Page 91
216-4 Crankshaft assembly, B201 and B202
The different thicknesses of bearing shells are
colour-coded as follows:
Standard size:
Red - thin bearing half, gives Increased clear-
ance
Blue - thicker bearing half, gives reduced clear-
ance.
ist undersize:
Yellow - thin bearing half, gives increased clear-
ance.
Green - thicker bearing half, gives reduced clear-
ance.
2nd undersize:
White - thin bearing half, gives increased clear-
ance.
Brown - thicker bearing half, gives reduced clear-
ance.
Example
Try to obtain the correct clearance by fitting two
thin bearing shells. If the clearance is excessive,
reduce it by fitting one thin and one thick, or two
thick shells.
If the clearance is excessive even after two thick
bearing shells have been fitted, the crankshaft
must be ground down to the next undersize and
the appropriate undersized bearing shells fitted.
(See the ‘Technical data’ section).
N.B.
The journals can be ground down one undersize
(0.25mm or 0.0098 in) without requiring rehar-
dening. Grinding to further undersize will neces-
sitate Tenifer rehardening.
To replace the crankshaft seal
at the flywheel end
The seal can be replaced with the engine in situ
or removed from the car, but the clutch and
flywheel must always be removed first.
Saab 900
Page 92
12 Fit new gaskets to the timing cover, using
dabs of grease to hold the gaskets in place.
13 Fit the timing cover.
14 Fit the timing cover bolts and the alternator
steady bar and reconnect the coolant hose
to the bottom of the water pump.
15 Fitanew’0 ring for the oil pump and offer up
the pump, locating it on the guide pins.
lf there are no guide pins, centre the pump
using tool 8393589.
Remove the old stuffing box, put the tool in
position and fit a new stuffing box.
For further details, see page 221-2.
Page 93
Lubrication system, B201 and B202 220-1
Lubrication system, B201 and B202
General
The engine has a forced-flow lubrication system.
Oil pressure is generated by a gear-type pump
consisting of a gear wheel and an eccentric ring
gear. The pump is driven by the crankshaft and is
interposed between the timing cover and
crankshaft pulley. A reduction valve in the timing
cover limits the oil pressure by directing excess
oil to the inlet side of the pump.
The oil pan is integral with the gearbox casing
but totally separated from the gearbox lubrica-
tion system. The oil filter is of the full-flow type,
i.e. all the oil circulated round the lubrication
points passes through the filter,
On the dipstick are marks for the minimum and
maximum levels of oil in the sump. The marks
represent oil quantities of 2.7 litres (2.9 liq qt)
3.7 litres (3.9 liqqt) respectively. The total
capacity of oil, including that in the filter, is:
B201, 3.8 litres (4 liqat); B202, 4.0litres
(4.2 liq qt).
Lubricating system, B202
= ee ce
—_—
Lubricating system, B201
Saab 900
Page 94
220-2 Lubrication system, B201 and B202
Quantity of oil circulating
When the engine is running, 1.2 litres of oil is
used to fill the oilways in the engine. This will re-
sult in the oil inthe sump dropping to a level mid-
way between the marks on the dipstick.
After the engine has been switched off, the oil in
the engine oilways starts to drain back to the
sump. The time taken for the oi! to drain back
into the sump depends on the temperature of the
engine. If the engine has reached its normal
operating temperature, it will take about an hour
for all the oil to drain back, although most of the
oil will have drained back to the sump within the
first ten minutes.
Oil level
The sensor for the oil warning light is located on
the oil filter adaptor.
The oil should be checked two or five minutes
after the engine has been switched off having
reached its normal operating temperature. Do
not top up the oil unless the level is lower than
midway between the MAX and MIN marks on the
dipstick.
Changing the oil
The oil and oil filter should be changed at the
scheduled service intervals.
To replenish the system after changing the oil,
3.8 litres (4.0 liq qt) will be required for B201 en-
gines and 4.0 litres (4.2 liq qt) for B202 engines.
B201
The oil flows through the inlet filter in the sump,
on through the oil pump and an oilway to the oil
filter adaptor, and thence through the main gal-
lery in the block. Oilways run from the gallery to
the main bearings and a rising oilway runs to the
cylinder head for lubrication of the camshaft and
valve gear.
