Page 1
16 valve turbo 85-93
Page 2
0
1
2
3
4
5
6
7
8
Technical Data
010
022
023
024
025
Technical Data-General
Engine-Technical Data
Electrical System----Technical Data
Transmission-Technical Data
Brakes -Technical Data
Lubrication and
Maintenance
100
110
Fundamentals for the Do-it-yourself Owner
Maintenance Program
200
201
210
211
Engine-General
Engine Removal and Installation
Engine Disassembly and Assembly
Cylinder Head Removal
and Installation
Pistons, Connecting Rods,
Cylinder Bores
Cylinder Head and
Valve Mechanism
215
216
220
234
240
252
254
261
291
Camshaft Timing Chain
Crankshaft
Lubrication System
Fuel Pump and Fuel Tank
Fuel Injection
Exhaust System
Exhaust Emission Control
Radiator and Cooling System
Turbocharger
Electrical
System
300
311
321
331
340
351
Electrical System----General
Battery
Alternator and Charging System
Starter
Ignition System
Lighting
363
364
368
371
Wipers and Washers
Electric Controls and Switches
Cruise Control
Wiring Diagrams, Fuses
and Relays
Transmission
400
411
412
432
Transmission-General
Clutch
Clutch Control
Manual Transmission Controls
444
472
Automatic Transmission Controls
Automatic Transmission
Seals and Gaskets
Brakes
500
516
517
520
521
522
Brakes-General
Brake Discs
Brake Pads
Brake Fluid and Brake Bleeding
Brake Master Cylinder
Brake Lines
523
524
541
551
Brake Calipers
Brake Pedal Mechanism
Brake Vacuum Booster
Parking Brake
600
601
631
Steering and Wheel
Alignment-General
Wheel Alignment
Ball Joints
632
641
643
644
Control Arms
Steering Column
Tie Rod Ends
Power Steering
Suspension
700
731
Suspension-General
Front Suspension
732
774
Rear Suspension
Wheel Bearings and Drive Axles
Body
800
812
820
830
Body-General
Convertible Top
Hood and Fenders
Doors, Windows, and Lids
851
853
854
860
Interior Trim and Upholstery
Dashboard and Consoles
Heating and Air Conditioning
Bumpers
Engine
212
214
Steering
and Wheel
Alignment
026
027
028
Steering and Wheel
Alignment -Technical Data
Suspension-Technical Data
Body-Technical Data
~
~
~
~
~
~
~
~
Page 3
Technical Data-General
010-1
:~j~ ~ [~ ~ :~:~ ;: ~ !: :!\.
on
-r-(
C
010 Technical Data-General
Technical Data-General
010-1
Lubrication and MaintenanceQuick Data . . __ .. _.. _
__
010-2
TECHNICAL DATA-GENERAL
f - - - - 9 9 . 1 in.----c..
~!
< + - - - - - - - - 1 8 4 . 3 i n . - - - - - - -..
mm
in.
Track (rear)
1440
56.7
Wheelbase
2517
99.1
Turning radius
5600
220.5
kg.
lb.
Curb weight (depending on
equipment)
1252-1411
2755-3105
Gross vehicle weight
(depending on equipment)
1677-1768
3690·3890
Weight distribution
89139-SG681
at curb weight
59-62% front
at gross weight
52-55% front
Vehicle capacity weight---ex.
conv. (five people, 180 lb.
luggage)
422
930
Maximum roof rack load---ex.
conv.
100
220
Maximum trailer weight:
General
mm
in.
trailer with brakes
900
2000
trailer without brakes
450
1000
75
165
Overall length (sedans,
convertibles)
4680
184.3
Overall length (hatchback)
4687
184.5
Overall width
1690
66.5
hatchback
14.9 cu.fl.
hatchback, parcel shelf reo
moved
19.1 cU.fl.
sedan
14.2 cU.fl.
convertible
10.7 cU.fl.
Maximum trailer tongue weight
Overall height (at curb weight)
1419
55.9
Overall height with convertible
at highest point
2230
87.8
Tnunk volume (SAE)
Road clearance (full load)
SPG models
120
4.7
all other models
137
5.4
alloy wheels
1430
56.4
steel wheels
1437
56.6
Track (front)
TECHNICAL DATA-GENERAL
Page 4
010-2
Technical Data-General
Engine Specifications
Model
Year
Displacement
cc (cu. in.)
