(210-2554 ed.3) Noise from the timing chain and oil sludge in the engine
Symptom: Rattling timing chain, abnormal whining, bellowing or knocking noise
from the engine or oil pressure lamp on. If none of the above symptoms is
present, no further diagnosis is to be performed.
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TECHNICAL SERVICE BULLETIN
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Bulletin Nbr:
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210-2554 ed.3
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Date:
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June 2006
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Market:
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US/CA
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Noise from the timing chain and oil sludge in the engine
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Saab 9-5 M98-03 with engine alternative B205 and B235
Saab 9-3 (9400) M99-03 with engine alternative B205 and B235
Various conditions can cause the formation of oil sludge in the engine
or a rattling noise from the timing chain.
In the case of customer complaint, the following procedure must be carried
out.
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Note
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If repair is to be covered under New Car Warranty or Special Policy,
prior authorization from Saab Field Representative is required.
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Symptom description
Rattling timing chain, abnormal whining, bellowing or knocking noise
from the engine or oil pressure lamp on. If none of the above symptoms is
present, no further diagnosis is to be performed.
Checking
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Check the oil level, fill as necessary. If more than 1 litre of
oil is added then run the engine for 15 minutes before the checking for noise.
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Listen to the engine for noise. The engine must be run to operating
temperature! If the engine sounds normal and oil pressure lamp does not come
on, consult with the owner about performing more frequent oil and filter changes
and switching to full-synthetic oil.
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I Procedure to determine extent of damage
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1.
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If the oil pressure lamp flashes or comes on
steady:
Check oil level, fill as necessary. Check the oil pressure in accordance
with WIS - Engine - Basic engine - Adjustment/Replacement - Measuring oil
pressure. If the pressure is in accordance with the specification, replace
the sensor. If not, continue with step 4.
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2.
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Checking in the event of noise:
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2.a.
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Check the oil level, fill as necessary. If more than 1 litre of
oil is added then run the engine for 15 minutes more before checking for noise.
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2.c.
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If a high-pitched whining noise is audible, particularly in a
cold engine, then it is most often from the oil filter or the check valve
in the oil filter adapter.
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2.d.
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If a low-pitched "bellowing" noise is audible at idling speed,
similar to the noise from a hydraulic pump, then this indicates a clogged
oil strainer.
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2.e.
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Lower-end knocking noise, bearing noise.
If either of the above noises are heard, proceed to step 4.
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2.f.
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If a timing or balance chain noise is heard, proceed with step
3.
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3.
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Checking Timing/Balance chain wear
If timing chain has excessive wear, the tensioner will protrude more
than 15 mm. If this has happened, the timing/balance chain and tensioners
must be replaced.
Use the following steps to determine chain wear:
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3.a.
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Remove small 12 mm hex bolt from end of tensioner so plunger does
not protrude further when removed.
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3.b.
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Remove tensioner from block and measure length, see pic.
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3.c.
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If timing chain tensioner length is greater than 15 mm, it will
be necessary to replace timing and balance chains as outlined in TSB 210-2480
ed. 2 (9-5), see WIS for this TSB. For 9-3, see WIS - Engine - Adjustment/Replacement
- Change of balance shaft chain B235 and B205. Before proceeding with chain
replacement, it must first be determined the extent of any further damage.
Continue with step 4.
Continue with step 4 to determine extent of damage before replacing
timing and/or balance chain and tensioner.
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3.d.
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If the timing chain tensioner length is less that 15mm, proceed
with step 4
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4.
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Determining extent of damage to engine lower
end
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4.a.
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Remove oil pan, refer to WIS-Engine-Basic engine-4-cyl petrol-Adjustment/Replacement-Oil
sump (in car).
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4.b.
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Inspect the main bearing and piston rod big end bearing on cylinder
1 and 4 with respect to abnormal wear or damage.
- Remove the main bearing caps and lower bearing half.
- Add a bead of Plasti-gauge. Type PG- 1 (green) must be used, p/n
30 06 558 or source locally.
- Fit the bearing caps with bearing shells (the marking figures on the
connecting rods turned to the same direction).
Tightening torque, with nut 20 Nm +70° (15 lbf ft +70°)
Tightening torque, with screw 25 Nm +100° (18 lbf ft +100°)
- Remove the bearing caps and bearing halves and measure the
Plastigauge strip. The bearing play must be between 0.014 - 0.062 mm.
