SAAB WIS ONLINE

INSTALLATION

INSTALLATION

Install the clutch release fork and bearing onto transmission. (MT model)

Remove the release bearing from clutch cover with flat type screw driver.


Install the release bearing on transmission.

Install the release fork into release bearing tab.


(A)

Release fork

(B)

Release bearing



Apply grease to the specified points.


• Spline FX2200

• Shaft SUNLIGHT 2



(A)

Spline (FX2200)

(B)

Shaft (SUNLIGHT 2)



Insert the release fork shaft into release fork.


Important

Make sure the cutout portion of release fork shaft contacts spring pin.

(A)

Release fork

(B)

Release shaft

(C)

Spring pin




Tighten the plug.

Tightening torque:

44 Nm (4.5 kgf-m, 32.5 ft-lb)


Install the front cushion rubbers to engine.

Tightening torque:

35 Nm (3.6 kgf-m, 25.8 ft-lb)

Install the engine onto transmission.

Position the engine in engine compartment, and then align it with the transmission.

Note

Be careful not to damage the adjacent parts or body panels with crank pulley, oil pressure gauge, etc.


Apply a small amount of grease to the splines of mainshaft. (MT model)

Tighten the bolts which hold the right upper side of transmission to engine.

Tightening torque:

50 Nm (5.1 kgf-m, 36.9 ft-lb)


Remove the lifting device and wire ropes.

Remove the garage jack.


Install the pitching stopper.

Tightening torque:

T1: 50 Nm (5.1 kgf-m, 37 ft-lb)

T2: 58 Nm (5.9 kgf-m, 43 ft-lb)


Remove the ST from torque converter clutch case. (AT model)

ST 32005099 STOPPER SET

Note

Be careful not to drop the ST into torque converter clutch case when removing ST.


Install the starter.

Install the torque converter clutch onto drive plate. (AT model)

Tighten the bolts which hold the torque converter clutch to drive plate.

Tighten other bolts while rotating the engine by using ST.

ST 32005164 CRANKSHAFT PULLEY WRENCH

Important

Be careful not to drop bolts into the torque converter clutch housing.


Tightening torque:

25 Nm (2.5 kgf-m, 18.1 ft-lb)


Clog the service hole with plug.

Install the bracket.


Install the power steering pump on bracket.

Install the power steering tank on bracket.


Install the power steering pump.

Tightening torque:

22±2 Nm (2.24±0.20 kgf-m, 16.2±1.48 ft-lb)


Install the power steering pipe bracket on intake manifold RH.


Connect the power steering switch connector.


Install the front side V-belt, and adjust it.

Lift-up the vehicle.

Tighten the nuts which hold the lower side of transmission to engine.

Tightening torque:

50 Nm (5.1 kgf-m, 36.9 ft-lb)


Tighten the nuts which install the front cushion rubber onto crossmember.

Tightening torque:

85 Nm (8.7 kgf-m, 62.7 ft-lb)

Note

Make sure the front cushion rubber mounting bolts (A) and locator (B) are securely installed.



Install the ATF cooler pipe to frame. (AT model)

Install the center exhaust pipe.



Lower the vehicle.

Connect the following hoses:

Fuel delivery hose, return hose and evaporation hose

Heater inlet and outlet hoses

Brake booster vacuum hose

Connect the following connectors and terminals:

Engine ground terminal

Engine harness connectors

Generator connector and terminal

A/C compressor connectors

Connect the following cables:

Accelerator cable

Clutch release spring

After connecting each cable, adjust them.

Install the air intake system.

Install the intercooler.

Install the air cleaner element and air cleaner upper cover.

Install the engine harness connector bracket.

Install the filler hose to air cleaner case.

Install the A/C pressure hoses.

Note

Use new O-rings.


Tightening torque:

25 Nm (2.5 kgf-m, 18.1 ft-lb)


Install the radiator.

Install the coolant filler tank.

Install the window washer tank.

Install the battery in the vehicle, and then connect the cables.

Fill engine coolant.



Charge the A/C system with refrigerant.



Remove the front hood stay, and close the front hood.

Take off the vehicle from lift arms.