Exhaust System: Removal & Installation Saab 9-5 I рестайлинг

To remove

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1. Remove the front exhaust manifold's heat shield.
2. Unbolt the front pipe from the turbo.
3. Unplug the oxygen sensor's connector.
4. Raise the car.
5. Snip the cable tie securing the oxygen sensor cable. Note the way the cable is run and lower the cable.
6. Separate the pipe joint between the front and rear exhaust systems. NOTE: Removal of the front exhaust system will be easier if a cable tie, part No. 83 95 212, is fastened round the front pipe.
7. Detach the front exhaust pipe from the rear exhaust manifold and lower away the front exhaust system.
8. Remove the oxygen sensor. To fit

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1. Coat the oxygen sensor threads with Molycote 1000, part No. 30 20 971.
2. Fit the oxygen sensor. Tightening torque: 55 Nm (40.6 lbf ft).
3. Fit the front exhaust pipe to the rear exhaust manifold. Tightening torque: 40 Nm (29.5 lbf ft). NOTE: Removal of the front exhaust system will be easier if a cable tie, part No. 83 95 212, is fastened round the front pipe.
4. Fit the pipe joint between the front and rear exhaust systems. Tightening torque: 22 Nm (16.2 lbf ft).
5. Use a cable tie to secure the oxygen sensor cable. Carefully run the cable back to the oxygen sensor connector.
6. Lower the car to the floor.
7. Plug in the oxygen sensor connector.
8. Bolt the front exhaust pipe to the turbo. Tightening torque: 24 Nm (17.7 lbf ft).
9. Fit the front exhaust manifold's heat shield. Tightening torque: 24 Nm (17.7 lbf ft).
10. Start the engine and check for leakage.

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1. Open the expansion tank cap to release the system pressure.
2. Raise the car.
3. Remove the lower front cover.
4. Drain off the coolant.
5. Undo the bolt at the turbo mounting on the engine block.
6. Loosen the upper screw on the turbo mounting.
7. Detach the turbo return hose to the sump.
8. Loosen the oil pipe to the turbo at the oil filter adapter.
9. Lower the car to the floor.
10. Remove the bypass pipe and valve. NOTE: There is an O-ring at the bypass pipe's attachment to the turbo intake pipe.
11. Remove the exhaust manifold's heat shield.
12. Unplug the radiator fan's connectors and move them aside.
13. Remove the bolts on each side of the fan assembly.
14. Loosen the clip holding the cooling system vent hose. On cars with automatic transmission, also remove the pipe mounting on the fan cowling.
15. Detach the upper radiator hose by undoing the hose clip and bending the hose aside.
16. Unhook and twist the fan assembly, then lift it out.
17. Unplug the boost pressure control valve connector.
18. Unplug the mass air flow sensor connector.
19. Detach the crankcase breather pipe fastened to the turbo intake pipe and detach the camshaft cover.
20. Bend the pipe and wiring aside.
21. Remove the mass air flow sensor and air hose.
22. Loosen the hoses to the turbo and the diaphragm box.
23. Unplug the quick-release coupling on the purge hose with 83 95 261 Tools, Fuel line.
24. Undo the intake pipe's V-clamp at the turbo.
25. Unbolt the intake pipe from the power steering pump mounting.
26. Lift out the intake pipe.
27. Disconnect the hose clip on the hose between the turbo and charge air cooler. Plug the hose to keep it clean using a plug 83 94 595 Plug, turbo hose or something similar.
28. Undo the retaining nuts and remove the front part of the exhaust system from the turbo.
29. Carefully lower the front exhaust system away from the turbo. 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.
30. Remove the oil pipe to the turbo. Save the copper washers.
31. Loosen the water pipe at the turbo. Save the copper washers.
32. Release the water pipe screw at the coolant pump.
33. Loosen the water return pipe from the turbo at the cylinder head and the pressure sensor mounting. Save the copper washers.
34. Undo the water return pipe's bolt at the turbo.
35. Remove the bolts securing the turbo to the exhaust manifold.
36. Relieve the tension on the multigroove belt with a puller shank 83 95 254 Puller shank, hydraulic belt tensioner.
37. Move the belt away from the power steering pump.
38. Remove the power steering pump bracket from the engine mount.
39. Undo the power steering pump bracket bolts and move the pump aside.
40. Push the turbo aside and remove the exhaust manifold. Save the spacer sleeves and washers.

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

Spray the connectors with Kontakt 61, part no. 30 04 520.

