Engine Mechanical - 4.2L: Diagnosis Saab 9-7X I

Diagnostic Starting Point - Engine Mechanical

Begin the system diagnosis by reviewing the Disassembled Views , Engine Component Description , and Lubrication Description . Reviewing the description and operation information will help you determine the correct symptom diagnostic procedure when a malfunction exists. Reviewing the description and operation information will also help you determine if the condition described by the customer is normal operation. Refer to Symptoms - Engine Mechanical in order to identify the correct procedure for diagnosing the system and where the procedure is located.

Strategy Based Diagnostics

1. Perform A Diagnostic System Check in Engine Controls before using the symptom tables (if applicable).
2. Review the system operations in order to familiarize yourself with the system functions. Refer to «Disassembled Views»(ref-268132-S21720020282007101800000) , «Engine Component Description»(ref-268132-S18328679872007101800000) , and «Lubrication Description»(ref-268132-S39852021042007101800000) .

All diagnosis on a vehicle should follow a logical process. Strategy based diagnostics is a uniform approach for repairing all systems. The diagnostic flow may always be used in order to resolve a system problem. The diagnostic flow is the place to start when repairs are necessary.

Visual/Physical Inspection

1. Inspect for aftermarket devices which could affect the operation of the engine.
2. Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.
3. Check for the correct oil level, proper oil viscosity, and correct filter application.
4. Verify the exact operating conditions under which the concern exists. Note factors such as engine RPM, ambient temperature, engine temperature, amount of engine warm-up time, and other specifics.
5. Compare the engine sounds (if applicable) to a known good engine and make sure you are not trying to correct a normal condition.

Symptom List

Refer to a symptom diagnostic procedure from the following list in order to diagnose the symptom

1. «Base Engine Misfire without Internal Engine Noises»(ref-268132-S38194518962007101800000)
2. «Base Engine Misfire with Abnormal Internal Lower Engine Noises»(ref-268132-S31447136152007101800000)
3. «Base Engine Misfire with Abnormal Valve Train Noise»(ref-268132-S22911807482007101800000)
4. «Base Engine Misfire with Coolant Consumption»(ref-268132-S02126961092007101800000)
5. «Base Engine Misfire with Excessive Oil Consumption»(ref-268132-S33278263732007101800000)
6. «Engine Compression Test»(ref-268132-S03424970002007101800000)
7. «Engine Noise on Start-Up, but Only Lasting a Few Seconds»(ref-268132-S38148650002007101800000)
8. «Upper Engine Noise, Regardless of Engine Speed»(ref-268132-S28876524542007101800000)
9. «Lower Engine Noise, Regardless of Engine Speed»(ref-268132-S01482958192007101800000)
10. «Engine Noise Under Load»(ref-268132-S15748772922007101800000)
11. «Engine Will Not Crank - Crankshaft Will Not Rotate»(ref-268132-S08669069462007101800000)
12. «Oil Consumption Diagnosis»(ref-268132-S12540880372007101800000)
13. «Oil Pressure Diagnosis and Testing»(ref-268132-S19563963222007101800000)
14. «Oil Leak Diagnosis»(ref-268132-S31787503812007101800000)
15. «Drive Belt Chirping, Squeal, and Whine Diagnosis»(ref-268132-S25844822372007101800000)
16. «Drive Belt Rumbling and Vibration Diagnosis»(ref-268132-S06228097152007101800000)
17. «Drive Belt Falls Off and Excessive Wear Diagnosis»(ref-268132-S19042195422007101800000)

Oil Consumption Diagnosis

Oil Consumption Diagnosis

Oil Pressure Diagnosis and Testing

Tools Required

1. J 21867 Pressure Gage and Hose Assembly. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. J 42907 Oil Pressure Tester. See «Special Tools»(ref-268132-S26120190452007101800000) .

