Page 91
Engine Disassembly and Assembly
210-5
Fig. 14. Cylinder block end plate gasket being trimmed at transmission gasket surface.
6. Align the compression rings so that their end gaps are
approximately aligned over the wrist pin. Make sure the
double oil scraper ring joints do not align. See Fig. 15.
Fig. 13. Main bearing cap markings.
4. Apply a small amount of grease to hold the new endplate gasket to the cylinder block. Install the plate,
being careful not to damage the crankshaft oil seal. If
necessary, trim the gasket at the transmission-to-engine flange. See Fig. 14.
CAUTION
• To prevent oil leaks, the crankshaft seal should be perfectly
centered around the crankshaft. A special guide (Saab tool
no. 83 92 540) fits over the crankshaft to center the end plate
and seal. The tool also protects the crankshaft seal during the
installation of the end plate.
NOTE
When installing the second compression ring, make sure the
"TOP" marking on the ring is facing up.
1
• Do not use an adhesive sealer on the gasket.
NOTE
For procedures on replacing the crankshaft oil seal, see 216
Crankshaft.
Fig. 15. Piston ring end gaps correctly aligned. Compression rings
shown at 1 and double oil scraper ring shown at 2.
Tightening torque
• cylinder block end plate to engine
(flywheel end)
20 Nm (15 ft-Ib)
5. Install the flywheel using a sealant on the mounting
bolts. Be sure the old bolts are cleaned before applying
the fresh sealant.
7. Lightly lubricate the pistons and rings with engine oil.
Install the pistons so that the notch in the top of the piston faces the camshaft timing chain and the numbers
on the connecting rod big-end face the exhaust side of
the engine. See Fig. 16. Install and tighten the connecting rod caps.
Tightening torques
• flywheel to crankshaft
17 mm bolt head
60 Nm (44 ft-lb)
19 mm bolt head
85 Nm (63 ft-lb)
NOTE
Make sure the flange on the connecting rod cap nut is towards
the rod cap, facing the piston.
DISASSEMBLING AND ASSEMBLING CYLINDER BLOCK
Page 92
210-6
Engine Disassembly and Assembly
11. Using engine oil, prime the cavity between the oil filter
housing and the oil pump. See Fig. 17. Then install the
oil filter housing and a new oil filter.
Tightening torque
• oil filter to oil filter housing
10 Nm (89 in-Ib)
0000
Fig. 16. Install piston so that top notch faces camshaft timing chain
and connecting rod big-end numbers face the exhaust side
of the block.
12. Install the crankshaft pulley with its key. While holding
the flywheel stationary, tighten the mounting bolt.
Tightening torque
• connecting rod cap
to connecting rod
55 Nm (41 ft-Ib)
8. Install the timing chain sprocket and the timing chain
guides. Hang the timing chain on the sprocket.
9. Install the timing chain cover using a new gasket. Do
not use sealer on this gasket.
Tightening torque
• timing chain cover to engine block .. 20 Nm (15 ft-Ib)
10. Install the oil pump using a new O-ring.
Tightening torque
• oil pump to timing chain cover
Fig. 17. Oil pump being primed through oil filter housing hole.
8 Nm (71 in-Ib)
DISASSEMBLING AND ASSEMBLING CYLINDER BLOCK
Tightening torque
• crankshaft pulley to crankshaft
1985-1990
1991 and later.
190Nm(140ft-lb)
175 Nm (129 ft-Ib)
13. The remainder of the assembly is the reverse of removal.
Tightening torques
• all other fasteners
M5 bolt.
M6 bolt.
M8 bolt
Ml0 bolt.
5 Nm (44 in-Ib)
10 Nm (89 in-Ib)
20 Nm (15 ft-Ib)
40 Nm (30 ft-Ib)
Page 93
Cylinder Head Removal and Installation
211-1
211 Cylinder Head Removal and Installation
General
211-1
Cylinder Head
Removal and Installation
211-1
211-1
211-3
To remove cylinder head
To install cylinder head
5. If applicable, remove the turbocharger as described in
291 Turbocharger.
GENERAL
This section covers only cylinder head removal and installation. For complete cylinder head, camshaft, and valve train repair information, see 214 Cylinder Head and Valve
Mechanism. For camshaft timing chain repair information,
see 215 Camshaft Timing Chain.
