Home ReviewsRefund
Home/Saab/9-7X/Saab 9-7X I (2005-2009)/Repair manual/Mechanical/Engine Mechanical - 4.2L: Overhaul
Contents Wiring diagrams Section: Mechanical All sections

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

Mechanical 18 illustrations ~1258 words

Cylinder Head Disassemble

Tools Required

  1. EN 46119 Valve Spring Compressor Adapter. See «Special Tools»(ref-268132-S26120190452007101800000) .
  2. J 8062 Valve Spring Compressor. See «Special Tools»(ref-268132-S26120190452007101800000) .
  3. J 38820 Valve Stem Seal Remover/Installer. See «Special Tools»(ref-268132-S26120190452007101800000) .

Scheme 119

Scheme 119
Scheme 119

Scheme 120

Scheme 120
Scheme 120

Scheme 121

Scheme 121
Scheme 121

Scheme 122

Scheme 122
Scheme 122

Scheme 123

Scheme 123
Scheme 123

Scheme 124

Scheme 124
Scheme 124

Scheme 125

Scheme 125
Scheme 125
  1. Remove the spark plugs.
  2. Use J 8062 and EN 46119 to compress the valve spring. See «Special Tools»(ref-268132-S26120190452007101800000) . IMPORTANT: Organize the valve train components when disassembling so they can be reassembled in the same location and matched up with the same components as previously installed.
  3. Remove the valve keys.
  4. Remove J 8062 and EN 46119 . See «Special Tools»(ref-268132-S26120190452007101800000) .
  5. Remove the valve spring retainer and valve spring.
  6. Remove the valves.
  7. Use J 38820 to remove the valve seals. See «Special Tools»(ref-268132-S26120190452007101800000) .
  8. Inspect the water jacket plug, for leakage. Replace if necessary.
  9. Inspect the (inner) oil gallery plug, for leakage. Replace if necessary.
  10. Inspect the (end) oil gallery plugs, for leakage. Replace if necessary.

Cylinder Head Assemble

Tools Required

  1. EN 46119 Valve Spring Compressor Adapter. See «Special Tools»(ref-268132-S26120190452007101800000) .
  2. J 8062 Valve Spring Compressor. See «Special Tools»(ref-268132-S26120190452007101800000) .
  3. J 38820 Valve Stem Seal Remover/Installer. See «Special Tools»(ref-268132-S26120190452007101800000) .

Scheme 126

Scheme 126
Scheme 126
  1. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the threads.
  2. Install the (end) oil gallery plugs. Tighten: Tighten the oil gallery plugs to 38 N.m (28 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
  3. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the plugs.
  4. Install the (inner) oil gallery plugs.
  5. Apply sealant GM P/N 12378521 (Canadian P/N 88901148) or equivalent to the plug.
  6. Install the water jacket plug.
  7. Use J 38820 to install the valve seals. See «Special Tools»(ref-268132-S26120190452007101800000) . There is only one size valve seal.
  8. Install the valves. 0.075 mm (0.003 in) oversized valves are available if the valve guides needed to be reamed. Use the same (original size) valve seal. IMPORTANT: Lubricate the valve stems with clean engine oil before installing.
  9. Install the valve spring and the valve spring retainer.
  10. Use J 8062 and EN 46119 to compress the valve spring. See «Special Tools»(ref-268132-S26120190452007101800000) .
  11. Install the valve keys.
  12. Remove J 8062 and EN 46119 . See «Special Tools»(ref-268132-S26120190452007101800000) .
  13. Measure the valve installed height using a ruler. Measure from the base of the valve spring to the top of the valve. Refer to «Engine Mechanical Specifications»(ref-268132-S23912727782007101800000) .
  14. Install the remaining valves, springs, and other components.
  15. Install the spark plugs. IMPORTANT: Do not try to centralize the electrode on the spark plug. The electrode is offset by design.

Scheme 127

Scheme 127: Camshaft Cover Cleaning and Inspection
Scheme 127: Camshaft Cover Cleaning and Inspection
  1. Remove and discard the rubber ignition coil seals, and the camshaft cover seal.
  2. Clean the camshaft cover with a suitable cleaning solvent.
  3. Inspect the camshaft cover for cracks or damage.
  4. Inspect the bolt threads for damage.
  5. Replace the camshaft cover if necessary.

