuit.

Scheme 803

Oil filter

The oil filter is screwed into the oil filter adapter and is easily accessible.

Note. The same oil filter as for the 4-cylinder SAAB 9-5 should be used.

Scheme 804

1. Generator
2. Belt tensioner
3. Power steering pump
4. Coolant pump
5. A/C compressor
6. Crankshaft

The engine is fitted with only one drive belt for all auxiliaries.

The drive belt for the auxiliaries has an automatic belt tensioner which is easy to service and has a long working life. The belt tensioner consists of a powerful spring which ten0sions the belt by means of a pulley.

Scheme 805

Background

To provide effective damping of engine movement, the rear and the right-hand engine mounts are of hydraulic type. Their most effective working range is between idling speed and about 1800 rpm.

The use of hydraulic engine mounts confers the following advantages

1. improved damping of horizontal engine movements during acceleration
2. improved damping of vertical engine movements on bumpy roads
3. reduction of structure-borne sound between engine and body.