SAAB WIS ONLINE

Exhaust manifold, 4-cyl.

Exhaust manifold, 4-cyl.

To remove

Warning

Be careful if the engine is warm. The coolant is hot and there is a risk of burns from the exhaust manifold.



1. Open the expansion tank cap to release the system pressure.


2. Raise the car.

3. Remove the lower front cover.

4. Drain off the coolant.

5. Undo the bolt at the turbo mounting on the engine block.


6. Loosen the upper screw on the turbo mounting.

7. Detach the turbo return hose to the sump.

8. Loosen the oil pipe to the turbo at the oil filter adapter.

9. Lower the car to the floor.

10. Remove the bypass pipe and valve.


Note

There is an O-ring at the bypass pipe's attachment to the turbo intake pipe.


11. Remove the exhaust manifold's heat shield.

12. Unplug the radiator fan's connectors and move them aside.

13. Remove the bolts on each side of the fan assembly.

14. Loosen the clip holding the cooling system vent hose.

On cars with automatic transmission, also remove the pipe mounting on the fan cowling.

15. Detach the upper radiator hose by undoing the hose clip and bending the hose aside.

16. Unhook and twist the fan assembly, then lift it out.

17. Unplug the boost pressure control valve connector.


18. Unplug the mass air flow sensor connector.

19. Detach the crankcase breather pipe, fastened to the turbo intake pipe, and the camshaft cover.

20. Bend the pipe and wiring aside.

21. Remove the mass air flow sensor and air hose.

22. Loosen the hoses to the turbo and the diaphragm box.


23. Undo the quick release coupling on the venting hose using tool No. 83 95 261.

24. Undo the intake pipe's V-clamp at the turbo.

25. Unbolt the intake pipe from the power steering pump mounting.

26. Lift out the intake pipe.

27. Undo the hose clip on the hose between the turbo and charge air cooler. Plug the hose to prevent dirt entering it. Use plug No. 83 94 595 or similar.

28. Undo the retaining nuts and remove the front part of the exhaust system from the turbo.

29. Carefully lower the front exhaust system away from the turbo.

Important

The flexible section at the front of the exhaust system should not be bent out of line by more than 7°, i.e. if the front exhaust system is allowed to hang, it must not bend more than the sag caused by its own weight.

If the pipe is overloaded, permanent deformation of the components will result. This can cause noise and leakage, and damage at a later stage.


30. Remove the oil pipe to the turbo. Save the copper washers.


31. Loosen the water pipe at the turbo. Save the copper washers.

32. Release the water pipe screw at the coolant pump.

33. Loosen the water return pipe from the turbo at the cylinder head and the pressure sensor mounting. Save the copper washers.

34. Undo the water return pipe's bolt at the turbo.

35. Remove the bolts securing the turbo to the exhaust manifold.

36. Off-load the multigroove V-belt using the pull bar, part no. 83 95 254.


37. Move the belt away from the power steering pump.

38. Remove the power steering pump bracket from the engine mount.

39. Undo the power steering pump bracket bolts and move the pump aside.


40. Push the turbo aside and remove the exhaust manifold. Save the spacer sleeves and washers.


To fit


Note

Smear the studs and gasket sparingly with Molycote 1000, part. no. 30 20 971 or similar, to prevent them baking on.

Spray the connectors with Kontakt 61, part no. 30 04 520.



1. Fit a new gasket to the exhaust manifold.

2. Fit the exhaust manifold.

3. Fit the washers, spacers and nuts.

Tightening torque: 25 Nm (18.4 lbf ft)

4. First fit the top left bolt in the power steering pump bracket. Then fit the other two bolts.

Tightening torque: 24 Nm (17.7 lbf ft).

5. Bolt the power steering pump bracket to the engine mount and tighten the bolts.


Tightening torque: 24 Nm (17.7 lbf ft).

6. Mount the multigroove V-belt and tighten it with the belt tensioner. Use the pull bar, part no. 83 95 254.

7. Bolt the turbo to the exhaust manifold.


Tightening torque:

Lock nuts 24 Nm (17.7 lbf ft)

Studs 22 Nm (16.2 lbf ft)

Important

It is essential that there is oil in the turbo bearing housing when the engine is started.