6. Remove the air conditioning compressor belt and tensioning pulley.
7. Loosen the power steering pump pivot bolts. Remove
the power steering pump V-belt and push the power
steering pump out of the way.
CYLINDER HEAD REMOVAL
AND INSTALLATION
8. Remove the center cover from above the spark plugs. Disconnect the spark wires from the spark plugs and remove
the distributor cap with the spark plug wire asserT'bly.
To remove cylinder head
9. Remove the valve cover and the valve cover split rubber plugs as described in 214 Cylinder Head and
Valve Mechanism.
1. Raise the hood and remove the hood hinge mounting
bolts. See Fig. 1. Carefully remove the hood from the car.
10. Remove the two bolts holding the timing chain cover to
the bottom of cylinder head. See Fig. 2.
r,
87033·211491
/-87223·S2I252
Fig. 1. Hood hinge mounting bolt being removed.
Fig. 2. Camshaft timing chain cover to cylinder head mounting bolt
being removed,
2. Disconnect the battery terminals and remove the battery from the car.
3. Drain the coolant from the radiator and from the engine
block. See 261 Radiator and Cooling System.
4. Remove the exhaust manifold.
11. Working from below, jack up the engine just enough to
relieve the weight on the right-hand engine mount (exhaust side of engine). Then remove mounting bolts
(and spacer sleeve) that are screwed into the cylinder
head.
GENERAL
Page 94
211-2
Cylinder Head Removal and Installation
12. Disconnect the coolant hose from the thermostat
housing.
13. Unbolt the fuel pressure regulator complete with bracket from the cylinder head. See Fig. 3. Do not disconnect
fuel hoses.
17. Disconnect the wires from the temperature sensor.
18. Set the engine to TDC by rotating the crankshaft in normal engine rotation until the "0" mark on the flywheel is
aligned with the timing mark on the end plate. Check
that the timing marks on the camshaft are also aligned.
See Fig. 5 and Fig. 6.
CAUTION
Do not tum the engine over using the camshafts. The camshafts are not designed to take this type of load. Use a wrench
on the crankshaft pulley center bolt to tum the engine over.
7257 -S2l306
Fig. 3.
Fuel pressure regulator.
14. Disconnect the fuel injection system ground wires from
the cylinder head.
15. Unbolt the AlC bracket from the cylinder head.
16. Unbolt the intake manifold, complete with fuel injectors
and fuel rail and set aside. See Fig. 4.
Fig. 5.
Rywheel 0° TDC mark aligned with timing mark on engine
end plate (arrows).
CAUTION
Cleanliness is essential when working with fuel injection components. Before removing the intake manifold, thoroughly clean
the area around the injectors, the fuel rail, and the intake manifold. If possible, blow the area clean using compressed air.
87134-S2l267
Fig. 6. Camshaft timing mark aligned with mark on camshaft bearing cap.
Fig. 4.
Intake manifold with fuel injectors and fuel rail being removed.
CYLINDER HEAD REMOVAL AND INSTALLA nON
Page 95
Cylinder Head Removal and Installation 211-3
19. Loosen, but do not remove, the camshaft sprocket center mounting bolts. Hold the camshaft flats with an
open-end wrench while loosening the bolts. See Fig. 7.
NOTE
Insert a stiff wire through the chain to prevent it from falling
into the timing chain cover area.
22. Siphon off any excess oil from the inside of the cylinder
head. Then remove the cylinder head bolts in stages,
working towards the center of the head starting with the
outer-most bolts "first.
23. Insert a threaded guide pin (Saab tool no. 83 92 128)
into one of the cylinder head bolt holes. Position the
timing chain and its pivoting guide so that it does not interfere with the removal of the cylinder head. Carefully
lift the cylinder head off, pivoting the head as it passes
the timing chain guide. See Fig. 9.
NOTE
As an altemative to the special guide pin, a wooden dowel can
be used. The guide pins are used to align the head during removal. If the guide pin or dowel is not used, there is risk of
damaging the chain guide when the head is lifted off.