Scheme 1

1. With the vehicle on a level surface, run the vehicle for a few minutes, allow adequate drain down time (2-3 minutes) and measure for a low oil level.
2. If required, add the recommended grade engine oil and fill the crankcase until the oil level measures full on the oil level indicator.
3. Run the engine briefly (10-15 seconds) and verify low or no oil pressure on the vehicle gage or light.
4. Listen for a noisy valve train or a knocking noise.
5. Inspect for the following: Oil diluted by water or glycol (anti freeze) Foamy oil
6. Remove the oil filter and install the J 42907 . See «Special Tools»(ref-268132-S26120190452007101800000) .
7. Install J 21867 or equivalent to the J 42907 . See «Special Tools»(ref-268132-S26120190452007101800000) .
8. Run the engine and measure the engine oil pressure.
9. Compare the readings to «Engine Mechanical Specifications»(ref-268132-S23912727782007101800000) .
10. If the engine oil pressure is below specifications, inspect the engine for one or more of the following: Oil pump worn or dirty Refer to «Oil Pump Cleaning and Inspection»(ref-268132-S23895321382007101800000) . Oil pump screen loose, plugged, or damaged Oil pump screen O-ring seal missing or damaged Malfunctioning oil pump pressure regulator valve Excessive bearing clearance Cracked, porous, or restricted oil galleries Oil gallery plugs missing or incorrectly installed Refer to «Engine Block Plug Installation»(ref-268132-S06354983662007101800000) . Broken valve lash adjusters Repair as necessary
11. If the reading on J 21867 or equivalent is within specifications, inspect for the following. See «Special Tools»(ref-268132-S26120190452007101800000) . Plugged or incorrect oil filter and/or malfunctioning oil bypass valve Malfunctioning vehicle oil pressure gage or sensor Repair as necessary

Oil Leak Diagnosis

Oil Leak Diagnosis

Scheme 2

A crankcase ventilation system is used in order to provide a more complete scavenging of crankcase vapors. The air cleaner supplies fresh air (1) through a filter to the crankcase.

Scheme 3

The crankcase mixes the fresh air with blow-by gases. This mixture then passes through an orifice in the cylinder head gasket and to a pipe located in the intake manifold.

The crankcase ventilation system has no serviceable components so no maintenance of the system is required.

Crankcase Ventilation System Inspection/Description

Diagnostic Aids

1. A chirping or squeal noise may be intermittent due to moisture on the drive belts or the pulleys. It may be necessary to spray a small amount of water on the drive belts in order to duplicate the customers concern. If spraying water on the drive belt duplicates the symptom, cleaning the belt pulleys may be the probable solution.
2. If the noise is intermittent, verify the accessory drive components by varying their loads making sure they are operated to their maximum capacity. An overcharged A/C system, power steering system with a pinched hose or wrong fluid, or a generator failing are suggested items to inspect.
3. A chirping, squeal or whine noise may be caused by a loose or improper installation of a body or suspension component. Other items of the vehicle may also cause the noise.
4. The drive belts will not cause a whine noise.

The accessory drive components can have an affect on engine vibration. Vibration from the engine operating may cause a body component or another part of the vehicle to make rumbling noise. Vibration can be caused by, but not limited to the A/C system over charged, the power steering system restricted or the incorrect fluid, or an extra load on the generator. To help identify an intermittent or an improper condition, vary the loads on the accessory drive components.

The drive belt may have a rumbling condition that can not be seen or felt. Sometimes replacing the drive belt may be the only repair for the symptom.

If replacing the drive belt, completing the diagnostic table, and the noise is only heard when the drive belts are installed, there might be an accessory drive component with a failure. Varying the load on the different accessory drive components may aid in identifying which component is causing the rumbling noise.

If the drive belt repeatedly falls off the drive belt pulleys, this is because of pulley misalignment.

An extra load that is quickly applied on released by an accessory drive component may cause the drive belt to fall off the pulleys. Verify the accessory drive components operate properly.

