SAAB WIS ONLINE

Turbo

Turbo

To remove

Warning

The turbocharger can be hot and great care must be observed.


Warning

The cooling system is under pressure. Hot coolant and steam can escape.

- Open the cap slowly to release the pressure.

- Carelessness can cause eye and burn injuries



1. Remove the battery cover and the engine cover.


2. Remove the battery cable.

3. Take the cap off the expansion tank to release any pressure.

4. Raise the car.

5. Undo the right-hand side of the spoiler shield.

6. Place a suitable receptacle under the radiator. Connect a hose to the radiator and drain the coolant. Close the cock and refit the spoiler shield.


7. CV : Remove Chassis reinforcement, front subframe, CV .

8. Remove the front nuts of the rear catalytic converter and move aside. Fix in position with 83 95 212 Strap .


9. Remove the mounting from the front catalytic converter and oil sump using 32 025 061 Crow foot spanner .

10. Lower the car.

11. Remove the battery.

12. Remove Battery cover, bottom, B284 .

13. Detach the breather hoses from the coolant reservoir.


14. Detach the breather pipe from the turbocharger and heat shield.

15. Detach and raise the expansion tank slightly.


16. Detach the lower hose of the coolant reservoir, unplug the level sensor connector and lift away the coolant reservoir.

17. Remove the upper heat shield from the turbocharger.


18. Remove the bolt of the ventilation pipe mounting.


19. Unplug the upper oxygen sensor connector and remove the cable anchorages. Move the cable up.

20. Carefully raise the heat shield slightly. Use 83 96 350 Removal socket, oxygen sensor when the oxygen sensor is removed.

21. Remove the turbocharger's lower heat shield.


22. Remove the bolt of the catalytic converter mounting.


23. Remove the catalytic converter nuts to the turbocharger.

Note

Lubricate the studs and nuts with rust removal oil and carefully loosen.


24. Remove Upper radiator member, B284E .

25. Unplug the mass air flow sensor connector. Detach the secondary air pipe, the delivery hose from the turbocharger intake manifold and the crankcase ventilation pipes.


26. Detach the turbocharger intake manifold from the air cleaner casing cover and the turbocharger.

27. Remove the bypass valve and unplug the connector.


28. Remove the upper radiator mounting.


29. Unplug the radiator fan connectors and detach the wiring harness from the fan cowling.

30. Remove the bolts of the lower turbocharger delivery pipe and the fan cowling.

31. Press the radiator assembly forward and remove the fan cowling.

32. Detach the inlet pipe of the secondary air injection pump from the pump.


33. Detach the discharge pipe of the secondary air injection pump from the pump.

34. Unplug the intake air sensor connector (688).


35. Detach the upper turbocharger delivery pipe.

36. Remove the screw holding the dipstick tube.


37. Remove the heat shield of the front exhaust manifold.

Note

Lubricate the studs and nuts with rust removal oil and carefully loosen.


38. Detach the intermediate exhaust pipe from the turbocharger and the front exhaust manifold.


39. Detach the vacuum hoses and crankcase ventilation pipe from the turbocharger.


40. Detach the lower turbocharger delivery hose from the turbocharger.

41. Detach the oil delivery pipe from the engine.


42. Remove the oil return pipe from the turbocharger.


43. Remove the oil delivery pipe's banjo screws from the turbocharger.

44. Remove the coolant pipe's banjo screw from the turbocharger.

45. Remove the nuts of the rear intermediate exhaust pipe.

46. Remove the bolt holding the turbocharger to the bracket. Use an impact socket and a long drawbar handle.

47. Remove the turbocharger.


To fit

Important

It is essential that there is oil in the turbocharger bearing housing when the engine is started, especially after a new turbocharger has been fitted.

Fill the turbocharger's oil inlet with oil from an oilcan. Rotate the compressor wheel by hand a number times to ensure that oil enters the bearings.



1. Position the turbocharger.

2. Fit the bolt that holds the turbocharger to the bracket.

Tightening torque: 65 Nm (48 lbf ft)


3. Fit the nuts of the rear intermediate exhaust pipe. Tighten alternatingly.

Tightening torque 30 Nm (22 lbf ft).

Important

The conical side of the nut should face the centre exhaust pipe.


4. Fit the coolant pipe's banjo screw to the turbocharger. Use new gaskets.

Note

Engines with aluminium washers: first fit washers part no. 551 700 02 on the banjo nipple where the tabbed gasket section is turned towards the turbo. Fit the banjo screw by screwing it through the gasket and then into the turbo.


Tightening torque 30 Nm (22 lbf ft).