Scheme 128

Scheme 128: Oil Pump Cleaning and Inspection
Scheme 128: Oil Pump Cleaning and Inspection

Scheme 129

Scheme 129
Scheme 129

Scheme 130

Scheme 130
Scheme 130
  1. Clean all parts of sludge, oil, and varnish by soaking in carburetor cleaner or cleaning solvent.
  2. Inspect for foreign material and determine the source of the foreign material.
  3. Inspect the oil pump housing and engine front cover for the following conditions: Cracks or casting imperfections Scoring Damaged threads
  4. Do not attempt to repair the oil pump housing. Replace the oil pump housing if damage is found.
  5. Inspect the oil pump gears for damage.
  6. Measure the inner oil pump gear tip clearance in several places.
  7. Measure the outer oil pump gear tip clearance in several places.
  8. Measure the oil pump gear side clearance. IMPORTANT: When deciding oil pump serviceability based on end clearance, consider depth of the wear pattern in the pump cover.
  9. Inspect the pressure regulator valve for the following conditions: Scoring Sticking Burrs - Burrs may be removed using a fine oil stone.
  10. Inspect the pressure regulator valve spring for loss of tension or bending. Replace the pressure regulator spring if damaged.
  11. Inspect the oil pump pipe pickup tube and screen assembly for the following conditions: Looseness - If the oil pump pipe pickup tube is loose or bent, replace the oil pump pipe pickup tube. Broken wire mesh or screen Inspect the O-ring seal at the base of the oil pump pickup tube for damage.

Scheme 131

Scheme 131: Oil Pan Cleaning and Inspection
Scheme 131: Oil Pan Cleaning and Inspection
  1. Clean the oil pan in solvent. Remove all sludge and debris from the oil pan.
  2. Remove all sealing material from the oil pan rails. IMPORTANT: Do not use a motorized tool or bristle disc to clean this component.
  3. Inspect the oil pan sealing surfaces for nicks or damage. Remove any minor nicks with a fine flat file.
  4. Inspect the threads in the oil drain plug hole.
  5. Replace the oil pan if necessary.

Scheme 132

Scheme 132: Engine Front Cover Cleaning and Inspection
Scheme 132: Engine Front Cover Cleaning and Inspection
  1. Clean the engine front cover with cleaning solvent.
  2. Remove all sealing material. IMPORTANT: Do not use a motorized tool or bristle disc to clean this component.
  3. Inspect the engine front cover sealing surfaces for nicks or damage. Use a fine flat file to remove any minor nicks.
  4. Inspect the engine front cover threaded holes for damage.
  5. Repair or replace the engine front cover as necessary.

Scheme 133

Scheme 133: Intake Manifold Cleaning and Inspection
Scheme 133: Intake Manifold Cleaning and Inspection
  1. Clean the intake manifold gasket mating surface.
  2. Inspect the threads on the retaining bolts.
  3. Inspect the intake manifold for cracks.
  4. Clean the internal ports of all debris.
  5. Replace the intake manifold if necessary.

Scheme 134

Scheme 134: Exhaust Manifold Cleaning and Inspection
Scheme 134: Exhaust Manifold Cleaning and Inspection
  1. Clean the exhaust manifold.
  2. Inspect the exhaust manifold for cracks or damage.
  3. Inspect the exhaust manifold threads and studs (if necessary).
  4. Check the exhaust manifold mating surface for flatness. Use a straight edge and a feeler gauge.
  5. Replace the exhaust manifold if necessary.

Scheme 135

Scheme 135: Water Pump Cleaning and Inspection
Scheme 135: Water Pump Cleaning and Inspection
  1. Remove all sealing material from the sealing surface.
  2. Inspect the water pump impeller for damage.
  3. Inspect the water pump shaft for looseness.
  4. Inspect the threads for damage.
  5. Replace the water pump if necessary.

Service Prior to Assembly

Dirt will cause premature wear of the rebuilt engine. Clean all of the components. Use the proper tools in order to measure components when inspecting for excessive wear. Repair or replace the components that are not within the manufacturers specification. When components are reinstalled into an engine, return the components to their original location, position, and direction. During assembly, lubricate all of the moving parts with clean engine oil or engine assembly lubricant (unless otherwise specified). This will provide initial lubrication when the engine is first started.

Scheme 136

Scheme 136
Scheme 136
  1. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the plug threads.
  2. Install the engine block oil gallery plug to rear of block. Tighten: Tighten the engine block oil gallery plug to 80 N.m (40 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) in Cautions and Notices.
  3. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the plug threads.
  4. Install the engine block oil gallery plugs to front and left of block. Tighten: Tighten the side engine block oil gallery plugs to 35 N.m (26 lb ft). Tighten the front (1) engine block oil gallery plug to 80 N.m (40 lb ft).
  5. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the coolant temperature sensor threads.
  6. Install the coolant temperature sensor. Tighten: Tighten the coolant temperature sensor to 20 N.m (15 lb ft).
  7. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the EVAP solenoid bolt threads. Tighten: Tighten the EVAP solenoid bolt to 10 N.m (89 lb in).
  8. Install the knock sensors. Tighten: Tighten the knock sensors to 25 N.m (18 lb ft).
  9. Add sealer GM P/N 12346004 (Canadian P/N 10953480) to the crankshaft position sensor bolt.
  10. Install the crankshaft position sensor and bolt. Tighten: Tighten the crankshaft position sensor bolt to 10 N.m (89 lb in).

More articles — Engine Mechanical - 4.2L