Remove/install/overhaul Saab 9000 I

INTRODUCTION

Removal, overhaul and installation procedures (when given by manufacturer) are covered in this article. If component removal and installation is primarily an unbolt and bolt on procedure, a simple tightening specification may be all that is furnished.

DISTRIBUTOR

Note. Information for removal and installation of distributor is not available from manufacturer. Refer to DISTRIBUTOR HOLD- DOWN BOLT TORQUE SPECIFICATIONS table when installing distributor.

DISTRIBUTOR HOLD-DOWN BOLT TORQUE SPECIFICATION

Removal & Installation

1. Remove firewall panel. Relieve fuel pressure by removing fuel pump fuse and starting engine. Wait until engine stalls. Turn ignition off. Disconnect fuel return line to pressure regulator and vacuum hose to intake manifold.
2. Disconnect electrical connector from injectors. Remove bolts from fuel injector rail, but leave injectors in place. Remove injector "O" ring seals from inlet manifold.
3. Lift out injector rail with injectors. Remove injector clip. Remove injector from fuel rail. To install injectors, lubricate injector "O" ring with Vaseline and reinstall. To complete installation, reverse removal procedure.

1. Remove and tilt up fuel rail. See «FUEL RAILS & INJECTORS»(/saab/9000/i-1984-1994/remont/removal-installation/#removeinstalloverhaul) removal and installation. Disconnect hose to fuel rail from fuel pressure regulator. Use rag to soak up any escaping fuel.
2. Disconnect hose to inlet manifold from fuel pressure regulator. Unscrew fuel pressure regulator from inlet manifold. Lift regulator and remove clip on fuel return hose.
3. Remove screw from fuel pressure regulator bracket. Remove fuel pressure regulator. To install, reverse removal procedure.

Scheme 1

Scheme 2

Scheme 3

1. Disconnect negative battery cable (-) and cover terminal pole on battery. Remove fuel pump access cover in floor of luggage compartment. Disconnect pump wiring. CAUTION: On cars with AH 2.4 fuel injection, disconnecting battery will erase control units adaptive memory. When engine is restarted it may operate erratically. The engine must be driven for at least 30 minutes for adaptive memory to be reset.
2. Disconnect fuel line from pump. Using an open-ended wrench, hold pump still while removing dome nut. WARNING: Fuel will be expelled when fuel lines are disconnected and pump is removed. DO NOT smoke or create sparks. Have an approved fire extinguisher handy. CAUTION: To reduce possibility of breaking pump terminal when loosening center banjo bolt use Part No. 83 94 330 wrench.
3. Lift pump up just enough to disconnect fuel return line from fuel reservoir and wiring from supply pump. Using flexible nut driver, loosen collar mounting strap. Carefully lift out pump.
4. To disassemble pump, pull main pump out of reservoir. The supply pump is held with a bracket and two screws.
5. To assemble pump, install wiring to supply pump and install supply pump into reservoir, pressing it against stop. NOTE: On supply pump, White wire goes to positive (+) terminal and Black wire to negative (-) terminal.
6. Install main pump into collar and adjust it to height in Fig. (Scheme 1). Install pump with collar into reservoir and adjust total height of pump assembly to specifications. See «MAIN FUEL PUMP IN RESERVOIR DIMENSIONS»(/saab/9000/i-1984-1994/remont/removal-installation/#removeinstalloverhaul) table. (Scheme 1): Main Fuel Pump MAIN FUEL PUMP IN RESERVOIR DIMENSIONS Application Inches (mm) Dimension "A" 1.65 +/- 0.08 (42 +/- 2) Dimension "B" (1) 9 1/2 (242) (1) From VIN J3001528 & J7004074. NOTE: Proper pump height and pump orientation in tank is very important. Scribe mark 1 21/32" or 1.65" (42mm) from top of pump to accurately position collar to pump during assembly. NOTE: Supply pump on some early models may be equipped with a "bow-tie" style strainer. For better fuel pick-up and delivery, a modified strainer should be installed; Saab Part No. 93 86 491. (Scheme 2) (Scheme 2): Supply Pump
7. Install pump into tank, making sure to reconnect fuel pump connector and fuel return line before fully installing pump. Orient pump (Scheme 3) Tighten mounting collar clamp. Using sealing washers, reinstall fuel line and banjo bolt/dome nut. Reconnect wiring. NOTE: The direction of pump rotation is determined by polarity of wiring so "+" and "-" signs are cast in pump housing to ensure proper wiring connection. (Scheme 3): Fuel Pump Orientation Relative to Tank

Rotor Type Pump

Note. Always replace O-rings when removing and installing rotor-type pump.