Com pression
ratio
Horsepower @
rpm SAE net
Torque Ib-ft @
rpm SAE net
Fuel system
900/900S/Convertible
1986-1987
1985 (121)
10.1: 1
125 @ 5500
128 @ 3000
Bosch LH 2.2
10.1: 1
128 @ 6000
128 @ 3000
Bosch LH 2.4
10.1: 1
128 @ 6000
128 @ 3000
Bosch LH 2.4
133 @ 2900
Bosch LH 2.4.2
1988
1985 (121)
1989-1990
900 TurborTurbo
Convertible
900 SPG
1985 (121)
1991-1993
2118 (129)
10.1: 1
140 @ 6000
1985-1988
1985 (121)
9.0:1
160 @ 5500
188 @ 3000
Bosch LH 2.2
1989-1993
1985 (121)
9.0:1
160 @ 5500
188 @ 3000
Bosch LH 2.4
1985-1986
1985(121)
9.0:1
160 @ 5500
188 @ 3000
Bosch LH 2.2
1987-1988
1985 (121)
9:0:1
165 @ 5500
195 @ 3000
Bosch LH 2.2
1989
1985(121)
9.0:1
165 @ 5500
195 @ 3000
Bosch LH 2.4
1990-1991
1985 (121)
9.0:1
175 @ 5500
195 @ 3000
Bosch LH 2.4
LUBRICATION AND MAINTENANCEQUICK DATA
Spark Plug Applications
Engine Oil Change
Saab recommended engine oil
SAE 10W-30, API Service
Rating SG or SF/CD
Altemate for extremely hot
climates
15W-40, API Service Rating
SG or SF/CD
Engine oil drain plug tightening
torque (13 mm or 19mm
wrench size)
29-39 Nm (21-29 ft-Ib)
Engine Oil Capacity
(including filter)
4.2 quarts (4.0 liters)
Ignition System Applications
Model
Spark Plug
1985-1993 Turbo
normal driving
NGK BCP 7EV
altemate
NGK BCP 7ES
city driving
NGK BCP 6EV
altemate
NGK BCP 6ES
Spark plug electrode gap
0.024-0.028 in. (0.6-0.7 mm)
Tightening torque-sparkplugs
25 to 29 Nm (18 to 21 ft-Ib)
Ignition Timing
1985-1992 turbo models
basic Hall ignition
1986-1992 non-turbo models
EZK ignition -Hall-effect with
knock sensor
Spark Plug Applications
Model
Spark Plug
1986-1988 Normally aspirated
NGK BCP 6ES
altemate
NGK BCP 6EV
1989-1993 Normally-aspirated
NGK BCP 5ES
LUBRICA nON AND MAINTENANCE-QUICK DATA
Distributor vacuum hose
disconnected and plugged,
where applicable
Turbo models
16°BTDC @ 850 rpm
Normally aspirated models
14°BTDC @ 850 rpm
Cooling System
Capacity (50/50 mixture antifreeze and water)
10.5 quarts (10 liters)
Page 5
Technical Data-General
Automatic Transmission
Engine Drive Belt Tensions
(measure using special belt tensioning gauge)
Drive belt tension
N
010-3
ATF
Ford Specification M2C-33F
(alternate: Ford Specification G)
ATF capacity
8.5 quarts (8.0 liters)
AJT final drive grade of oil
SAE EP 80 or 75 API-GL-4 or
API-GL-5
Altemate grade of oil
10W-30 engine oil
AJT final drive capacity
1.3 quarts (1.25 liters)
(Ib)
Altemator
checking (minimum)
one belt
200
(45)
two belts
420
(95)
one belt
310±20
(70±5)
two belts
645±20
(145±5)
ATF drain plug tightening
torque
5-8 Nm (48-72 in-Ib)
535±45
(120±10)
AJT final drive drain or filler
plug tightening torque
39-59 Nm (28-44 ft-Ib)
adjusting, used belts
adjusting, new belts
one belt
AlC compressor
checking (minimum)
245
(55)
adjusting, used belt
355±20
(80±5)
adjusting, new belt
535±45
(120±10)
checking (minimum)
220
(50)
adjusting, used belt
310±20
(70±5)
1985-1987 models
1.0 mm (0.04 in.)
adjusting, new belt
445±45
(100±10)
1988 and later models
4.0 mm (0.16 in.)
Power steering
Manual Transmission
Grade of oil
SAE 10W-30 SF/CC, SF/CD,
SG
Alternate grade of oil
SAE EP 75 API-GL-4 or APIGL-5
Oil capacity
3.1 quarts (3.0 liters)
Brake System
Brake Fluid Grade
SAE Dot 4
Brake Pad Wear Limit
WARNING
Do not use SAE DOT 5 brake fluid. Brake system failure may
result.
