SAAB WIS ONLINE

Power unit, fitting

Power unit, fitting

To fit

Warning

A large number of hoses, cables, etc., are secured with cable ties. After tightening, the ties are cut off and leave more or less sharp edges at the fastening point. Watch out for the risk of cuts due to these sharp ends on the cable ties!



1. Position the lifting trolley and power unit in relation to the car body. Insert a 82 93 102 Extension, 500 mm, 3/8 square through the hole in the subframe to the mountings on the body.



2. Raise the power unit until the drive joints are in line with the wheel hubs. Insert the drive shafts into the hubs. Make sure that nothing gets caught or is damaged.

3. Raise a little higher and position the lower swivel joints to the steering swivel members. If necessary, adjust the trolley lift screws to provide even contact with the body. Check that the guide pins are positioned correctly relative to the reference holes in the body. See Centring tool, engine and subframe .

4. Thread the bolts through the subframe and into the body.

5. Raise the engine completely and tighten the bolts on the subframe and rear brackets.

Tightening torque, subframe 75 Nm + 135° (55 lbf ft +135°)

Tightening torque, rear bracket bolts: 90 Nm +45° (60 lbf ft + 45°)

6. Lower and remove the trolley lift.

7. Tighten the bolts securing the lower suspension ball joints.

Tightening torque 50 Nm (37 lbf ft)

Important

Ensure that the steering knuckle stub is visible on the top of the steering knuckle housing before the bolt is fitted.



8. Position and tighten the lower links of the anti-roll bar. Use a thin wrench in the keys to hold them still.

Tightening torque 64 Nm (47 lbf ft)

9. Fit and tighten the track rod ends.

Tightening torque 35 Nm (26 lbf ft)

10. Fit the ground cable to the gearbox and plug in the angle sensor (option) that is part of the headlight levelling system.


11. Clean the joints and connecting pipes on the exhaust pipe.


12. Fit a sleeve clamp round the front pipe and fit the front exhaust pipe to the catalytic converter. Use a new seal and new nuts.

Tightening torque 25 Nm (18 lbf ft)

13. Adjust the sleeve clamp so that the pipe ends are in the centre of the clamp. Tighten the nuts on the clamp.

Tightening torque 40 Nm (30 lbf ft)

14. Lower the car and fit the right and left-hand engine mountings.

Tightening torque, right-hand 70 Nm + 60° (52 lbf ft + 60°)

Tightening torque, left-hand 70 Nm + 45° (52 lbf ft + 45°)


15. Undo the strap and remove the radiator member. Thread the bolts securing the A/C compressor.


16. Remove the plug and fit the banjo nipple to the power steering pump. Use a new washer.

Tightening torque 30 Nm (22 lbf ft)


17. Remove 30 07 739 Hose pinch-off pliers from the delivery and return power steering hoses.

18. Raise the car and tighten the bolts securing the A/C compressor.

Tightening torque 20 Nm (15 lbf ft)

19. Remove 83 96 152 Centring kit, engine from the subframe.


20. Tighten the rear bolts on the torque arms.

Tightening torque 70 Nm + 90° (52 lbf ft + 90°)


21. Fit the screws securing the clamps holding the power steering pipe to the subframe.


22. Make sure that the pulleys are clean and oil free. Detension and fit the poly-V-belt in the direction of rotation marked. Make sure that the belt is correctly seated on the pulleys.


23. Make sure that the steering assembly is in the straight ahead position. Fit the steering shaft to the steering gear. Use a new bolt.

Tightening torque 27 Nm (20 lbf ft)


24. Lower the car and fit the coolant hose to the generator bracket.


25. Connect the quick coupling on the right-hand coolant hose and the clips on the bulkhead.

26. Connect the quick couplings on the fuel return line.

27. Remove 30 07 739 Hose pinch-off pliers from the clutch hose and connect the quick coupling to the clutch's slave cylinder. The connection must be at right angles, as illustrated. Check that the connection is sound.