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4.c.
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In the event of bearing damage, replace the short block assembly,
continue with cleaning of engine components.
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4.d.
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If the bearings are within the specification, continue with Cleaning
of engine components.
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II Cleaning of engine components
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To insure that engine does not return with additional subsequent damage
it is imperative that all components are cleaned before reassembly.
Cylinder head
If it is determined after inspection that the cylinder head must be
cleaned to a higher level than can be done while installed in the car, the
head is to be removed, completely disassembled and fully cleaned.
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Remove the intake and exhaust manifolds and thermostat housing.
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Remove camshaft bearing caps, camshafts, tappets, valve springs,
valves and valve seals.
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Refit the bearing caps loosely.
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Place cylinder head in an appropriate cleaning solution long enough
to fully remove all contamination.
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Blow out all passages and cavities and check that all contamination
has been removed. Any residue must be removed with a stiff brush.
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Reassemble with new valve seals, depending on condition it may
be necessary to dress valves prior to reassembly.
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Oil Pan
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Remove baffle plate, pickup tube and delivery pipe.
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Clean all components in a suitable cleaning solution.
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Upon reassembly, a new pickup tube (p/n 91 86 156) and o-ring
(p/n 91 38 009) must be used.
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Oil filter Adapter Housing and Thermostat
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Remove baffle plate, pickup tube and delivery pipe.
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Remove the thermostat from the adaptor housing.
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Wash both items in suitable cleaning solution.
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Camshaft cover
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Remove all gasket material and clean cover in suitable cleaning
solution.
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Check the crankcase ventilation pipes in the camshaft cover.
Blow clean with compressed air or with a steel wire so that a free flow is
obtained.
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In extreme cases, it may be necessary to replace the camshaft
cover if it cannot be properly and thoroughly cleaned.
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Inspect all ventilation hoses with regard to condition and leakage
before fitting to new engine.
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Carry out the procedure "Fitting renovation kit, crankcase ventilation",
Saab 9-5 and 9-3 (9400) respectively.
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Replace oil filter element.
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Fill engine with semi-synthetic oil.
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Run the engine to the temperature that starts the radiator fan
and then for a further 5 minutes at 2000-3000 rpm.
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Drain the oil and replace the oil filter.
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Refill with FULL-SYNTHETIC oil.
When filling the oil for the second time, and for the extended special
policy to be valid, a fully synthetic long-life oil in accordance with Saab
Automobile's requirements specification is strongly recommended. This requirement
also applies for the engines where the previous recommendation was mineral
or synthetic based oil.
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Test drive the car and check that the steering wheel stands straight
when driving on a straight road. Adjust as necessary.
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Consult with owner concerning shorter maintenance intervals and
use of full synthetic, long-life oil.
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Parts needed
55 561 200 Renovation kit, crankcase ventilation
Other parts, as per EPC
If needed
91 86 156 (CA: 55557225) Pickup tube/strainer
91 38 009 (CA: 30544347) O-ring
55 560 445 Hose to oil pan
55 560 463 Hose for camshaft cover
93 99 973 (CA: 30585634) Hose with check valve
Other parts, as per EPC
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Fitting Renovation kit, crankcase ventilation, Saab 9-5
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1.
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Disconnect the battery's negative cable.
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2.
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Remove the upper engine cover.
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3.
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Install a new oil filler
pipe.
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4.
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Remove the hose from the pipe connection on the turbo's intake
manifold.
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5.
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Remove the hoses from the nipple in the camshaft cover. Check
the condition of the hoses, replace if necessary.
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6.
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Remove the old nipple and bushing from the camshaft cover and
install the new nipple and bushing.
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8.
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Remove the oil trap's
two upper hoses.
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9.
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Remove the lower hose to the oil trap. Remove the stay to the
intake manifold and the oil trap. If necessary, remove the generator positive
cable.
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10.
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Install the new oil trap,
the lower hose to the oil trap (replace hose if necessary) and the stay for
the intake manifold. If the positive cable was removed, connect it to the
generator.
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12.
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Check the function of
the check valve on the small circuit with 30 14 883 Pressure/Vacuum pump,
replace if necessary. The arrow must point toward the throttle body.
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Note
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Arrow's direction on the check valve.
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13.
