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Basic Engine, 2.0L: Overhaul Saab 9-5 II

Mechanical 20 illustrations ~1315 words

Balance Shaft Assembly

There are 2 block mounted balance shafts located on each side of the crankcase at the bottom of the cylinder bores. The balance shafts are driven by a single roller chain that also drives the water pump. The chain is tensioned by a hydraulic tensioner that is supplied pressure by the engine oil pump. This design promotes the maximum effectiveness of the balance shaft system and reduces noise and vibration.

Cylinder Head Assembly

The cylinder head is a semi-permanent mold aluminum casting. Pressed-in powdered metal valve guides and valve seat insets are used. The fuel injection nozzle is located below the intake port. The cylinder head incorporates camshaft journals and camshaft caps.

Assembling Components

  1. When assembling components, use only the sealant specified or equivalent in the service procedure.
  2. Sealing surfaces should be clean and free of debris or oil.
  3. Specific components such as crankshaft oil seals or valve stem oil seals may require lubrication during assembly.
  4. Components requiring lubrication will be identified in the service procedure.
  5. When applying sealant to a component, apply the amount specified in the service procedure.
  6. Do not allow the sealant to enter into any blind threaded holes, as it may prevent the bolt from clamping properly or cause component damage when tightened.
  7. Tighten bolts to specifications. Do not overtighten.

Cylinder Head Assembly (LDK, LHU)

Special Tools

  1. EN-8062 Valve Spring Compressor
  2. EN-9666 Valve Spring Tester
  3. EN-43963 Valve Spring Compressor (off car)

For equivalent regional tools, refer to SPECIAL TOOLS (LDK, LHU) .

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  1. WARNING: In order to avoid damage, install the spark plugs after the cylinder head has been installed on the engine. Install NEW cylinder head plugs (1). Coat the plugs with sealer. Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
  2. Inspect the valve springs.
  3. Look for the following conditions when inspecting the valve springs: Expanded height Unparallel spring ends Spring tension using EN-9666 tester Any distorted springs should be replaced
  4. Inspect the valves (1) and the valve seats. Refer to «VALVE AND SEAT GRINDING»(ref-653636-S10580900292014090100000) .
  5. Install the valves (1). Replace any valves, if required.
  6. NOTE: Always use NEW valve stem oil seals when assembling the cylinder head. Install the new valve seals (1). Fully seat the seals on the valve guides.
  7. Install the springs (1).
  8. WARNING: Compressed valve springs have high tension against the valve spring compressor. Valve springs that are not properly compressed by or released from the valve spring compressor can be ejected from the valve spring compressor with intense force. Use care when compressing or releasing the valve spring with the valve spring compressor and when removing or installing the valve stem keys. Failing to use care may cause personal injury. WARNING: Do not compress the valve springs to less than 24.0 mm (0.943 in). Contact between the valve spring retainer and the valve stem oil seal can cause potential valve stem oil seal damage. Install the retainer (2).
  9. Using the EN-8062 compressor and the EN-43963 compressor, compress the valve spring.
  10. Install the valve keys (1).
  11. Slowly release the EN-8062 compressor and the EN-43963 compressor from the valve/spring assembly.
  12. Inspect for proper valve key seating.
  13. Install the remaining valves, springs, and other components.
  14. Lubricate the camshaft position sensor O-ring with clean engine oil.
  15. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the intake camshaft position sensor (1) and bolt. Tighten the intake camshaft position sensor bolt to 10 Nm (89 lb in) .

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Scheme 323: Oil Pump Dismantling
Scheme 323: Oil Pump Dismantling

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  1. Remove the oil pressure relief valve plug (1), spring (2), and plunger (3).
  2. Remove the oil pump gerotor cover (1) and bolts.
  3. Clean all of the parts in cleaning solvent. Remove varnish, sludge, and dirt.
  4. Inspect the oil pump (2, 3) for wear and scoring. Ensure that all components are within specifications. Refer to «ENGINE MECHANICAL SPECIFICATIONS (LDK, LHU)»(ref-653636-S28533554622014090100000) .
  5. Replace the front cover (4) and oil pump assembly if it is out of specification or damaged.

