Exhaust System: Other Saab 9-5 I рестайлинг

To fit

Note. The rubber mounts can be smeared with non-acidic vaseline for easier fitting.

Fit in reverse order.

Adjust the system so that it is not under tension or in contact with the bottom of the car.

Tightening torque

Front/rear exhaust system: 22 Nm (16.2 lbf ft)

Scheme 38

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1. Remove the upper engine cover.
2. Remove the bypass pipe with valve. NOTE: There is an O-ring at the bypass pipe's attachment to the turbo intake pipe.
3. Remove the exhaust manifold's heat shield.
4. Unplug the connectors to the oxygen sensors. Cut off the cable tie and pull out the cables.
5. Loosen the two upper nuts at the connection between the turbo/front exhaust system.
6. Raise the car.
7. Loosen the third nut at the connection between the turbo/front exhaust system.
8. Undo the upper bolt on the stay securing the catalytic converter to the engine.
9. Separate the pipe joint between the front and rear exhaust systems.
10. Remove the clips and carefully pull away the rubber mountings
11. Lower the front exhaust system. IMPORTANT: The flexible section at the front of the exhaust system should not be bent out of line by more than 5°, i.e. if the front exhaust system is allowed to hang, it must not bend more than the sag caused by its own weight. If the pipe is overloaded, permanent deformation of the components will result. This can cause noise and leakage, and damage at a later stage.

Note. Coat the studs sparingly with Molycote 1000, part no. 30 20 971 or similar.

Scheme 41

Scheme 42

1. Fit the front pipe with rubber mountings and clips.
2. Fit the nuts on the rear pipe joints. Tightening torque 22 Nm (16 lbf ft)
3. Fit the lower nut on the turbocharger.
4. Fit the stay securing the exhaust pipe to the engine. Tightening torque 25 Nm (19 lbf ft)
5. Lift up the oxygen sensor cables and lower the car.
6. Fit the two upper nuts on the exhaust system. Tightening torque 24 Nm (18 lbf ft)
7. Lay out the oxygen sensor cables and plug in the connectors.
8. Secure the cables with a cable tie.
9. Fit the upper engine cover and the heat shield over the exhaust manifold.
10. Lubricate the O-ring on the bypass pipe with acid-free vaseline and fit the pipe with valve and vacuum hose. Tightening torque 8 Nm (6 lbf ft)

Scheme 43

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Scheme 46

1. Remove the bypass pipe with valve. NOTE: There is an O-ring at the bypass pipe's attachment to the turbo intake pipe.
2. Remove the exhaust manifold's heat shield.
3. Remove the oxygen sensor.
4. Loosen the two upper nuts at the connection between the turbo/front exhaust system.
5. Raise the car.
6. Remove the lower front cover.
7. Loosen the third nut at the connection between the turbo/front exhaust system.
8. Separate the pipe joint between the front and rear exhaust systems.
9. Remove the clips from the rubber mounts.
10. Carefully withdraw the rubber mounts.
11. Lower the front exhaust system. IMPORTANT: The flexible section at the front of the exhaust system should not be bent out of line by more than 7°, i.e. if the front exhaust system is allowed to hang, it must not bend more than the sag caused by its own weight. If the pipe is overloaded, permanent deformation of the components will result. This can cause noise and leakage, and damage at a later stage.

Ensure that the system hangs straight so that no stresses occur during fitting.

Fit in reverse order.

Note. Coat the studs sparingly with Molycote 1000, part no. 30 20 971 or similar.

Tightening torque

Turbo/front exhaust pipe: 24 Nm (17.7 lbf ft)

Front/rear exhaust system: 22 Nm (16.2 lbf ft)

Bypass pipe/intake pipe: 8 Nm (5.9 lbf ft)

Bypass pipe, hose clip: 8 Nm (5.9 lbf ft)

Oxygen sensor: 55 Nm (40.5 lbf ft)

Note. Smear the studs and gaskets sparingly with Molycote 1000, part, no. 30 20 971 or similar, to prevent them baking on.

Note. Spray the connector with Kontakt 61, part no. 30 04 520, before plugging it in.