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Connect the new hose
kit (with T-connection) between the nipple on the oil filler pipe and the
connection on the turbo's intake manifold.
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14.
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Install the insulation
under the throttle body coolant hose so that the insulation's short sides
point upward.
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15.
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Install the crankcase
ventilation hose so that the check valve is located above the coolant hoses.
The crankcase ventilation hose must follow the route of the lower coolant
hose through the intake manifold and then on to the oil trap.
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16.
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Connect the oil trap's
upper hoses. If the hose with part no. 55 560 463 is replaced then the nipple
enclosed with the hose must not be used. Use the nipple enclosed with the
spare parts kit.
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17.
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Connect the new hose kit together at the T-connection.
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18.
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Make sure that the check
valve has good contact with both coolant hoses. Affix a cable tie around the
insulation on each side of the check valve.
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19.
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Connect the hoses to the nipple on the camshaft cover.
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20.
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Install the upper engine cover.
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21.
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Connect the cable to the battery's negative terminal.
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22.
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Set the correct time and date in SID.
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Fitting Renovation kit, crankcase ventilation, Saab 9-3 (9400)
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1.
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Disconnect the battery's negative cable.
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2.
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Remove the upper engine cover.
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3.
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Install a new oil filler
pipe.
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4.
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Remove the hose from the pipe connection on the turbo's intake
manifold.
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5.
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Remove the hoses from the nipple in the camshaft cover. Check
the condition of the hoses, replace if necessary.
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6.
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Remove the old nipple and bushing from the camshaft cover and
install the new nipple and bushing.
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8.
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Remove the oil trap's
two upper hoses.
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9.
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Remove the lower hose to the oil trap. Remove the stay to the
intake manifold and the oil trap. If necessary, remove the generator positive
cable.
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10.
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Install the new oil trap,
the lower hose to the oil trap (replace hose if necessary) and the stay for
the intake manifold. If the positive cable was removed, connect it to the
generator.
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12.
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Check the function of
the check valve on the small circuit with 30 14 883 Pressure/Vacuum pump,
replace if necessary. The arrow must point toward the throttle body.
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Note
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Arrow's direction on the check valve.
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13.
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Man:
Remove the vacuum pipe from the
turbocharger delivery pipe.
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14.
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Remove the upper turbocharger
delivery pipe from the throttle body and cylinder head. Move the turbocharger
delivery pipe aside.
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15.
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Unplug the temperature
sensor connector.
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16.
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Detach and move aside
the cable duct from the cylinder head.
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17.
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Unplug the throttle body connector.
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18.
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Connect the new hose
kit (with T-connection) between the nipple on the oil filler pipe and the
connection on the turbo's intake manifold.
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19.
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Install the insulation
under the throttle body coolant hose so that the insulation's short sides
point upward.
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20.
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Install the crankcase
ventilation hose in so that the check valve is located above the coolant hoses.
The crankcase ventilation hose must follow the route of the lower coolant
hose through the intake manifold and then on to the oil trap.
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21.
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Connect the oil trap's
upper hoses. If the hose with part no. 55 560 463 is replaced then the nipple
enclosed with the hose must not be used. Use the nipple enclosed with the
spare parts kit
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22.
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Connect the new hose kit together at the T-connection.
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23.
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Make sure that the check
valve has good contact with both coolant hoses. Affix a cable tie around the
insulation on each side of the check valve.
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24.
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Plug the connector into
the throttle body.
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25.
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Fit the cable duct to the cylinder head.
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26.
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Plug the connector into
the temperature sensor
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27.
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Install the turbocharger
delivery pipe. If necessary, replace the throttle body O-ring.
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28.
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Man:
Install the vacuum pipe.
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29.
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Connect the hoses to the nipple on the camshaft cover.
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30.
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Install the upper engine cover.
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31.
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Connect the cable to the battery's negative terminal.
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32.
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Set the correct time and date in SID.
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Warranty/Time Information
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Note: Saab field representative authorization required prior to beginning
repairs
Failed Object: 19052
Fault/Reason code: 74
Warranty Type (US):
(01) During New Car Warranty period
(11) Beyond New Car Warranty but within 8 years
For Location Codes, Repair/Action codes, Labor operations and times:
Refer to the Oil sludge Diagnostics Repair Matrix included in this TSB.
Note: Labor operations are not to be combined. The operations are designed
to stand along according to the repair/action performed.