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Scheme 325: Oil Pump Assemble
Scheme 325: Oil Pump Assemble

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  1. Lubricate all oil pump parts with engine oil.
  2. Install the inner gear (2) into the outer gear (3).
  3. NOTE: If gears are improperly installed in the front cover, the gerotor cover will not bolt on. Install the gears together into the front cover (4) with the hub of the center gear facing the front cover.
  4. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the oil pump gerotor cover (1) and bolts. Tighten the oil pump rotor bolts to 6 Nm (53 lb in) .
  5. Install the pressure relief valve plunger (3).
  6. Install the pressure relief valve spring (2).
  7. Install the relief valve plug (1) and tighten to 40 Nm (30 lb ft) .

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Scheme 327: Turbocharger Cleaning and Inspection (LDK, LHU)
Scheme 327: Turbocharger Cleaning and Inspection (LDK, LHU)

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  1. Completely inspect the turbocharger (1) and all other engine components that may cause similar conditions before replacing the turbocharger. Refer to «SYMPTOMS - ENGINE MECHANICAL»(ref-653636-S42805254002014090100000) .
  2. Clean all mating surfaces.
  3. Inspect all the threaded holes for damage.
  4. Inspect the wastegate actuator rod for damage.
  5. Inspect the compressor and turbine blades for damage or foreign material.
  6. Clean the turbocharger inlet mating surfaces.
  7. NOTE: Do not replace the turbocharger if cracks are found on the turbocharger inlet flange partition wall (1). Replacement should only be performed if external leaks are present. Inspect the turbocharger inlet mating surfaces for damage. Replace the turbocharger if damage is found.
  8. Inspect the turbocharger wastegate regulator solenoid hoses for damage. Replace the hoses if necessary.
  9. Inspect the turbocharger wastegate regulator solenoid valve assembly (2) and bracket (1). Replace as necessary.
  10. Inspect the turbocharger air bypass diaphragm assembly (2), valve cover (1), and valve spring (3). Replace as necessary.
  11. NOTE: Do not remove the PCV hose from the fitting as damage to the hose will occur. Inspect the positive crankcase ventilation (PCV) O-ring (2) for damage. Replace the O-ring if damaged or leaking.
  12. Inspect the PCV hose and PCV fitting (1) for damage. Replace the camshaft cover if damage to the PCV hose or fitting is present.

Service Prior to Assembly

The importance of cleanliness during assembly cannot be overstated. Dirt or debris will cause engine damage. An automobile engine is a combination of many machined, honed, polished and lapped surfaces with tolerances that are measured in ten thousandths of an inch. When any internal engine parts are serviced, care and cleanliness are important. A liberal coating of engine oil should be applied to friction areas during assembly in order to protect and lubricate the surfaces on initial operation. Throughout this section, it should be understood that proper cleaning and protection of machined surfaces and friction areas are part of the repair procedure. This is considered standard shop practice even if not specifically stated.

Lubricate all moving parts with engine oil or a specified assembly lubricant. This will provide lubrication for initial start up.

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Scheme 332: Cylinder Block Cleaning and Check (LDK, LHU)
Scheme 332: Cylinder Block Cleaning and Check (LDK, LHU)

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  1. NOTE: Apply sealant to all plugs prior to installation. Install the drain plug with sealant in the water pump. Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
  2. Refer to «FASTENER CAUTION»(ref-653635-S22306564902014090100000) . Install the coolant jacket plugs with sealant and tighten to 35 Nm (26 lb ft) . 2.1. Install the rear oil channel plugs (3) with sealant and tighten to 60 Nm (44 lb ft) . 2.2. Install the other oil channel plugs (1, 2) with sealant and tighten to 35 Nm (26 lb ft) .
  3. Lubricate the crankshaft position (CKP) sensor O-ring with clean engine oil. Refer to «ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS (LDK, LHU)»(ref-653636-S40994991802014090100000) .
  4. Install the CKP sensor (1) and bolt and tighten to 10 Nm (89 lb in) .
  5. Install the oil pressure switch (2) and tighten to 26 Nm (19 lb ft) .
  6. Install the knock sensors (1) with the bolts and tighten to 25 Nm (18 lb ft) .
  7. Install the piston's oil jets (1) and tighten to 15 Nm (11 lb ft) .

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