SAAB WIS ONLINE

Engine B235R

Engine B235R

To dismantle the engine



1. Remove the starter motor.

2. Remove the generator and belt tensioner. Remove the support bearing bracket with intermediate shaft and the inboard drive shaft joint. Remove the left-hand drive shaft. Use 87 92 616 Removal tool, drive shafts . Plug the gearbox with 87 92 244 Protective plugs, F25 drive shaft hole.

3. Remove the generator bracket and crankcase breather's oil trap complete with hoses.

4. Remove the intake manifold stay.

5. Undo the nut on the rear engine mounting.

6. Dismantle the leads to the oxygen sensor.

7. Detach the exhaust pipe from the turbocharger.


8. Lift the power train and roll away the table with the subframe. Remove the bracket, engine mounting and bolts lower, rear on the engine to the gearbox.

9. Fit 83 95 220 Holder, 4-cyl engine to the engine and lift over the power train to 78 74 878 Floor stand.


10. Drain the engine oil.

11. Undo the bolts and lift aside the gearbox. Use 87 92 442 Lifting cable .


12. Detach the oil filler pipe from its mounting.

13. Remove the bracket for the electric leads from the cylinder head.

14. Unplug all electric connectors between the intake manifold and engine.

15. Remove the boost pressure control valve and detach the hoses from the wastegate


16. Remove the steering servo bracket with the lifting eye.

17. Remove the A/C compressor bracket.

18. Remove the turbo steady bar, disconnect the water and oil pipes and remove the turbocharger complete with exhaust manifold. If it does not come away easily, heat it carefully.

19. Remove the throttle body preheating hose.


20. Remove the bolts retaining the intake manifold.

Lift it away from the power train.

21. Remove the thermostat housing's cover complete with thermostat.

22. Remove the water pump complete with filler pipe and the sleeve with the O-rings.


23. Remove the oil filter and the adapter housing.

24. Remove the protective cap and the crankshaft position sensor.

25. Align the 0 mark on the crankshaft pulley with the mark on the transmission casing.


26. Fit 83 94 868 Flywheel locking attachment and remove the crankshaft pulley.

27. Remove the flywheel, pressure plate and clutch plate, and remove the flywheel locking attachment.

28. Remove the ignition discharge module.


29. Remove the spark plugs and remove the camshaft cover.

30. Remove the chain tensioner. First remove the plug, then use a 27 mm socket.


31. Remove the camshaft sprockets, holding each camshaft steady with a spanner applied to the end of it.

32. Fit a rubber band round the chain guides and remove the cylinder head. Start with the bolts in the timing cover and then continue in reverse order to assembly. Collect the bolts with a magnet.

33. Turn the engine to a suitable working position and remove the oil sump and the pipe to the oil filter.


34. Remove the oil pump and timing cover.

35. Remove the top chain guide and chain tensioner for the balancer-shaft chain.


36. Remove the idler sprocket and balancer-shaft chain.

37. Remove the oil pump driver and sprocket from the crankshaft.

38. Remove the balancer-shaft and camshaft chain guides.

39. Remove the timing chain guard and remove the chain complete with sprocket.

Important

Turn the balancer shafts 180°, so that the weights point upward and remove them with great care so that the inner bearing bushings are not damaged.


40. Remove the balancer shafts complete with sprockets and bearing housings.

41. Remove the end plate.


Important

When dismantling bearing caps and shells, store them carefully and in the right order so that they can be reassembled in their original positions.


42. Remove any carbon deposits from the edges, turn the engine into a convenient position and remove all big-end bearing caps.

Note

Use a 12 point 14 mm socket.


43. Fit Protective sleeve 75 19 531 onto the studs and press or carefully tap the pistons out of the cylinders.

44. Remove all main bearing caps and lift out the crankshaft.

Important

Observe the utmost care when handling the slotted ring.


45. Remove the slotted ring.

46. Remove all the bearing shells for both the main bearings and big-end bearings. Also remove the two thrust washers from main bearing no. 3.

47. Remove the piston cooling nozzles.


To assemble the engine

All engine components must be thoroughly cleaned before fitting.



1. Fit the piston cooling nozzles. Place all main bearings in their correct positions and coat them with oil.

Tightening torque: 18 Nm (13 lbf ft).

Important

Observe the utmost care when handling the slotted ring.


2. Fit the slotted ring, place the crankshaft in position and fit the two thrust washers at the main bearing between the No. 2 and No. 3 cylinders. Fit the washers with the embossed side facing towards the main bearing so that the bearing surface is the right way round.

3. Lubricate and fit all main bearing caps in their correct places, making sure that they are the right way round.

Tightening torque 20 Nm + 70° (15 lbf ft + 70°).