S 2266
Rising oilway in the block (arrowed)
Saab 900
=_-
Page 95
Ll
Lubrication system, B201 and B202 220-3
B202 engine
In the cylinder head, the oil flows through pipes
to the camshaft bearings and the hydraulic cam
followers. The hydraulic chain tensioner is con-
nected to the rising oilway by adrilled passage in
the cylinder head. Also connected to the main oil
gallery is an oil line for lubrication of the turbo
unit. On Turbo engines, the oil cooler is con-
nected by means of a special adaptor for the oil
filter, which also incorporates the oil thermostat
and connectors for the oil cooler,
SD GO EG ¢
Bos Ben Pn Medio
Oil is filled through the dipstick pipe.
[Salm
Rising oilway in the cylinder head
Cam follower lubrication
Saab 900
Page 96
220-4 Lubrication system, B201 and B202
Pressure switch and adaptor, M86 on-
wards
The pressure switch is of the screw-in type and
has an M14x 1.5 thread and a flat seal.
Tightening torque: 25 Nm (18.5 Ibf ft)
The switch breaks the circuit at 0.3 bar (4.3 psi)
and makes the circuit at 0.55 bar (8.0 psi).
The adaptor for the engine oil filter matches the
thread on the pressure switch and also the seal.
Oil pump filter inlet pipes of different
lengths, manual and automatic cars
The length of the inlet pipe to the oi! pump filter
differs between manual and automatic cars.
It is essential that the correct inlet pipe be fitted;
if the wrong one is fitted, inadequate lubrication
can result, with consequent damage to the en-
gine.
Pressure switch
$2/1003
$2/1003
Sarii01
Saab 900
Page 97
2,
Oil pump, B201 and B202 221-1
Oil pump, B201 and B202
The oil pump is a gear type with one gear whee!
and an eccentric ring gear. The pump is mounted
on the timing cover and is driven by a hub
mounted on the crankshaft.
The oil pump reduction valve is situated in the
timing cover and returns excess oil to the inlet
side of the pump.
To remove
The oil pump can be removed with the engine in
the car,
1 Clean the area round the oil pump.
2 Remove the crankshaft pulley centre-bolt
and the pulley from the crankshaft. Im-
mobilize the crankshaft by attaching locking
segment 8392987 to the flywheel ring
gear.
3 Remove the oi! pump retaining bolts and ex-
tract the pump.
Saab 900
Page 98
221-2 Oil pump, B201 and B202
To check
Use a straightedge and feeler gauge to check the
end float between the pump body and the gear-
wheel.
Permissible end float: 0.03-0.08mm
(0.0012 -0,0031 in)
i To refit
1 Oil the gearwheels.
\/' 2 Refit the ring gear with the mark on its face
uppermost.
3 Fit anewseal in the groove in the pump body
and check that the locating dowel is fitted.
#
4 Refit the pump. Extract the pump gear
slightly and engage the dog on the gear in
the slot in the hub.
Saab 900
Page 99
EE
Oil pump, B201 and B202 221-3
A= Early design
8 = Latest design
5 Remove the oil filter adaptor casting and fill
the oilway to the oil pump pressure side with
engine oil.
Caution
The oil pump must be primed with oil prior to fit-
ting.
—
wG, 6 Refit the oil filter adaptor.
Centring of the oil pump
Should noise emanate from an otherwise ser-
viceable oil pump, or if a pump not equipped with
locating pins is to be fitted, tool 8393589
should be used to fit the pump. This obviates the
need for locating pins.
To remove
1 Remove the pulley from the crankshaft.
2 Remove the pump.
3 Remove existing locating pins.
4 Remove the shaft seal in the pump.
Saab 9006
Page 100
221-4 Oil pump, B201 and B202
Fitting and centring
1 Fit tool 83 93589 to the pump.
Check the condition of the 'O’ ring on the
pump and replace if defective.
2/1519
2 Fitthe pump complete with the special tool.
3 Fit the pulley retaining bolt and tighten the
special tool to a torque of 27 Nm (20 Ibf ft)
using a 400-mm (15.75-in) long torque
wrench.
4 Secure the pump (8 + 2 bolts).
5 Remove tool 8393 589, using strap wrench
8393332 or a large pair of water-pump
pliers.
6 Fit anew shaft seal on the pump.
7 Fit the pulley.
Tightening torque: 190 Nm (140 Ibf ft)
Saab 900