Steering and Wheel Alignment
Power Steering Fluid
GM Power Steering Fluid (GM
9985010), Texaco TL4634 or
equivalent
LUBRICAnON AND MAINTENANCE-QUICK DA TA
Page 6
Engine-Technical Data
022-1
022 Engine-Technical Data
Engine Tightening Torques
022-1
Crankshaft
022-6
Connecting Rods and Piston Pins
022-2
Lubrication System
022-6
Piston Rings
022-3
LH Fuel Injection
022-7
Pistons
022-3
Cooling System
022-8
Cylinder Head and Valve
Mechanism
Turbocharger
022-8
022-4
ENGINE TIGHTENING TORQUES
Tightening Torques
Nm
ft·rb (in-Ib)
Cylinder block end plate to
engine (flywheel end)
20
15
stage 1
60
44
stage 2
80 plus and
additional
90° (1/4
tum)
59 plus and
additional 90 0
(1/4 tum)
automatic transmission
33--39
24-29
manual transmission
25±3
18±2.2
Engine oil cooler line to oil filter
housing
7-10
(62-89 in-Ib)
Engine oil drain plug to case
29--39
21-29
EGR valve to cylinder head
8
(71 in-Ib)
turbo models
25
18
normally aspirated models
20
15
Cylinder head to cylinder block
Engine to transmission
Tightening Torques
Nm
ft·lb (in-I b)
Camshaft sprocket to camshaft
63
46
Camshaft bearing caps to
cylinder head
15
11
Camshaft timing chain
tensioner to timing case
63
46
Flywheel to crankshaft (17 mm
bolt head)
60
44
Clutch slave cylinder to
transmission case
6-14
(53-124 in-Ib)
FlyWheel to crankshaft (19 mm
bolt head)
85
63
Coolant drain plug to engine
block
15
11
55
41
Coolant temperature sensor
(LH sensor)
20
15
Fuel pump to fuel tank
(threaded collar)-1990 and
later
20
15
Connecting rod cap to
connecting rod
55
Ignition distributor to cylinder
head
Intake manifold to cylinder
head
22
16
Exhaust manifold to cylinder
head
41
Crankshaft pulley to crankshaft
1985-1990
190
140
1991 and later
175
129
continued on next page
continued
ENGINE TIGHTENING TORQUES
I
Page 7
022-2
Engine-Technical Data
Tightening Torques
Nm
ft-Ib (in-Ib)
Main bearing caps to cylinder
block
110
81
Oil filter to oil filter housing
10
7.4
CONNECTING RODSAND PISTON PINS
Oil pressure switch to oil filter
housing
small (1/4"-18 NPTF)
10
(89 in-Ib)
large (M 14X1.5)
30
22
Oil pump to timing chain cover
8
(71 in-Ib)
Oxygen sensor
40
30
Spark plugs to cylinder head
28
21
Thermostat housing to cylinder
head
18
13
Timing chain cover to engine
block and cylinder head
20
15
Timing chain tensioner to
cylinder head
63
46
Valve cover to cylinder head
15
89082
Connecting rods
mm
in.
56.000-56.019
2.2047-2.2055
11
Diameter of big end
(bearing shells
removed)
24.005-24.010
0.9451-0.9453
0.0010-0.0024
M5 bolt
5
(44 in-Ib)
Diameter of small end
(bushing installed)
M6 bolt
10
(89 in-Ib)
Big-end clearance
0.026-0.062
M8 bolt
20
15
40
30
Maximum permissible
weight variation per set
9 g (0.32 oz.)
M10 bolt
Piston pins
mm
in.
Piston pin diameter
23.996-24.000
0.9447-0.9449
All other fasteners
Piston pin to connecting rod clearance
CONNECTING RODS AND PISTON PINS
B202 engine
0.005-0.014
0.0002-0.0006
B212 engine
0.002-0.011
0.00008-0.0004
Page 8
Engine-Technical Data
022-3
PISTON RINGS
1
Piston Ring
Top compression ring
Second compression ring
Oil scraper ring
End gap
0.35-0.55 mm 0.0138-0.0217 in.
0.30-0.45 mm 0.0118-0.0177 in.
0.38-1.40 mm 0.0150-0.0551 in:
Width (thickness)
1.73-1.75 mm 0.0681-0.0689 in.
1.98-1.99 mm 0.0780-0.0783 in.
2.63-2.73 mm 0.1035-0.1075 in'"
Side clearance in piston
groove
0.05-0.09 mm 0.0020-0.0035 in.
0.04-0.07 mm 0.0016-0.0028 in.
•Applies to segment part of ring
"Oil scraper ring segment width (thickness) 0.58-0.64 mm 0.0028-0.02552 in
PISTONS
Piston diameter
mm
in.