4. Turn the compression rings so that the gaps are staggered 180° and centred with the ends of the gudgeon pin. Also make sure that the gaps in the top and bottom rings of the three-part scraper ring are not in line with each other.


5. Fit protective collars 75 19 531 onto the crankshaft studs, oil the pistons and rings, then fit the pistons in their respective cylinders. The arrow markings on the piston crown should be turned towards the engine's transmission side. Use piston fitting tool 78 62 287 and carefully tap down the pistons in the bores.

6. Lubricate and fit all big-end bearing caps in their original positions, making sure that they are the right way round (number to number, groove in shell to groove in shell).

Tightening torque 20 Nm + 70° (15 lbf ft + 70°).

7. Apply a bead of flange seal, part no. 93 21 795, approximately 1 mm wide to the mating face of the end plate and fit the end plate. Be careful with the seal.


8. Align the crankshaft with the wedge straight up (corresponding to the 0 mark on the crankshaft pulley).

9. Fit the flywheel, alternatively the drive plate, with threadlock, part no. 74 96 292, on the bolts.

10. Fit the flywheel locking attachment 83 94 868 and tighten the bolts to torque.

Tightening torque, flywheel and drive plate 20 Nm + 50° (15 lbf ft + 50°)

11. Lubricate the bearing surfaces on the balancer shafts and in the bearing housings and insert the balancer shafts into their respective tunnels, taking the utmost care to avoid damaging the bearing shells inside.


Important

The shaft with the smaller thrust ring marked INL should be mounted on the inlet side and the shaft with the larger thrust ring marked EXH should be mounted on the exhaust side.


12. Check the timing chain and fit the sprocket and chain onto the crankshaft end, marking to marking, and bolt the safety plate in place.

13. First fit the fixed chain guide, which is common to the timing chain and balancer-shaft chain, and then the pivoted chain guides for the timing and balancer-shaft chains.

14. Fit the balancer-shaft sprocket and the oil-pump driver onto the crankshaft end.

15. Cock the chain tensioner and insert a paper clip or similar object through the hole in the cylinder to prevent triggering of the tensioner. Before this, check that the plunger is turned to the position where it really is pressed out by the spring.


16. Fit the chain tensioner.

Tightening torque: 10 Nm (7 lbf ft).

Warning

It is extremely important for the function that the correct torque is applied when fitting.


17. Inspect the balancer-shaft chain and fit it and the idler sprocket so that the upper setting marks behind the balancer-shaft sprocket and bearing housing are in line with each other. Tauten the chain between the crankshaft and balancer shafts. Fit the idler sprocket last. Hold the bolt in place with your thumb, mesh the teeth of the sprocket with the chain and roll it along the chain into position.


18. Check the marking on the balancer-shaft sprocket and remove the flywheel locking attachment.

19. Setting: Fit the timing cover using two bolts only and do not tighten them. Mount the crankshaft pulley. Rotate the pulley one revolution. Reset the crankshaft relative to the timing cover. Remove the timing cover and crankshaft pulley carefully, making sure that the crankshaft does not move, and check the settings of the balancer shafts.

20. Make sure the mating face on the timing cover is completely clean. Apply a bead of flange sealant, part no. 93 21 795, approx. 1 mm wide on the timing cover. Apply the bead in the centre of the sealing surfaces.


21. Fit the timing cover.

Tightening torque 22 Nm (16 lbf ft).

22. Fit the oil pump, flywheel locking attachment and crankshaft pulley. Remove the flywheel locking attachment.

Tightening torque 175 Nm (130 lbf ft).

23. Fit the oil pump pressure pipe and check that there are no impurities or other foreign matter in the oil sump.


24. Fit the adapter housing and oil filter.

25. Make sure the mating surface on the oil sump is completely clean and apply an even coat of flange sealant, part no. 93 21 795, turn over the engine and fit the oil sump.

Tightening torque 22 Nm (16 lbf ft).

26. Carefully clean all sealing surfaces. Apply a 2 mm thick and 10-20 mm long bead of Loctite 518, part no. 93 21 795, to the inner part of the upper contact surface of the timing cover (against the cylinder head). Turn the engine in the stand, turning the crankshaft 45° to lower the pistons.

Fit a rubber band round the chain guides and mount the cylinder head with a new gasket. Check that it is correctly seated on the locating sleeves and that the chain runs freely.


Tighten the cylinder head bolts in three stages:

Step I: 40 Nm (30 lbf ft)

Step II: 60 Nm (44 lbf ft)

Step III: Tighten a further 90°

Tighten the bolts in the order shown in the illustration.

27. Fit the two screws between the timing cover and the cylinder head.


Tightening torque 22 Nm (16 lbf ft).