28. Fit the gear selector cables to the gearbox.


29. Fit the expansion tank to the body. Plug in the coolant level switch connector.


30. Undo the engine wiring harness mountings and fit the clamp to the body and the ground cables.


31. Connect the engine wiring harness to the electrical centre and tighten the screw.

32. Fit the positive cable to the battery's positive terminal.

33. Fit the two bolts securing the electrical centre and the cover.

34. Fit the windscreen washer fluid filler pipe.

35. Connect the intake hose and fit the air cleaner casing. Fit the air filter and air cleaner casing lid.


36. Plug in the mass air flow sensor, connect the crankcase ventilation hose and fit the turbocharger intake hose.


37. Plug in the connector for the A/C pressure sensor.


38. Fit the radiator.


39. Fit the A/C pipe to the clasp on the right-hand structural member.

40. Make sure that the lugs on the condenser and charge air cooler are correctly positioned and fit the bolts securing the radiator.

41. Fit the upper coolant hose to the thermostat housing.

42. Fit the lower coolant hose.

43. Fit the fan cowling and tighten the bolts. Cut the cable tie securing the radiator assembly.


44. Fit the two connectors to the left-hand structural member.

45. Fit the upper radiator mountings to the body.


46. Fit the radiator seal.

47. Plug in the reversing light switch connector.


48. Connect quick-coupling on the vacuum hose to the vacuum pump.

49. Connect the connector and clips that hold the wiring to the fan cowling.

50. Fit the battery tray and plug in the bonnet switch connector.


51. Fit the power steering fluid reservoir and bracket.

52. Fit the cover with vacuum tank, etc.

53. Plug in the connectors on the cover. Connect the vacuum hoses to the swirl throttle, throttle body, plastic pipe to the vacuum valve, and vacuum pump.


54. Fit the bleeder hose to the radiator and the pipe to the cylinder head.

55. Fit the battery and connect the battery cables.

Important

To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.


56. Fit the charge air pipe and hose and fit the stay connected to the radiator.


57. Connect the charge air hose to the charge air pipe on the camshaft cover.

58. Fit the charge air pipe and hose.

59. Connect the charge air hose to the throttle body and fit the upper mounting holding the charge air pipe to the radiator.


60. Fit the upper radiator crossmember


61. Connect the quick coupling on the bonnet cable and press the clip into the body.

62. Fit the battery cooler pipe and battery cover.


63. Fit the upper engine cover.

64. Raise the car and fit the lower seal between the charge air cooler and radiator.


65. Fit the bolts securing the receiver drier to the radiator. Make sure the radiator drain plug is closed.

66. Fit the lower bolt to the charge air pipe and the bracket to the radiator.

67. Fit the hose between the charge air cooler and charge air pipe and the cover on the right-hand side.

68. Fit the lower charge air pipe mounting to the fan cowling.


69. Fit the charge air hose between the charge air pipe and charge air cooler and the cover on the left-hand side.

70. Lower the car slightly and fit the bumper.


71. Plug in the headlight washer hose.


72. Fit the wing liners in both front wheel housings.


73. Raise the car and suspend the spoiler shield from its front edge. Plug in the connector for the headlight washers and connect the hose.


74. Fit the front spoiler shield and the lower engine cover.

75. Lower the car slightly and remove the fabric-backed tape from the steering wheel. Fit the hub nuts.

Tightening torque 230 Nm (170 lbf ft)

76. Fit the wheels. Refer to Wheels

Tightening torque 110 Nm (81 lbf ft)

77. Lower the car, check the engine oil level and fill the cooling system to about 20 mm above the mark on the expansion tank.

78. Bleed the fuel system, referring to Bleeding of fuel lines .

79. Top up the washer fluid.

80. Check the level of fluid in power steering fluid reservoir.

81. Bleed the clutch as described under Bleeding the clutch hydraulic system in the car .

82. Remove the covers from the wings and return the electrical system to its original state. Refer to Procedures after reconnecting the battery .