If the drive belt is the incorrect length, the drive belt tensioner may not keep the proper tension on the drive belt.

Excessive wear on a drive belt is usually caused by an incorrect installation or the wrong drive belt for the application.

Minor misalignment of the drive belt pulleys will not cause excessive wear, but will probably cause the drive belt to make a noise or to fall off.

Excessive misalignment of the drive belt pulleys will cause excessive wear but may also make the drive belt fall off.

Inspection Procedure

1. Remove the drive belts. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) . NOTE: Allowing the drive belt tensioner to snap into the free position may result in damage to the tensioner.
2. Position a hex-head socket on the belt tensioner pulley bolt head.
3. Move the drive belt tensioner through it's full travel. The movement should feel smooth. There should be no binding. The tensioner should return freely.
4. If any binding is observed, replace the tensioner. Refer to «Drive Belt Tensioner Replacement»(ref-268132-S05659799512007101800000) .
5. Install the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .

Camshaft Position Actuator Diagnosis

For overall description of the camshaft position actuator refer to Exhaust Camshaft Position Actuator Description .

The camshaft position actuator will only phase 25-cam degrees retard (counterclockwise). Full advance (clockwise) is 0 degrees.

Scheme 4

The camshaft position actuator should always be serviced/replaced in the full advanced position (full clockwise or 0 degrees). New replacement (service) camshaft position actuators are shipped at full advance or 0 degrees. To be sure the camshaft position actuator is performing properly, perform the following to help in the diagnostics.

The camshaft position actuator must be removed from the engine to perform the proper diagnostic test.

Scheme 5

Scheme 6

Scheme 7

Scheme 8

1. Clamp the camshaft actuator in a vice. Use care not to damage the contact area of the sprocket.
2. Scribe or draw a line (1) on the camshaft position actuator outer ring face, in the full advanced position. With the engine at TDC on #1 cylinder, the wording should be level.
3. Apply compressed air pressure to the oil port (1) on the back side of the actuator to unlock the locking pin.
4. Turn the actuator, by hand, to the full counterclockwise position.
5. Scribe or draw a line (2) on the camshaft position actuator at that position.
6. Measure the distance between the two lines. The measurement (3) should be 14-15 mm (0.55-0.59 in). IMPORTANT: It is normal for oil and air to leak out of the camshaft actuator when compressed air is applied. It is also normal for oil bubbles to form on the camshaft sprocket surface due to porosity caused by the casting process. Do not replace the actuator due to this leakage. The camshaft position actuator must be replaced if it does not unlock when air pressure is applied, does not lock when air pressure is removed, or does not move within the 14-15 mm (0.55-0.59 in).

Scheme 9

1. Install 3/8 inch breaker bar on the drive belt tensioner arm and turn the breaker bar clockwise enough to relieve the tension on the drive belt.
2. Remove the drive belt.
3. Release the tension on the tensioner arm.

Engine Block Cleaning and Inspection

Tools Required

1. J 8001 Dial Indicator Set
2. J 8087 Cylinder Bore Gauge. See «Special Tools»(ref-268132-S26120190452007101800000) .
3. J 45059 Angle Meter. See «Special Tools»(ref-268132-S26120190452007101800000) .