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1. Fit a new gasket to the exhaust manifold.
2. Fit the exhaust manifold.
3. Fit the washers, spacers and nuts. Tightening torque: 25 Nm (18.4 lbf ft)
4. First fit the top left bolt in the power steering pump bracket. Then fit the other two bolts. Tightening torque: 24 Nm (17.7 lbf ft).
5. Bolt the power steering pump bracket to the engine mount and tighten the bolts. Tightening torque: 24 Nm (17.7 lbf ft).
6. Attach the multigroove belt and adjust the belt tensioner. Use a puller shank 83 95 254 Puller shank, hydraulic belt tensioner.
7. Bolt the turbo to the exhaust manifold. Tightening torque: Lock nuts 24 Nm (17.7 lbf ft) Studs 22 Nm (16.2 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.
8. Fit the front part of the exhaust system to the turbo and tighten the nuts. Tightening torque: 24 Nm (17.7 lbf ft). IMPORTANT: When fitting the front exhaust system to the turbo, the nuts should be tightened alternately to avoid distorting the flange. The flange must not abut against the turbo connection flange.
9. Fit the turbo water return pipe. Use new copper washers. Tightening torque: Water return pipe/cylinder head: 25 Nm (18.4 lbf ft) Water return pipe/turbo: 25 Nm (18.4 lbf ft)
10. Fit the turbo water pipe. Tighten the pipe also at the coolant pump end. Use new copper washers. Tightening torque: Water pipe/turbo 25 Nm (18.4 lbf ft) Water pipe/coolant pump: 20 Nm (14.7 lbf ft)
11. Fit and tighten the turbo oil pipe at the turbo. Use new copper washers. Tightening torque: Oil pipe to turbo/turbo: 20 Nm (14.7 lbf ft)
12. Fit a new O-ring greased with non-acidic vaseline to the turbo intake pipe. Slide the V-clamp on the pipe and position same. Bolt the pipe to the power steering pump bracket to facilitate tightening/fitting the V-clamp.
13. Slacken the adjusting screw on the intake pipe to adjust the pipe.
14. Tighten the intake pipe bolt on the power steering pump bracket. Also tighten the adjusting screw. Tightening torque: 24 Nm (17.7 lbf ft).
15. Tighten the V-clamp between the turbo and the turbo intake pipe. Tightening torque: 3 Nm (2.2 lbf ft)
16. Connect the hoses to the diaphragm box and turbo, and the vent hose.
17. Remove the plug from the charge air cooler intake pipe.
18. Connect the charge air cooler intake pipe to the turbo. Tightening torque: 8 Nm (5.9 lbf ft)
19. Fit the heat shield. Press the left clip on first. Coat the nut with Molycote 1000, part no. 30 20 971. Tightening torque: 20 Nm (14.7 lbf ft).
20. Fit the fan assembly. Ensure that it is positioned on the lower hooks. Tighten the two bolts on the sides of the fan assembly. Tightening torque: 8 Nm (5.9 lbf ft)
21. Plug in the fan assembly's connectors.
22. Fit the clip that holds the cooling system vent hose. On cars with automatic transmission, also attach the pipe mounting on the fan cowling.
23. Fit the upper radiator hose.
24. Fit the mass air flow sensor and air hose.
25. Fit the crankcase breather pipe to the camshaft cover and turbo intake pipe. Tightening torque: 24 Nm (17.7 lbf ft). IMPORTANT: Fit new copper washers to the bolt on the turbo intake pipe.
26. Plug in the mass air flow sensor and boost pressure control valve connectors.
27. Connect the bypass pipe and valve. Use a new O-ring lubricated with acid-free petroleum jelly (vaseline).
28. Tighten the bypass pipe screw and hose clamp. Tightening torque: 8 Nm (5.9 lbf ft)
29. Raise the car.
30. Connect the turbo oil return hose to the sump.
31. Fit and tighten the turbo oil pipe at the oil filter adapter. Tightening torque: 25 Nm (18.4 lbf ft)
32. For the turbo mounting. Tightening torque: 24 Nm (17.7 lbf ft).
33. Lower the car to the floor.
34. Check that the radiator drain cock is closed. Fill with coolant. For the correct mixture, see «TECHNICAL DATA»(ref-212216-S22882441022005122200000) . Close the radiator cap.
35. Start the car.
36. Set the heater control at full heat.
37. Warm up the engine to expel any air from the cooling system.
38. Raise the car and check for oil and water leaks.
39. Fit the lower front cover.
40. Lower the car to the floor.
41. Top up with coolant/oil as necessary.

The oxygen sensor is sensitive to impacts and jolting and must be handled with care.

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1. Position the car on a lift.
2. Remove the upper engine cover.
3. Remove the turbo bypass pipe and valve.
4. Unplug the connector for the temp/pressure sensor and detach the turbocharger delivery pipe from the throttle body. Leave the hose clip hanging.
5. Raise the car and undo the turbocharger delivery pipe connection to the charge air cooler.
6. Plug the charge air cooler outlet. Lower the car.
7. Remove the turbo delivery pipe.
8. Remove the exhaust manifold's heat shield.
9. Detach the hose connection from the front SAI valve by pressing together the clip and pulling it back. Undo the nut on the valve bracket.
10. Note the radio code if applicable. Remove the battery and vent hose.
11. Undo the bolt securing the front SAI pipe.
12. Remove the SAI pipe with valve from the exhaust manifold.
13. Detach the crankcase ventilation pipe between the turbo inlet pipe and the cylinder head and the hose from the oil trap.
14. Detach the turbo intake pipe. Bend the pipe aside.
15. Detach the turbo's outlet hose to the charge air cooler.
16. Unplug the fan motor connectors.
17. Remove the radiator fan.
18. Close off the inlet and return water hoses to the turbo. Use 30 07 739 Pinch-off pliers.
19. Remove the water pipes to the turbo.
20. Undo and remove the dipstick tube.
21. Remove the front pipe from the turbo.
22. Unplug the oxygen sensor connectors.
23. Raise the car.
24. Cut off the cable tie securing the oxygen sensor cables. Note how the cables are run and lower the cable.
25. Separate the pipe joint between the front and rear exhaust systems. NOTE: To ease disassembly of the front exhaust system, attach a 83 95 212 Cable tie around the front pipe.
26. Detach the front pipe from the rear exhaust manifold. Lower away the front exhaust system.
27. Remove the turbo's oil return pipe.
28. Remove the turbo mounting bracket.
29. Detach the oil pipe from the oil filter adapter.
30. Lower the car to the floor.
31. Undo the nuts securing the front exhaust manifold.
32. Remove the front exhaust manifold with turbo.