Scheme 4

Scheme 5

1. Disconnect negative battery cable. Remove access panel from above pump located in luggage compartment. Remove fuel line and wiring clamp. Disconnect wiring. Disconnect fuel lines using round jaw type pliers (pull straight up). Tie fuel lines back.
2. Loosen large thread retaining collar while holding pump stationary. Lift pump assembly up then tilt slightly to remove from tank.
3. Carefully insert new pump (ejector side first). Ensure matching mark on pump is aligned with mark on tank. (Scheme 4) (Scheme 4): Pump Assembly Alignment Marks (Relative to Tank)
4. Lubricate new collar seal with petroleum jelly and insert into retaining collar. Install collar while aligning matching marks. (Scheme 5) Press down firmly. Tighten collar until collar unit stops. NOTE: For (Scheme 5) below, locating marks on retaining collar must be within 30° to either side of marks on pump and tank. (Scheme 5): Retaining Collar & Fuel Tank Alignment Marks CAUTION: DO NOT allow pump assembly to turn when tightening collar. Otherwise ejector assembly may be damaged. Check locating marks on pump are still aligned after tightening.
5. Reconnect fuel lines using new O-rings. The return line (with check valve) attaches to outlet nearest front of car. The supply line attaches to rear of outlet. Reconnect wiring and fit clamp.

Exhaust Gas Oxygen (O2) Sensor

O2 sensor is mounted on the exhaust pipe just below the exhaust header. Ensure sensor is free of contaminants, avoid using cleaning solvents of any type. Always use anti-seize compound on threads prior to installation. Tighten O2 sensor to 25-30 ft. lbs. (35-41 N.m).

1. Drain about 2 qts. (1.9L) of coolant. Disconnect throttle cable and remove bracket from throttle housing. Remove TPS connector.
2. Disconnect preheater hoses from throttle body. Disconnect hoses from auxiliary air valve. Remove turbo delivery pipe (if equipped). Disconnect vacuum hoses from throttle body. Remove throttle body mounting bolts. Remove throttle body. To install, reverse removal procedure. Tighten throttle housing to 13.5 ft. lbs. (18 N.m).

Remove TPS connector. Remove TPS. To install, reverse removal procedure. To adjust, see ADJUSTMENTS article in this section.

1. Release A/C compressor belt tensioner. Remove top pipe to oil cooler and clips securing pipe to radiator. Remove A/C compressor mounting bolts and move compressor out of the way.
2. Remove solenoid valve mounted on radiator. Disconnect electrical connectors to electric fan. Remove electric fan. Remove air intake hose to air cleaner, mass airflow meter, and turbo unit.
3. Disconnect turbo pressure pipe. Remove bolts securing oil pipe to turbo unit and cylinder head. Unbolt clutch slave cylinder. Disconnect oil pipe fitting from block and remove clip on inlet manifold. Remove exhaust pipe from turbo charger.
4. Unhook front rubber hangers to exhaust pipe. Remove bracket between turbocharger and oil pan. Remove and plug oil return pipe. Remove exhaust manifold assembly from cylinder head. Lift off exhaust manifold with turbo assembly.
5. Remove turbocharger unit from exhaust manifold on bench. Replace lock nuts to turbocharger mounting bolts and exhaust flange. Tighten mounting nuts and bolts to specification. See «TURBOCHARGER & EXHAUST MANIFOLD TORQUE SPECIFICATIONS»(/saab/9000/i-1984-1994/remont/removal-installation/#removeinstalloverhaul) table. To complete installation, reverse removal procedure.

TURBOCHARGER & EXHAUST MANIFOLD TORQUE SPECIFICATIONS

See also:
• DISTRIBUTOR HOLD- DOWN BOLT TORQUE SPECIFICATIONS