28. Remove the rubber band and check that the camshafts are in alignment with their setting marks and turn the crankshaft back to the 0 mark.

29. Fit the camshaft sprockets and chain. Start with the camshaft on the exhaust side.

The marking on the sprockets should be in the centre of the chain markings (only when the engine is fully zeroed, i.e. crankshaft aligned with the 0 mark). Do not tighten the bolts yet.

30. Prepare the chain tensioner for mounting by pressing down the catch and pressing in the chain tensioner.


31. Fit the chain tensioner, using a 27 mm socket.

Tightening torque 63 Nm (47 lbf ft).

32. Fit the chain tensioner plug with push rod and spring.

Tightening torque 22 Nm (16 lbf ft).

33. Check that the chain is correctly seated in the guides. Rotate the crankshaft two complete turns and check the settings of the crankshaft pulley and camshafts.

34. Tighten the camshaft sprocket bolts.

Tightening torque 63 Nm (47 lbf ft).

35. Check the condition of the spark plugs. Replace them if necessary. Fit the spark plugs.


Tightening torque 28 Nm (21 lbf ft).

36. Clean the sealing surface of the camshaft cover with benzine.

37. Apply oil to the opening on the camshaft cover and fit the cover, starting at the opening. Then, tighten the bolt located furthest to the front at the timing chain end. Continue all the way round the outside and inside. See illustration.

Tightening torque 15 Nm (11 lbf ft).

38. Lubricate the ignition discharge module contact surfaces with Krytox, part no. 30 19 312. Fit the ignition discharge module.

Tightening torque 11 Nm (8 lbf ft).

39. Fit the protective cap and the crankshaft position sensor.


40. Inspect the water pump's O-rings and change them if necessary.

Clean the opening in the block and tighten the connecting piece to torque with its large wing horizontal and pointing towards the flywheel end.

Lubricate the O-rings with acid-free petroleum jelly and fit the water pump and pipe. Fit the clip for the crankshaft position sensor at the same time.

41. Clean the surface for the gasket and fit a new exhaust manifold gasket.

42. Fit the turbocharger with exhaust manifold and steady bar.


Tightening torque 25 Nm (19 lbf ft).

43. Connect the water and oil pipes.

Important

The rubber seals should be placed against the adapter housing, water pump and cylinder head.


44. Fit the turbo control.

45. Fit the A/C compressor bracket.

46. Fit the servo pump bracket.

47. Fit the boost pressure control valve and hoses to the wastegate.

48. Fit the thermostat housing.


49. Clean all gasket surfaces between the intake manifold and cylinder head.

50. Align the intake manifold gasket with the aid of the outer retaining bolts and fit the intake manifold.

Tightening torque 22 Nm (16 lbf ft).

51. Reconnect the hoses from the throttle body.

52. Connect all the electrical connections between the intake manifold and the rest of the power train, and fit the cable channel in the lifting eye.


53. Fit the oil filler pipe with bracket.

54. Fit the gearbox and flywheel access panel.

55. Connect a lifting sling and lift the engine from the stand to the subframe.

56. Remove the retainer.

57. Fit the rear engine mounting bracket and the gearbox retaining bolts. Remove the plug.

58. Change the stuffing box and fit the left-hand drive shaft.


59. Position the engine on the subframe and fit the rear engine mounting, tightening it with a torque wrench.

Tightening torque 50 Nm (37 lbf ft).

60. Fit the front exhaust pipe with sensor. Fit the gearbox steady bar and tighten it, using a torque wrench.

61. Remove the plug and change the stuffing box in the gearbox. Fit the bearing bracket with intermediate shaft and inboard drive shaft. Check the oil level in the gearbox and top up if necessary.

62. Fit the oil trap and connect its hoses.

63. Fit the intake manifold steady bar.

64. Fit and connect the generator, starter motor and belt tensioner.

65. Check that the oil plug is properly tightened. The power train is now ready for fitting in the car.

Tightening torque 25 Nm (19 lbf ft).


Replacement of balancer-shaft bearings

To remove



1. Remove the blanking-off washer.

2. Insert press tool 83 94 470 from the flywheel end and connect the pull rod with a nut.

3. Carefully remove the bearing by slowly tightening the nut.


To fit



1. Clean the bearing surface in the cylinder block.

2. Fit the bearing on press tool 83 94 470 .

3. Insert the fitting tool from the flywheel end and connect the pull rod with nut.

4. Tighten the nut until the mark on the tool is 5 mm from the edge of the hole for the blanking-off washer. The bearing is now in the correct position.

5. Dismantle and remove the tool.

6. Check that the oil passage is open by blowing compressed air through the centre main bearing.

7. Fit a new blanking-off washer.