Page 41
211-22 Cylinder head
rv. S Remove the tensioning pulley and drive belt
for the AC compressor.
6 Slacken the securing bolts for the steering
Hy} Servo pump bracket, remove the drive belt
nT and push the pump out of the way.
{ 7 Release the wiring loom from the clips on
t the cylinder head. If the cylinder is to be
mounted on the floor stand, remove the
clips.
8 Remove the two bolts in the timing cover,
which are screwed into the cylinder head
from underneath.
i Ht 9 Remove the RH engine mounting bolts
14h i screwed into the cylinder head, together
ly i f with the spacer sleeves.
ay
i
it 10 Disconnect the coolant hose from the ther-
|i mostat housing.
11 Remove the fuel pressure regulator.
i 12 Disconnect the earth connections for the LH
i fuel injection system.
i | 13 Remove the auxiliary air valve (N/A to cars
with catalytic converter).
14 Unbolt the AC bracket from the cylinder
head.
I Saab 900
Page 42
Cylinderhead 211-23
15 Remove the inlet manifold complete with in-
16
17
18
19
20
21
jection valves and fuel injection manifold.
Disconnect the lead from the temperature
sensor.
Remove the inspection plate on the valve
cover, and the HT leads complete with dis-
tributor cap.
Remove the valve cover. Disconnect the
crankcase ventilation hose and remove the
split rubber plugs from the cylinder head.
Line up the timing marks on the crankshaft
and camshafts as detailed in section 214.
Remove the chain tensioner (see section
Palys
Remove the camshaft sprockets.
Do
not alter the setting of the camshaft or
crankshaft after the sprockets have been re-
moved, as rotation of one of the shafts can result
in damage to the valves.
22
Block up the engine to lift the cylinder head
off the engine steady bar. Remove the cylin-
der head bolts and siphon off the oil from the
cylinder head.
Saab 900
Page 43
ee
211-24 Cylinder head
F 23 Fit a guide pin in one of the bolt holes ...
Sf mlearn
... (See illustration) and lift off the cylinder
head, taking care to ensure that the pivoting
and fixed guides for the timing chain are not
damaged. Refit the drain plug in the block
and close the drain valve on the radiator.
‘i fi i For work on the cylinder head, use the bracket
Wiad (available as a special tool) for mounting the cy-
mi linder head on the engine stand.
| f N.B.
ia Never stand the cylinder head on its flanges as
| iil open valves will protrude. Stand the cylinder
F head on wooden blocks.
Saab 900
Page 44
Cylinderhead 211-25
Dismantling the cylinder head
(engine removed from car)
1 Remove the inspection plate on the valve
cover. Disconnect the HT leads and vacuum
hose and remove the distributor cap com-
plete with leads.
2 Remove the valve cover and turn the
crankshaft to bring the ‘O' mark on the
flywheel in line with the timing mark on the
end plate. \
i
2/1461 /
3 Remove the centre bolts securing the cam-
shaft sprockets.
N.B.
Never move the camshaft or crankshaft with the
timing chain removed, as a fully open valve can
collide with the piston at top dead centre.
Page 45
a_i
211-26 Cylinder head
4 Remove the chain tensioner.
5 Remove the camshaft sprockets.
A) || 6 Remove the EGR pipe, the turbo discharge
| pipe, and the oil supply and return pipes.
7 Remove the inlet manifold complete with
pressure regu lator, and the auxiliary air
valve.
Saab 900
Page 46
Cylinderhead 211-27
8 Remove the cylinder head bolts.
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Page 47
211-28 Cylinder head
N.B.
Never stand the cylinder head on its flanges as
open valves will protrude, Stand the cylinder
head on wooden blocks.
To refit the cylinder head
1 Align the '0’ mark on the flywheel with the
timing mark on the end plate.
1 | 2 Line up the marks on the camshafts with
| iB: their respective timing marks.
4
4}
if 3 Fit the cylinder head gasket, making sure
| that itis held in position by the guide sleeves
in the cylinder head flange.
Saab 900
Page 48
Cylinderhead 211-29 a
4 Fit guide pin 83 92 128 and position the tim-
ing chain and pivoting guide as shown.
5 Fit the cylinder head. Use the guide pin asa
pivot for the cylinder head, which must be
swivelled slightly to enable it to pass the
pivoting guide, Thereafter, the head will be
guided by the sleeves.
6 Fit the cylinder head bolts and tighten them
to the specified torque (see the ‘Technical
data’ section). Remember to fit the two M8
bolts in the underside of the cylinder head.
7 Fitthe camshaft sprockets, fitting the sproc-
ket for the exhaust-valve camshaft first.
Make sure that the chain between the
crankshaft sprocket and the camshaft
sprocket is kept tight and properly located in
the guide channel. Next fit the sprocket on i}
the inlet-valve camshaft. Keep the chain
tight between the sprockets.
8 Lightly tighten the centre bolts securing the
camshaft sprockets.
aim tl
Page 49
211-30 Cylinder head
9 Fit the chain tensioner (see section 215}.
S77
10 Rotate the crankshaft two complete turns ; 7
clockwise, viewed from the timing end.
Check that the earlier settings of the
crankshaft and camshafts have not altered
(timing marks lined up).
DAS Aa ae a
11 Tighten the centre bolts for the camshaft
sprockets.
Tightening torque: 63 Nm (47 Ibf ft)
N.B.
Use a spanner on the flats on each camshaft to
hold the shaft still when tightening the bolts, to
ensure that the set positions do not alter,
| i 12 Refit the valve cover. Make sure that the
seals and split rubber plugs are properly
seated in their grooves.
| Saab 900
Page 50
Cylinderhead 211-31
13 Fit the distributor cap and reconnect the HT
leads and vacuum hose,
14 Fit the inspection plate on the valve cover.
15 Fit the exhaust manifold and turbo unit, and
connect the EGR pipe, the turbo discharge
pipe, the oil supply pipe and the oi! return
pipe.
16 Fit the inlet manifold, the auxiliary air valve,
the pressure regulator and the lifting lug.
Connect the vacuum hose to the distributor.
Retightening the cylinder head
(Applies to bolts 15-mm across flats and
Torx M12 bolts.)
The cylinder head bolts must be tightened down
at the following times (does not apply to heads
fitted with the new, special gasket that elimi-
nates the need for retorquing):
a At the 600-mile (1000-km) Warranty Ser-
vice,
b After refitting the cylinder head in conjunc-
tion with engine overhaul or repair. After fit-
ting the head, run the engine to normal
temperature, allow to cool for 30 min and
then retighten the head.
1 In the sequence shown, slacken and retor-
que each bolt to 80 Nm (59 Ibf ft).
2 In the same sequence, tighten the bolts
through a further 1/4-turn (90°).
Stage 1 Tightening torque: 80 Nm (59 Ibf ft)
Stage 2 Tighten through further 1/4-turn (90°)
Saab 900
=e