Fill the turbo oil inlet with oil from an oilcan. Rotate the compressor by hand many times so that the oil penetrates into the bearings.


8. Fit the front part of the exhaust system to the turbo and tighten the nuts.

Tightening torque: 24 Nm (17.7 lbf ft).

Important

When fitting the front exhaust system to the turbo, the nuts should be tightened alternately to avoid distorting the flange. The flange must not abut against the turbo connection flange.


9. Fit the turbo water return pipe. Use new copper washers.

Tightening torque:

Water return pipe/cylinder head: 25 Nm (18.4 lbf ft)

Water return pipe/turbo: 25 Nm (18.4 lbf ft)

10. Fit the turbo water pipe. Tighten the pipe also at the coolant pump end. Use new copper washers.

Tightening torque:

Water pipe/turbo: 25 Nm (18.4 lbf ft)

Water pipe/coolant pump: 20 Nm (14.7 lbf ft)

11. Fit and tighten the turbo oil pipe at the turbo. Use new copper washers.

Tightening torque:

Oil pipe to turbo/turbo: 20 Nm (14.7 lbf ft)

12. Fit a new O-ring greased with non-acidic vaseline to the turbo intake pipe. Slide the V-clamp on the pipe and position same. Bolt the pipe to the power steering pump bracket to facilitate tightening/fitting the V-clamp.


13. Slacken the adjusting screw on the intake pipe to adjust the pipe.

14. Tighten the intake pipe bolt on the power steering pump bracket. Also tighten the adjusting screw.

Tightening torque: 24 Nm (17.7 lbf ft).

15. Tighten the V-clamp between the turbo and the turbo intake pipe.

Tightening torque: 3 Nm (2.2 lbf ft)

16. Connect the hoses to the diaphragm box and turbo, and the vent hose.

17. Remove the plug from the charge air cooler intake pipe.

18. Connect the charge air cooler intake pipe to the turbo.

Tightening torque: 8 Nm (5.9 lbf ft)

19. Fit the heat shield. Press the left clip on first. Coat the nut with Molycote 1000, part no. 30 20 971.

Tightening torque: 20 Nm (14.7 lbf ft).

20. Fit the fan assembly. Ensure that it is positioned on the lower hooks. Tighten the two bolts on the sides of the fan assembly.


Tightening torque: 8 Nm (5.9 lbf ft)

21. Plug in the fan assembly's connectors.

22. Fit the clip that holds the cooling system vent hose.

On cars with automatic transmission, also attach the pipe mounting on the fan cowling.

23. Fit the upper radiator hose.

24. Fit the mass air flow sensor and air hose.


25. Fit the crankcase breather pipe to the camshaft cover and turbo intake pipe.

Tightening torque: 24 Nm (17.7 lbf ft).

Important

Fit new copper washers to the bolt on the turbo intake pipe.


26. Plug in the mass air flow sensor and boost pressure control valve connectors.

27. Connect the bypass pipe and valve. Use a new O-ring lubricated with acid-free petroleum jelly (vaseline).

28. Tighten the bypass pipe screw and hose clamp.

Tightening torque: 8 Nm (5.9 lbf ft)

29. Raise the car.

30. Connect the turbo oil return hose to the sump.


31. Fit and tighten the turbo oil pipe at the oil filter adapter.

Tightening torque: 25 Nm (18.4 lbf ft)

32. For the turbo mounting.

Tightening torque: 24 Nm (17.7 lbf ft).

33. Lower the car to the floor.

34. Check that the radiator drain cock is closed. Fill with coolant. For the correct mixture, see “Cooling system”, Technical Data . Close the radiator cap.


35. Start the car.

36. Set the heater control at full heat.

37. Warm up the engine to expel any air from the cooling system.

38. Raise the car and check for oil and water leaks.

39. Fit the lower front cover.

40. Lower the car to the floor.

41. Top up with coolant/oil as necessary.