Scheme 10

Scheme 11

Scheme 12

Scheme 13

1. Clean the sealing material from all gasket mating surfaces.
2. Clean the engine block with a cleaning solution.
3. Flush the engine block with clean water.
4. Clean the oil passages.
5. Coat the cylinder bores and the machined surfaces with engine oil.
6. Inspect the threaded holes. Clean the holes with a tap, if needed.
7. Use a straight edge and a feeler gauge to check the deck surface for flatness. Carefully remove any minor irregularities. Replace the block if there is more than 0.08 mm (0.003 in) gap.
8. Inspect the cylinder bores. Use J 8087 to measure the cylinder bore. See «Special Tools»(ref-268132-S26120190452007101800000) . Inspect the bores for the following conditions: Wear Taper Runout Ridging
9. Replace the cylinder sleeve if the bore is out of specification.
10. Inspect the oil pan rail for nicks. Use a flat file to remove an nicks.
11. Inspect the front cover attaching area for nicks. Use a flat file to remove any nicks.
12. Inspect the mating surfaces of the transmission case.
13. Use the following procedure to measure the engine block flange runout at the mounting bolt hole bosses: Temporarily install the crankshaft. Measure the crankshaft flange runout. Hold a gauge plate flat against the crankshaft flange. Place J 8001 (dial indicator stem) on the transmission mounting bolt hole boss. Set the indicator to zero. Record the readings obtained from all of the bolt hole bosses. The measurements should not vary more than 0.25 mm (0.010 in). Recheck the crankshaft flange runout if the readings vary more than 0.25 mm (0.010 in). If the crankshaft flange runout is within the specification, replace the engine block.
14. Remove the crankshaft.
15. Re-install the crankshaft bearing caps, stiffener, and bolts. Tighten: Tighten the crankshaft bearing cap bolts to 25 N.m (18 lb ft). Use J 45059 to tighten the crankshaft bearing cap bolts an additional 180 degrees. See «Special Tools»(ref-268132-S26120190452007101800000) . NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
16. Inspect the crankshaft main bearing bores. Use J 8087 to measure the bearing bore concentricity and alignment. See «Special Tools»(ref-268132-S26120190452007101800000) . IMPORTANT: Perform the following inspections, and reconditioning (if necessary), with the crankshaft main bearing caps installed and tightened to specification.
17. Remove the crankshaft main bearing cap stiffener and main bearing caps with bearings.

Scheme 14

1. When honing the cylinder bores, follow the manufacturer's recommendations for equipment use, cleaning, and lubrication. Use only clean sharp stones of the proper grade for the amount of material to be removed. Dull, dirty stones cut unevenly and generate excessive heat. DO NOT hone to a final grade with a coarse or medium-grade stone. Leave sufficient metal so that all the stone marks will be removed with the fine grade stones. Perform the final honing with a fine-grade stone and hone the cylinder bore in a cross hatch pattern at 45-65 degrees to obtain the proper clearance. CAUTION: Refer to «Safety Glasses Caution»(ref-268087-S01092725012007101800000) in Cautions and Notices.
2. During the honing operation, thoroughly check the cylinder bore. Repeatedly check the cylinder bore fit with the selected piston. All measurements of the piston or cylinder bore should be made with the components at normal room temperature.
3. When honing to eliminate taper in the cylinder bore, use full strokes the complete length of the cylinder bore. Repeatedly check the measurement at the top, the middle, and the bottom of the cylinder bore. The finish marks should be clean but not sharp. The finish marks should be free from imbedded particles or torn or folded metal.
4. When finished, the reconditioned cylinder bores should have less than or meet the specified out-of-round and taper requirements.
5. After the final honing and before the piston is checked for fit, clean the cylinder bore with hot water and detergent. Scrub the cylinder bores with a stiff bristle brush. Rinse the cylinder bores thoroughly with clean hot water. Dry the cylinder bores with a clean rag. Do not allow any abrasive material to remain in the cylinder bores. Abrasive material may cause premature wear of the new piston rings and the cylinder bores. Abrasive material will contaminate the engine oil and may cause premature wear of the bearings.
6. Perform final measurements of the piston and the cylinder bore.
7. Permanently mark the top of the piston for the specified cylinder to which it has been fitted.
8. Apply clean engine oil to each cylinder bore in order to prevent rusting.

Crankshaft and Bearings Cleaning and Inspection

Tools Required

1. J 45059 Angle Meter. See «Special Tools»(ref-268132-S26120190452007101800000) .
2. J 8087 Cylinder Bore Gauge. See «Special Tools»(ref-268132-S26120190452007101800000) .