Turbo engine with Mahle pistons (cont'd)
Piston and Cylinder
Classification Codes
first oversize
(0.5mm)
90.460-90.475
3.5614-3.5620
second oversize
(1.0mm)
90.960-89.975
3.5811-3.5817
Normally aspirated engine with Mahle or KS pistons
(ex. 8212 engine)
AA
mm
89.978-89.988
3.5424-3.5428
standard A8
89.988-89.996
3.5428-3.5431
standard 8
89.996-90.004
3.5431-3.5435
standard C
90.004-90.020
3.5435-3.5441
first oversize
(0.5mm)
90.482-90.497
3.5623-3.5629
second oversize
(1.0 mm)
90.982-89.997
3.5820-3.5826
Normally aspirated engine with Hepolite pistons
(ex. 8212 engine)
69084-S2l1102
Piston diameter
standard A
in.
standard A
89.977-89.985
3.5424-3.5427
standardA8
89.985-=89.991
3.5427-3.5430
standard 8
89.991-89.999
3.5430-3.5433
standard C
89.999-90.015
3.5433-3.5439
Normally aspirated engine with Hepolite pistons
(ex. 8212 engine)
Turbo engine with Mahle pistons
standard A
89.960-89.970
3.5417-3.5421
standard A8
89.970-89.978
3.5421-3.5424
standard 8
89.978-89.986
3.5424-3.5427
standard C
89.986-90.002
3.5427-3.5434
continued
first oversize
(0.5 mm)
90.477-90.492
3.5621-3.5627
second oversize
(1.0 mm)
90.977-89.992
3.5818-3.5824
continued on next page
PISTONS
Page 9
022-4
Engine-Technical Data
Piston diameter
CYLINDER HEAD AND VALVE
MECHANISM
in.
mm
B212 engine (2.1 liter engine)
standard A
92.982-92.992
3.6607-3.6611
standard B
92.993-93.002
3.6611-3.6615
standard B
93.003-93.012
3.6615-3.6619
first oversize
(0.5 mm)
93.482-93.492
3.6804-3.6808
second oversize
(1.0mm)
93.982-93.992
3.7001-3.7005
nominal piston
clearance
0.009-0.035
0.00035-0.00137
Piston-to-Cylinder Clearance (mm)
non-turbo
(KS)
piston!
cylinder
classification
B202 engine (2.0 L)
AlA
0.012-0.032
turbo
non-turbo
(Hepolite)
0.030-0.050
0.015-0.033
ABIA
0.004-0.022
0.022-0.040
0.009-0.025
AB/B
0.014-0.032
0.032-0.050
0.019-0.035
B/A
BIB
0.006-0.024
CIB
0.014-0.032
0.001-0.019
0.024-0.042
0.011-0.029
0.008-0.034
B212 engine (2.1 L)
AlA
0.008-0.028
BIB
0.009-0.027
BIB
0.009-0.027
CYLINDER HEAD AND VALVE MECHANISM
Cylinder head "'eight
(dimension A)
mm
in.
New
140.5±0.1
5.533±0.004
After machining
140.1±0.05
5.516±O.004
Machining limit
0.4
0.0016
Page 10
Engine-Technical Data
022-5
Exhaust valve
44.5"
~
6.955-6.980 mm
(0.2738-0.2748 in.)
,
t
I
1.5mm
(0.06 in.)
approx.
JI-
29.0 mm
(1.14 in.)
I
Intake valve
t
6.960"6.975 mm
(0.2740-0.2746 in.)
I
J
32.0 mm
(1.26 in.)
1.5mm
~::~--~~~~~~';Japprox.
(0.06 in.)
%
,,-
I
89088
Valves
mm
Valve clearance
non-adjustable
in.
Valve guides
valve guide wear
(clearance between
valve guide and valve
stem)
maximum pennissible
0.5
length
49.00
1.929
outside diameter
12.039-12.050
0.4740-{).4744
bore for valve guide in
cylinder head
12.000-12.018
0.4724-{).4731
0.02
~---------------
B9087
Camshaft
mm
in.
0.07
Bearing diameter
28.922-28.935
1.1387-1.1392
45.0±1.5
1.77±O.06
Axial play (maximum
pe nn issible)
0.08-{).35
0.0031-{).0138
installed height
37.0
1.46
height when compressed with pressure
of 131-141 Ibs.
28.4
1.12
Cam followers
mm
in.
Diameter
32.96-32.98
1.2976-1 .2984
Height
26
1.02
Bore for cam followers
in camshaft bridge
33.000-33.016
1.2992-1 .2998
Valve Springs
out-of-square (maximum)
1.75
free height
I
CYLINDER HEAD AND VALVE MECHANISM