Page 81
Engine Removal and Installation
201-7
___-------- e
Fig. 15. Clutch slave cylinder hydraulic line being removed.
Fig. 17. Left-hand engine mount being loosened. Spacer sleeve is hidden behind bracket (dotted line).
34. Attach an engine hoist to the engine. The front lifting
point is at the intake manifold. The rear lifting point is at
the Ale bracket. Raise the engine slightly.
NOTE
The AlC bracket has a lifting eye, which is used to attach the
lifting hoist hook. If the bracket has been removed, bolt a separate lifting eye to the coolant pump cover using the existing
mounting bolts.
35. Remove the bolts from the three engine mounts (front,
left, and right). Remove the bump stop on the front and
right-hand mounts. The left-hand mount is a through
bolt with a spacer. See Fig. 16, Fig. 17, and Fig. 18.
Fig. 18. Right-hand engine mount.
36. Raise the engine just enough to separate the left-hand
inner drive axle joint from the driver. See Fig. 19.
CAUTION
Cleanliness is essential when working on drive axle joints.
Even a small amount of sand or dirt will appreciably shorten
the service life of the joint. Cover or wrap the joint and inner
drivers on the transmission.
37. Disconnect the power steering pump return line from
the bottom of the power steering pump.
Fig. 16. Front engine mount and bump stop assembly.
38. Remove the oil pressure sensor connector and disconnect the oil cooler lines from the oil filter housing. See
Fig. 20.
REMOVING AND INSTALLING ENGINE
Page 82
201-8
Engine Removal and Installation
Fig. 19. Engine being raised just enough to separate inner drive axle
joint from driver
Fig. 21. Engine being lowered into engine compartment. Note engine
tilted down in front during installation.
cut off dUring the removal procedure. Use new self-locking
nuts when reinstalling the lower ball joint to the control arm.
WARNING
Always replace self-locking nuts and bolts. These fasteners
are designed to be used only once. They may become unreliable and fail when used a second time.
Refill the engine with engine oil and coolant, and refill the
power steering system. If applicable bleed the clutch slave
cylinder as described in 412 Clutch Control. The remainder
of installation is the reverse of removal.
8721&-2'1516
Tightening torques
Fig. 20. Top view of oil filter housing showing oil pressure sensor and
oil cooler lines.
39. Raise the engine and transmission assembly out of the
car. Be careful not to damage the radiator or APC solenoid valve.
Before installing the engine make sure the drive axle drivers
are packed with grease. See n4 Wheel8earings and Drive
Axles. Install any coolant drain plugs removed earlier. When
lowering the engine into the engine compartment, incline the
engine slightly down in the front. See Fig. 21.
Lower the engine into position just enough to install the
power steering pump return line and oil cooler lines. Align the
left-hand drive axle joint and the engine mounts and lower the
engine into its final position. Be sure to install the spacer
sleeve on the left-hand engine mount. Reconnect all hoses,
connectors and ground wires. Be sure to replace any wire ties
REMOVING AND INSTALLING ENGINE
• clutch slave cylinder to
6 to 10 Nm (53 to 89 in-Ib)
transmission case
• coolant drain plug to engine block .. 15 Nm (11 ft-Ib)
• oil cooler line to
oil filter housing
7 to 10 Nm (62 to 89 in-I b)
• lower ball joint to
lower control arm
40 to 55 Nm (30 to 41 ft-Ib)
• road wheel to wheel bearing hub
lug nuts
90 to 110 Nm (66 to 81 ft-Ib)
lug bolts
105 to 125 Nm (77 to 92 ft-Ib)
• power steering line
union
• all other fasteners
M5 bolt.
M6 bolt.
M8 bolt.
M10 bolt
20 to 34 Nm (15 to 25 ft-Ib)
5 Nm (44 in-Ib)
10 Nm (89 in-Ib)
20 Nm (15 ft-Ib)
40 Nm (30 ft-Ib)
Page 83
Engine Removal and Installation
SEPARATING ENGINE FROM
TRANSMISSION
The engine must be first removed from the car to separate
the transmission from the engine.
201-9
CAUTION
If the engine does not immediately lift off the transmission, do
not attempt to pry them apart until making sure that all fasteners have been removed.
10. Remove all old traces of oil and dirt from the flanges.
To separate engine from transmission
(manual transmission)
1. Thoroughly clean the external surfaces of the engine
and transmission.
2. Drain the engine oil and remove the EGR pipe, if applicable.
11. Before refitting the engine to the transmission, make
sure the two guide sleeves are fitted in the transmission
flange. Place a new gasket onto the transmission
flange and apply a sealing compound (Permatex Llltrablue) to the slots shown in Fig. 23.
12. Apply a thread sealing compound (Loctite 45, Saab
Part No. 3009081) to the six bolt holes shown in Fig. 24.
3. Remove the plastic clutch cover from over the flywheel.
4. Remove the transmission oil dipstick tube.
5. On turbo models, disconnect the oil return line from the
turbocharger.