5. Fit the oil delivery pipe's banjo screws to the turbocharger using new gaskets.

Note

Engines with aluminium washers: first fit washers part no. 551 700 00 on the banjo nipple where the tabbed gasket section is turned towards the turbo. Fit the banjo screw by screwing it through the gasket and then into the turbo.


Tightening torque 30 Nm (22 lbf ft).

6. Attach the oil return pipe to the turbocharger using new gaskets.

Tightening torque: 14 Nm (10 lbf ft)

7. Attach the oil delivery pipe to the engine using new gaskets.

Note

Engines with aluminium washers: first fit washers part no. 551 700 00 on the banjo nipple where the tabbed gasket section is turned towards the engine. Fit the banjo screw by screwing it through the gasket and then into the engine.


Tightening torque 30 Nm (22 lbf ft).

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.



8. Attach the lower turbocharger delivery hose to the turbocharger.


9. Attach the vacuum hoses and crankcase ventilation pipes to the turbocharger.

10. Attach the intermediate exhaust pipe to the front exhaust manifold and the turbocharger. Use a new gasket and coat the studs with 90 513 210 Universal paste .


Important

The conical side of the nut should face the centre exhaust pipe.


11. Tighten the nuts as illustrated - first on the exhaust manifold and then on the turbocharger. Tightening order 11a, 11b, 11c, and 11d alternatingly on the turbocharger.

Tightening torque 30 Nm (22 lbf ft)

Important

The surfaces should align with one another when the nuts are fitted. Check using a feeler gauge. If the surfaces are not flat or the pipe is deformed, the centre exhaust pipe and/or exhaust manifold must be replaced.


12. Fit the heat shield of the front exhaust manifold.

Tightening torque 10 Nm (7 lbf ft)


13. Fit the screw holding the dipstick tube.

Tightening torque: 10 Nm (7 lbf ft).

14. Fit the upper turbocharger delivery pipe.


15. Plug in the intake air sensor connector (688).

16. Attach the discharge pipe of the secondary air injection pump.


17. Attach the secondary air injection pump's inlet pipe to the pump.

18. Press the radiator assembly forward and position the fan cowling.

19. Fit the bolts of the lower turbocharger delivery pipe and the fan cowling.


20. Plug in the radiator fan connectors and attach the wiring harness to the fan cowling.

21. Fit the upper radiator mounting.

22. Fit the bypass valve and plug in the connector.


23. Attach the turbocharger intake manifold to the turbocharger and the air cleaner casing cover.


24. Plug in the mass air flow sensor connector. Attach the secondary air pipe, the delivery hose to the turbocharger intake manifold and the crankcase ventilation pipes.

25. Fit Upper radiator member, B284E .

Important

When fitting the front catalytic converter to the turbocharger, tighten the nuts in a crosswise pattern to avoid tightening the flange crooked.


26. Fit the catalytic converter nuts to the turbocharger. Coat the studs with 90 513 210 Universal paste .

Tightening torque 25 Nm (18 lbf ft).


27. Fit the bolt of the catalytic converter mounting.

28. Fit the turbocharger's lower heat shield.


29. Lightly coat the threads of the front oxygen sensor with 90 513 210 Universal paste and fit the oxygen sensor using 83 96 350 Removal socket, oxygen sensor .

Tightening torque 45 Nm (33 lbf ft).


30. Carefully press down the heat shield.

31. Secure the cable and plug in the connector.

32. Fit the bolt of the ventilation pipe mounting.

33. Fit the upper heat shield to the turbocharger.


34. Attach the lower hose of the coolant reservoir and plug in the level sensor connector.


35. Fit the coolant reservoir in the mounting.


36. Attach the breather pipe to the turbocharger and heat shield. Use a new gasket.

Tightening torque, banjo screw: 30 Nm (22 lbf ft).

Note

Engines with aluminium washers: first fit washers part no. 551 700 02 on the banjo nipple where the tabbed gasket section is turned towards the turbo. Fit the banjo screw by screwing it through the gasket and then into the turbo.


37. Attach the breather hoses to the coolant reservoir.

38. Fit Battery cover, bottom, B284 .

39. Fit the battery.

40. Raise the car.

41. Fit the mounting on the front catalytic converter and oil sump.


42. Fit the rear catalytic converter using a new gasket.

Tightening torque 25 Nm (18 lbf ft).

43. CV : Fit Chassis reinforcement, front subframe, CV .

44. Lower the car.

45. Carry out Cooling system pressure testing and Bleeding and charging the cooling system, B284 .

46. Check the oil level and top up as necessary.

47. Connect the battery cable.

48. Fit the battery cover and the engine cover.

49. Remove the wing covers and restore car electrical functions, see After disconnecting the battery .

50. Start the engine and check for any exhaust, oil and coolant leakage.