Scheme 47

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Scheme 54

1. Clean the sealing surfaces and fit a new gasket to the front exhaust manifold.
2. Fit the front exhaust manifold with turbo. Tightening torque: 20 Nm (14.7 lbf ft). IMPORTANT: It is essential that there is oil in the turbo bearing housing when the engine is started. Fill the turbo oil inlet with oil from an oilcan. Rotate the compressor by hand many times so that the oil penetrates into the bearings.
3. Raise the car.
4. Fit a new gasket on the front pipe against the rear exhaust manifold. NOTE: To ease disassembly of the front exhaust system, attach a 83 95 212 Cable tie around the front pipe.
5. Fit the front exhaust pipe to the rear exhaust manifold. Tightening torque: 40 Nm (29.5 lbf ft).
6. Fit the pipe joint between the front and rear exhaust systems. Tightening torque: 22 Nm (16.2 lbf ft).
7. Secure the oxygen sensor cables with cable ties. Carefully run the cables back to the oxygen sensor connectors.
8. Fit the oil pipe to the oil filter adapter. Fit new gaskets and sealing washers. Tightening torque: 20 Nm (14.7 lbf ft).
9. Fit the turbo mounting bracket. Tightening torque: 24 Nm (17.7 lbf ft).
10. Fit the turbo's oil return pipe. Tightening torque: M6 bolt: 14 Nm (10.3 lbf ft)
11. Lower the car to the floor.
12. Plug in the oxygen sensor connector.
13. Bolt the front exhaust pipe to the turbo. Tightening torque: 24 Nm (17.7 lbf ft).
14. Fit the dipstick tube.
15. Fit the turbo water return pipe. Use new seal washers. Tightening torque: Banjo bolt, turbo 25 Nm (18.4 lbf ft) Retaining screw cylinder head 14 Nm (10.3 lbf ft)
16. Remove the pinch-off pliers from the inlet and return water hoses to the turbo.
17. Fit the radiator fan. Tightening torque: 8 Nm (5.9 lbf ft)
18. Plug in the connectors to the radiator fan motors.
19. Fit the hose between the turbo and the charge air cooler. Tightening torque: 8 Nm (5.9 lbf ft)
20. Fit the turbo's intake pipe. Tightening torque: V-clamp 3 Nm (2.2 lbf ft) U-clamp cylinder head 14 Nm (10.3 lbf ft)
21. Fit the hose to the mass air flow sensor
22. Fit the crankcase ventilation pipe between the cylinder head and the turbo inlet pipe. Connect the hose from the oil trap.
23. Fit the SAI pipe with valve and new gaskets to the bracket and the hose connection to the front SAI valve. Check the connection.
24. Lower the turbo delivery pipe and connect it to the throttle body.
25. Raise the car and remove the plug in the charge air cooler outlet.
26. Connect and tighten the turbocharger delivery pipe hose clip to the charge air cooler.
27. Lower the car and tighten the turbocharger delivery pipe hose clip to the throttle body.
28. Plug in the connector for the temp/pressure sensor.
29. Fit the front exhaust manifold's heat shield. Tightening torque: 24 Nm (17.7 lbf ft).
30. Fit the turbo bypass pipe with valve. Tightening torque: 8 Nm (5.9 lbf ft)
31. Fit the battery and vent hose. Fit the battery cover.
32. Check the oil and water levels. Top up as necessary.
33. Start the engine and check for any oil and water leakage.
34. Fit the upper engine cover.
35. Reset the clock and program the radio code if applicable.

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1. Note the radio code if applicable, remove the battery cover and undo the positive cable on the battery.
2. Remove the upper engine cover and the air inlet to the generator.
3. Detach the oxygen sensor connectors from the holder on the rear SAI valve by releasing the catch and pushing them down.
4. Undo the SAI pipe mounting on the cylinder head. Undo the connections to the exhaust manifold.
5. Undo the hose connections for the SAI valve and remove the pipe with valve.
6. Undo the two outer nuts on the rear exhaust manifold.
7. Raise the car.
8. Detach the front pipe from the front and rear exhaust manifold. Secure the front exhaust pipe with a cable tie, 83 95 212 Cable tie. IMPORTANT: The flexible section at the front of the exhaust system should not be bent out of line by more than 7°, i.e. if the front exhaust system is allowed to hang, it must not bend more than the sag caused by its own weight. If the pipe is overloaded, permanent deformation of the components will result. This can cause noise and leakage, and damage at a later stage.
9. Undo the two lower nuts on the rear exhaust manifold.
10. Lower the car to the floor.
11. Undo the three upper nuts on the rear exhaust manifold and remove the exhaust manifold.

Note. Smear the studs and gaskets sparingly with Molycote 1000, part, no. 30 20 971 or similar, to prevent them baking on.

Scheme 59

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Scheme 61

1. Clean the sealing surfaces and fit a new gasket for the rear exhaust manifold. Fit the rear exhaust manifold.
2. Fit the three upper nuts on the rear exhaust manifold. Tightening torque: 20 Nm (14.7 lbf ft).
3. Raise the car.
4. Fit the two lower nuts on the rear exhaust manifold. Tightening torque: 20 Nm (14.7 lbf ft).
5. Fit a new gasket between the front exhaust pipe and rear exhaust manifold.
6. Fit the front exhaust pipe to the front and rear exhaust manifolds. Tightening torque: Turbo, locknuts: 24 Nm (17.7 lbf ft) Rear exhaust manifold: 40 Nm (29.5 lbf ft)
7. Lower the car to the floor.
8. Fit the two outer nuts on the rear exhaust manifold. Tightening torque: 20 Nm (14.7 lbf ft).
9. Attach the hose connection to the SAI pipe and check the connection.
10. Fit the SAI pipe with new gaskets to the exhaust manifold and cylinder head.
11. Fasten the oxygen sensor connectors to the holder.
12. Fit the air intake to the generator and the upper engine cover.
13. Connect the positive cable to the battery, fit the battery cover, adjust the clock and set the radio code if applicable.

Scheme 62

Check exhaust system mountings, integrity and damage.

List Of Lubricants

LUBRICANTS LIST

Scheme 63

Heat shields

Heat shields are fitted over the exhaust system's hottest zones to protect exposed areas from heat radiation from the exhaust system.

Scheme 64

1. Check valve
2. Filter element
3. Mass air flow sensor
4. Turbocharger
5. Charge air cooler
6. Bypass valve
7. Solenoid valve
8. Throttle body
9. Charge air absolute pressure sensor/Intake air temperature sensor
10. Manifold absolute pressure sensor
11. Engine
12. Crankcase ventilation oil trap
13. Check valves
14. Purge valve
15. EVAP canister
16. Wastegate valve
17. Charge air regulator
18. Charge air control valve
19. Oxygen sensor
20. Pre-catalytic converter
21. Main catalytic converter
22. Front silencer
23. Rear silencer
24. Brake vacuum strenghtener
25. Brake servo
26. Check valve

Scheme 65

Heat shields are fitted over the exhaust system's hottest zones to protect exposed areas from heat radiation from the exhaust system.

Scheme 66

Heat shields are fitted over the exhaust system's hottest zones to protect exposed areas from heat radiation from the exhaust system.