6. Remove the starter motor and unscrew the starter motor stay plate.
7. Remove the transmission input shaft. Remove the clutch
slave cylinder mounting bolts. See 411 Clutch.
8. Remove all of the engine to transmission mounting
bolts. Remove the bracket for the oil filler pipe at the
throttle housing.
9. Carefully lift the engine away from the transmission.
See Fig. 22. Guide off the clutch release-bearing
sleeve and slave cylinder as the engine is lifted off.
Fig. 23. Sealing compound being installed to slots (arrows) on transmission flange.
I
I
I
L
-------.J
Fig. 22. Engine being lifted off transmission together with clutch release-bearing sleeve and slave cylinder.
Fig. 24. Bolt holes in transmiSSion case requiring thread sealei'.
SEPARATlNG ENGINE FROM TRANSMISSION
Page 84
201-10
Engine Removal and Installation
The remainder of the procedure is the reverse of removal.
Fig. 25 shows engine-to-transmission bolt identification and
location.
4. Disconnect the throttle (kick-down) cable at the throttle
housing.
5. On turbo models, remove the turbocharger support.
Tightening torques
• engine to transmission
• all other fasteners
M5 bolt
M6 bolt
M8 bolt
M10 bolt
25 Nm (18 ft-Ib)
5 Nm (44 in-Ib)
10 Nm (89 in-Ib)
20 Nm (15 ft-Ib)
40 Nm (30 ft-Ib)
To separate engine from transmission
(automatic transmission)
6. Remove all of the engine to transmission mounting
bolts. Remove the ATF cooler lines from the transmission.
7. Remove the 8 bolts holding the drive plate to the torque
converter. When all bolts are removed, position the
drive plate so that the two brackets on the drive plate
perimeter are horizontal.
NOTE
To best access the bolts, spin the drive plate until the bolts are
accessible from above.
1. Thoroughly clean the external surfaces of the engine
and transmission.
2. Drain the engine oil and remove the oil filler pipe.
8. Carefully lift the engine straight off the transmission.
See Fig. 22 above for reference.
3. Remove the plastic cover from above the drive plate
and torque converter.
--~--------------~----------------------
---
Bolts to threaded holes in gearbox
!
mmmm
Stud
in gearbox
Longer bolt for
engine mounting
(no washer)
,
T
Bolts to threaded holes in engine
Fig. 25. Engine-to-transmission mounting bolt identification for manual transmission.
SEPARATlNG ENGINE FROM TRANSMISSION
87096-S/2853
Page 85
Engine Removal and Installation
201-11
CAUTION
If the engine does not immediately lift off the transmission, do
not attempt to pry them apart until making sure that all fasteners have been removed.
NOTE
Use Saab special tool 87 90 255 to support the torque converter
once the engine is removed from the transmission. See Fig. 26.
If the torque converter is left unsupported, the torque converter
oil seal may be damaged. As an altemative, remove the torque
converter and store it in its normally installed position.
1.
2.
3.
4.
Mating flange (3 bolt holes)
Oil cooler outlets
Primary drive cover
Oil filler hole
5. Gear selector cable hole
6. Speedometer cable hole
7. Reverse gear switch hole
Fig. 27. Areas of automatic transmission which must be plugged prior
to cleaning.
Fig. 26. Torque converter support bracket (arrow).
9. Remove all old traces of oil and dirt from the flanges.
NOTE
When cleaning the removed transmission, plug all of the
openings shown in Fig. 27.
10. Before refitting the engine to the transmission, carefully
inspect the drive plate for cracks. Make sure both mating surfaces are completely clean. Make sure the two
brackets on the drive plate perimeter are horizontal.
11. Place a new gasket onto the transmission flange and
apply a sealing compound (Permatex Ultra-blue) to the
slots shown in Fig. 28.
Fig. 28. Sealing compound being installed to slots (arrows) on transmission flange,
SEPARA TlNG ENGINE FROM TRANSMISSION
Page 86
201-12
Engine Removal and Installation
12. Apply a thread sealing compound (Loctite 45, Saab
Part No. 453009081) to the three bolts holes shown in
Fig. 29.
CAUTION
Saab part numbers are for reference only. Consult an authorized Saab dealer for the most up-to-date parts information.
13. Install the engine to the transmission. Take care not to
damage the torque converter centering pin when lowering the engine onto the transmission. Tighten mounting
bolts in stages.
The remainder of the procedure is the reverse of removal.
Be sure to fill the engine with oil.
Tightening torques
• engine to transmission
• all other fasteners
M5 bolt
M6 bolt
M8 bolt
M10 bolt
25 Nm (18 ft-Ib)
5 Nm (44 in-Ib)
10 Nm (89 in-Ib)
20 Nm (15 ft-Ib)
40 Nm (30 ft-Ib)
Fig. 29. Bolt holes in transmission case requiring thread sealer.