Fig. 7. Camshaft sprocket mounting bolt being loosened, Hold camshaft on flats (arrow) when loosening bolts.
20. Remove the camshaft timing chain tensioner. See
Fig. 8.
II
87263-S2I264
Fig. 9. Cylinder head being removed.
Fig. 8. Camshaft timing chain tensioner being removed from side of
cylinder head.
CAUTION
Do not rotate the engine if the camshaft timing chain tension
is relieved. The pistons can hit the valves and damage them.
21. Remove the camshaft sprockets.
24. Place the cylinder head on wooden blocks to prevent
damaging the open valves.
To install cylinder head
1. Check to make sure the camshafts and the crankshaft
are correctly set to OOTDC as shown above in Fig. 5
and Fig. 6.
2. Place a new cylinder head gasket onto the cylinder
block.
3. Fit the guide pin (or dowel) to the cylinder block and position the timing chain and pivoting chain guide as
shown in Fig. 10.
CYLINDER HEAD REMOVAL AND INSTALLA nON
Page 96
211-4
Cylinder Head Removal and Installation
Tightening torque
• timing chain tensioner
to cylinder head
63 Nm (47 ft-Ib)
8. Rotate the crankshaft by hand in the direction of normal
engine rotation two full revolutions. Recheck that the
TDC marks are all correctly aligned. If any faults are
found reset the timing chain.
9. Tighten the camshaft sprocket mounting bolts whiie
holding the camshafts stationary as shown earlier in
Fig. 7.
Fig. 10. Guide pin installed in cylinder block (arrow), and timing chain
and chain guide correctly positioned for installation of cylinder
head.
4. Slide the cylinder head into position, using the guide
pin as a pivot when lowering the cylinder head over the
chain guide. Install and torque the cylinder head bolts.
See Fig. 11.
@)
CD ® ®
Tightening torque
• camshaft sprocket to camshaft ..... 63 Nm (47 ft-Ib)
10. Install the valve cover as described in 214 Cylinder
Head and Valve Mechanism.
11. Install the distributor cap, the spark plug wires, and the
center cover above the spark plugs.
12. Using new nuts, install the exhaust manifold, and if applicable, the EGR pipe. Install the intake manifold.
Tightening torques
I
0 ® ® ®
@
87265-87835
• exhaust manifold to cylinder head
turbo engines
all other engines
• intake manifold to cylinder head
• EGR valve to cylinder head
25 Nm (18 ft-Ib)
20 Nm (15 ft-Ib)
22 Nm (16 ft-Ib)
8 Nm (71 in. Ib)
Fig. 11. Cylinder head bolt tightening sequence.
Tightening torques
• cylinder head to cylinder block
60 Nm (44 ft-Ib)
stage 1
80 Nm (59 ft-Ib)
stage 2
plus and additional 90° (1/4 turn)
13. If applicable, install the turbocharger. Connect the turbo discharge pipe, the oil supply pipe and the oil return
pipe.
14. The remainder of installation is the reverse of removal.
NOTE
5. Install the two M8 bolts into the underside of the cylinder head as shown above in Fig. 2.
Upon first start up, the hydraulic lifters will most likely be noisy.
Avoid racing the engine above 3,000 rpm until the noise has
dissipated.See 214 Cylinder Head and Valve Mechanism
for more information on hydraulic cam followers.
6. With all TDC (timing) marks aligned, install the exhaust-side camshaft sprocket, making sure there is no
chain slack between the cam sprocket and crankshaft
sprocket.
Tightening torques
7. Install the intake-side camshaft sprocket, keeping the
chain tight between the two sprockets. Hand tighten
the sprocket mounting bolts. Install the timing chain
tensioner.
• all other fasteners
M5 bolt
M6 bolt
M8 bolt
M10 bolt
CYLINDER HEAD REMOVAL AND INSTALLA nON
5 Nm (44 in-Ib)
10 Nm (89 in-Ib)
20 Nm (15 ft-Ib)
40 Nm (30 ft-Ib)
Page 97
Pistons, Connecting Rods, Cylinder Bores
212-1
212 Pistons, Connecting Rods,
Cylinder Bores
General.