Scheme 15

Scheme 16

Scheme 17

Scheme 18

1. Clean the crankshaft of all elements. IMPORTANT: Use care when handling the crankshaft. Avoid damaging the crankshaft reluctor wheel. Nicks, burrs or other damage to the teeth may effect the On-Board Diagnostics (OBD) II system performance.
2. Inspect the crankshaft oil passages for obstructions.
3. Inspect the crankshaft for the following conditions: Damaged threads (1) Damaged mounting faces Worn crankshaft pin (2) Wear without any grooves or scratches (3) Grooves or scoring (3) Scratches (3) Pitting or embedded bearing material (3) Overheating (discoloration) (3)
4. Inspect the corresponding crankshaft bearing inserts for embedded material and determine the source of the material.
5. Inspect the outer surfaces of the crankshaft bearings for the following conditions: Wear - surface wear indicates either movement of the insert or high spots in the surrounding material (spot wear) Overheating or discoloration Looseness or rotation indicated by flattened tangs and wear grooves IMPORTANT: If cracks, severe gouges or burned spots are found, replace the crankshaft. Remove slight roughness using a fine polishing cloth soaked in clean engine oil. Remove any burrs using a fine oil stone.
6. Inspect the crankshaft main bearings for craters or pockets. Flattened sections on the crankshaft bearing halves also indicate fatigue. IMPORTANT: Note the location of the crankshaft main bearing high spots. If the spots are not in line, the crankshaft is bent. Replace the crankshaft.
7. Inspect the thrust surfaces of the main thrust bearing for the following conditions: Wear Grooving - Grooves are caused by irregularities of the crankshaft thrust surface.
8. Inspect the crankshaft bearings for excessive scoring or discoloration.
9. Inspect the crankshaft bearings for dirt or imbedded debris.
10. Inspect the crankshaft bearings for improper seating indicated by bright, polished sections.
11. Inspect the crankshaft bearings for uneven side-to-side wear. This may indicate a bent crankshaft or a tapered bearing journal.
12. Inspect the connecting rod bearing bores using the following procedure: Tighten the connecting rod bearing cap to specification. Use J 8087 to measure the bearing bore for taper and out-of-round. See «Special Tools»(ref-268132-S26120190452007101800000) . Record the readings. No taper or out-of-round should exist. IMPORTANT: If crankshaft bearing failure is due to conditions other than normal wear, investigate the cause of the condition. Inspect the crankshaft or connecting rod bearing bores.
13. Measure the crankshaft bearing journal diameter with a micrometer in several places, 90 degrees apart. Average the measurements.
14. Measure the crankshaft bearing journal taper and runout.
15. Install the crankshaft bearing caps. IMPORTANT: Refer to the pin stamp on the crankshaft main bearing caps for sequence and direction of installation. The pin stamp arrow points to the front of the engine.
16. Install the crankshaft main bearing cap stiffener.
17. Install the crankshaft bearing cap bolts. Tighten: Tighten the crankshaft bearing cap bolts to 25 N.m (18 lb ft). Use J 45059 to tighten the crankshaft bearing cap bolts an additional 180 degrees. See «Special Tools»(ref-268132-S26120190452007101800000) . NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
18. Measure the crankshaft main bearing inside diameter with an inside micrometer.
19. Measure the connecting rod inside diameter in the same direction as the length of the rod with an inside micrometer.
20. If the specified clearances cannot be met, the crankshaft, connecting rods, or block may need to be replaced.

Scheme 19

1. Inspect the crankshaft balancer sealing area for grooves, nicks, or burs (1).
2. Inspect the crankshaft balancer belt ribs for dents or damage (2).
3. Replace the crankshaft balancer if damage is present.

Scheme 20

1. Inspect the engine flywheel for cracks (1).
2. Inspect the engine flywheel teeth for damage (2).
3. Replace the engine flywheel if damage is present.