SEPARA TlNG ENGINE FROM TRANSMISSION
Page 87
Engine Disassembly and Assembly
210-1
210 Engine Disassembly and Assembly
General
210-1
Disassembling and Assembling
Cylinder Block
To disassemble cylinder block
To assemble cylinder block
210-2
210-2
210-4
GENERAL
Fig. 1 shows the complete engine assembly. This repair
group covers disassembly and assembly of the engine cylinder block only. Cylinder block reconditioning procedures and
specifications can be found in 212 Pistons, Connecting
Rods, Cylinder Bores, and in 216 Crankshaft.
87042-8211105
Fig. 1. Exploded view of engine assembly (transmission shown
removed),
GENERAL
Page 88
210-2
Engine Disassembly and Assembly
DISASSEMBLING AND ASSEMBLING
CYLINDER BLOCK
7. Remove the center bolt from the crankshaft pulley. See
Fig. 3. Remove the pulley from the crankshaft.
-------~-------.-------------
Disassembly and assembly procedures forthe Saab cylinder
block are similar to those of most other water-cooled engines.
Thoroughly mark the position and orientation of all parts as
they are removed. Connecting rods, rod caps, rod bearings,
pistons, main bearing caps and main bearings are assembled
in an exact location and orientation. This "assembly code" is
critical to proper engine operation if any of the parts are going
to be reused.
To disassemble cylinder block
1. Remove the engine from the car and separate the
transmission 'from the engine as described in 201 Engine Removal and Installation.
2. Remove the cylinder head as described in 211 Cylinder Head Removal and Installation.
3. Remove the plastic clutch cover from above the flywheel.
Fig. 3. Crankshaft pulley mounting bolt being removed.
8. Remove the oil pump mounting bolts and remove the
pump from the timing chain cover. See Fig. 4.
4. With the alternator V-belt installed and tensioned, loosen the bolts from the coolant pump pulley.
5. Remove the alternator V-belt.
6. Immobilize the flywheel with a holding fixture. See
Fig. 2.
Fig. 4. Oil pump being removed from timing chain cover.
9. Disconnect the lower hose from the coolant pump.
10. Remove the alternator together with its stabilizer bar.
Fig. 2. Rywheel being immobilized using holding fixture (arrow).
DISASSEMBLING AND ASSEMBLING CYLINDER BLOCK
11. Remove the mounting bolts from the timing chain cover
and remove the cover together with the water pump
and hoses. See Fig. 5.
Page 89
Engine Disassembly and Assembly
Fig. 5. Timing chain cover with coolant pump and hoses being removed,
210-3
Fig. 7. Crankshaft sprocket being removed.
12. Remove the pivoting timing chain guide. See Fig. 6.
Fig. 8.
Fig. 6.
Fixed timing chain guide being removed.
Pivoting camshaft timing chain guide being removed.
CAUTION
13. Pull off the crankshaft sprocket with the timing chain.
See Fig. 7. Remove the key from the keyway in the
crankshaft.
Before removing the pistons from the cylinders, remove any
ridge or carbon deposits from the top of the cylinder. Install
small lengths of rubber hose over the connecting rod studs to
protect the cylinders during piston removal.
14. Remove the fixed timing chain guide. See Fig. 8
15. Unscrew the oil filter and unbolt the oil filter housing
from the cylinder block.
16. Mark the cylinder number on the top of each piston. Remove the piston and connecting rod assemblies.
NOTE
Observe the markings on the connecting rod big-ends. Where
necessary, mark all parts so that they can be reinstalled in
their exact positions. This includes noting which bearing shells
are in the upper positions and which ones are in the lower positions.
DISASSEMBLING AND ASSEMBLING CYLINDER BLOCK
Page 90
210-4
Engine Disassembly and Assembly
17. Turn the engine block on its end so that the flywheel is
facing up and remove the flywheel. See Fig. 9.
{\J
...
d>
,0...
m
{\J
(7j
Fig. 11. Crankshaft being removed.
;~
Fig. 9. Flywheel being removed.
18. Remove the cylinder block end plate. See Fig. 10.
1. Lubricate the bearing shell saddles and Install the upper shells into position. Carefully install the crankshaft.
2. Fit the center thrust washers to the crankshaft. See Fig.
12. Check that the crankshaft end float is within specification as described in 216 Crankshaft.
Fig. 10. Cylinder block end cover being removed.
19. Remove the crankshaft bearing caps and remove the
crankshaft. See Fig. 11.
Fig. 12. Crankshaft thrust washer being installed.
3. Lubricate the lower bearing shells and install the shells
and main bearing caps in their original locations.
NOTE
Note the main bearing cap markings and locations for reinstallation.
Tightening torque
• main bearing caps
to cylinder block
11 0 Nm (81 ft-Ib)
To assemble cylinder block
NOTE
NOTE
When reusing old parts, make sure that they are installed in
their original positions.
DISASSEMBLING AND ASSEMBLING CYLINDER BLOCK
Note the markings on the bearing caps. See Fig. 13.