212-1
Cylinder Block and
Piston Reconditioning
212-2
Connecting Rods and Pistons
Cylinders
To check piston-to-cylinder clearance
212-2
212-3
212-3
Piston Rings
TABLES
a. Connecting Rod and
Piston Pin Specifications
b. Piston-to-Cylinder Clearances
c. Piston Ring Specifications
212-4
212-2
212-4
212-5
C\I
,....
N
GENERAL
This repair group provides the specifications and special
reconditioning information necessary to repair the Saab short
block. The information contained here is intended to be used
as a reconditioning guide for the professional or experienced
automotive mechanic. Many of the operations described below require precision measuring equipment. If you lack the
skills, tools, or a suitable workplace for reconditioning, we
suggest you leave these repairs to an authorized Saab dealer
or other qualified shop.
Be sure to carefully 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.
NOTE
Cylinder block disassembly and assembly is covered in 210
Engine Disassembly and Assembly.
Fig. 1. Exploded view of cylinder block.
GENERAL
Page 98
212-2
Pistons, Connecting Rods, Cylinder Bores
CYLINDER BLOCK AND
PISTON RECONDITIONING
All of the disassembled parts should be thoroughly cleaned
before inspection.
Connecting Rods and Pistons
If pistons, piston pins, piston rings, connecting rods, and
bearings are to be reused, they should always be reinstalled
in their exact positions. Used parts should never be interchanged between cylinders.
The piston pin should fit without any play. The fit can be
quickly checked by pushing the pin through the rod by hand.
There should be slight resistance as the pin moves through
the rod. A more accurate check can be made using a micrometer.
Each connecting rod is matched to its cap and identified by
a number. See Fig. 2. Connecting rods should be checked for
bend, twist and bearing bore out-of-roundness using connecting rod alignment and measuring equipment.
CAUTION
The pistons, piston rings, and connecting rods must be installed according to their markings. See 210 Engine Disas"
sembly and Assembly.
Tightening torque
• connecting rod cap to
connecting rod
55 Nm (41 ft-Ib)
Piston pins, connecting rod bushings, and connecting rods
are all available as individual replacement parts. The piston
pin circlips should be replaced with new circlips any time they
are removed. Table a lists connecting rod and piston pin
specifications.
Table a. Connecting Rod and
Piston Pin Specifications
Connecting rods
big end diameter
56.000-56.019 mm
(2.2047-2.2055 in.)
small end diameter,
bushing installed
24.005-24.010 mm
(0.9451-0.9453 in.)
big-end oil clearance
0.026-0.062 mm
(0.0010-0.0024 in.)"
maximum permissible
weight variation per set
9 g (0.32 oz:)
piston pin diameter
23.996-24.000 mm
(0.9447-0.9449 in.)
Piston pin to connecting rod
oil clearance
8202 engine
0.005-0.014 mm
(0.0002-0.0006 in.)
8212 engine
0.002-0.011 mm
(0.00008-0.0004 in.)
, See 216 Crankshaft for more information on connecting rod big-end clearances and
bearing shell color codes.
Saab supplies pistons in size ranges or classifications.
These are "A", "B" and "C." The cylinder bores and the pistons
are individually coded. The piston codes are on the piston
domes and the cylinder block codes are stamped into the cylinder block. See Fig. 3. The Saab block is originally fitted with
either an "A" class piston or a "B" class piston, depending on
the final size of the bore. It is possible to find both classes in
one cylinder block. Other piston classes are available as standard and oversize replacements when servicing the engine.
Small amounts of wear in the cylinders can usually be corrected by installing a larger standard piston. If the cylinder is
excessively worn, it may require boring to fit an oversized piston. Piston diameters and their corresponding classifications
are listed in 0 TECHNICAL DATA.
Fig. 2. Connecting rod big-end and cap matching numbers. Always install connecting
rod nuts with flange on nut facing piston.
CYLINDER BLOCK AND PISTON RECONDITIONING
CAUTION
When replacing pistons, use only pistons from the same maniJfacturer. Saab engines can be fitted with pistons from one of
three manufacturers-Mahle, KS (Karl Schmidt), or Hepolite.
The manufacturer's stamp is found on the Inside of the piston.
Page 99
Pistons, Connecting Rods, Cylinder Bores
212-3
Cylinders
When checking the piston-to-cylinder clearance, a set of
feeler gauges with a 112 inch wide blade and a spring scale
are needed to perform the procedure described below. A conventional piston-to-cylinder clearance measuring procedure
can be used (micrometer and bore gauge), although the
method described below is simpler and is the one recommended by Saab.
To check piston-to-cylinder clearance
1. Lightly oil the cylinder and the piston.
2. Insert a feeler gauge blade into the cylinder and then
install the piston (piston rings removed) upside down
into its matching cylinder. Select a feeler gauge that fits
snugly.
Fig. 3. Piston and cylinder classification locations.
NOTE
NOTE
• The classifications for standard replacements pistons are
AB, B, and C (B on B212 engines), with the C or B class pistons being the largest and most commonly used replacement
piston on high-mileage engines.
• The 1/2 in. wide feeler gauge blade is critical to accurate
results.
• Standard piston class A is not available as a replacement
part.
When measuring the piston diameter, make measurements
at right angles (90°) to the wrist pin and at the height indicated
in Fig. 4.
• The feeler gauge blade should be inserted at right angles to
the wrist pin.
3. Connect the spring scale to the feeler gauge and pull
on the scale. See Fig. 5. Note the amount of force required to start the gauge moving out of the cylinder.
NOTE
1--·----------
Repeat the above step at several depths in the cylinder.
I
i
o .
I
1
~---------~~
v
A
"'"
87057
Fig. 4. Piston measuring point (dotted line) used when checking
piston diameter. Distance varies depending on piston manu-
Piston measuring point (distance A)
• Manufacturer
Mahle
KS
"
16 mm (5/8 in.)
22 mm (7/8 in.)
Fig. 5. Piston·to-cylinder clearance being checked using spring
scale and feeler gauge with 1/2 inch blade.
4. Continue to try different feeler gauges until the pulling
lorce is within the specified limits listed below.
CYLINDER BLOCK AND PISTON RECONDITIONING
Page 100
212-4
Pistons, Connecting Rods, Cylinder Bores
See Fig. 6. Use an inverted piston to position the rings squarely in the bore. Be sure to check the end gap at the bottom of
the piston's travel when checking rings in a worn cylinder. Piston ring specifications are listed in Table c. The end gap
should be checked after the final cylinder hone, if applicable.
Correct spring scale force
• 8-12 N (1.7-2.6 Ib-ft)
CAUTION
When replacing pistons, do not mix pistons from different
manufacturers. Pistons can be individually replaced, although
they must be from the same manufacturer.
NOTE
• The thickness of the correct feeler gauge equals the pistonto-cylinder clearance. Piston-to-cylinder clearances vary depending on the piston manufacturer and piston/cylinder classifications. See Table b.
• If the piston-to-cylinder clearance is excessive, the piston
should be replaced with a larger standard piston. Excessively
wom cylinders can be bored to accept oversized pistons. See
o TECHNICAL DATA for piston classifications and diameters.
Piston Rings
Check piston ring end gaps, ring side clearances in the piston, and ring thicknesses. Piston ring end gaps are checked
with the piston rings inserted one at a time into the cylinders.
Fig. 6.
Piston ring end gap being checked in cylinder block using feeler gauge.
Table b. Piston-to-Cylinder Clearances
Non-turbo (KS)
Turbo
Non-turbo (Hepolite)
AlA
0.012-0.032 mm
0.030-0.050 mm
0.015-0.033 mm
AB/A
0.004-0.022 mm
0.022-0.040 mm
0.009-0.025 mm
AB/B
0.014-0.032 mm
0.032-0.050 mm
0.019-0.035 mm
B/A
-
0.014-0.032 mm
0.001-0.019 mm
B/B
0.006-0.024 mm
0.024-0.042 mm
0.011-0.029 mm
C/B
-
0.008-0.034 mm
-
AlA
-
-
0.008-0.028 mm
B/B
-
-
0.009-0.027 mm
B+/B+
-
-
0.009-0.027 mm
Piston/cylinder classification
8202 engine (2.0 L)
8212 engine (2.1 L)
CYLINDER BLOCK AND PISTON RECONDITIONING