SAAB WIS ONLINE

To fit

To fit



1. Lubricate the primary shaft splines, see .

2. If the slave cylinder is new or without brake fluid it must be bled, see Bleeding of slave cylinder .

3. Insert 83 95 162 Protective sleeve, drive shafts into the right-hand shaft seal in the gearbox to protect the seal when the gearbox is fitted.

Important

Always replace the drive shaft seals. Lubricate with gearbox oil, see


4. Raise the car.

5. Make sure that the locating studs are in place. Lubricate with thin anti-corrosion oil.

6. Connect 87 92 608 Holder for single-column lift . Adjust the jack so that it is directly under the centre of the gearbox by the mating face.


7. Fit the gearbox with lifting tool onto a pillar jack.

Important

Push in the gearbox until approx. 20 mm remain and remove tool 83 95 162.


8. Push in the rest of the gearbox. Turn the engine shaft, if needed, so that the gearbox can be fitted.

9. B235R: Position the protective cover plate behind the flywheel. Fit the bolts between the gearbox and engine oil sump as well as the bolts to the protective cover.


Tightening torques:

Gearbox - oil sump: 40 Nm (30 lbf ft)

10. Tighten the lower bolts between the engine and gearbox.


Tightening torque: 70 Nm (50 lbf ft)

11. Remove the lifting tool from the gearbox and remove the jack.

Replace and tighten the gearbox bolts.

Tightening torque: 24 Nm (18 lbf ft)

12. Fit the ground cables to the mounting and the gearbox.


13. Fit tool 83 95 162 in the left shaft seal.

14. Make sure that the driver is clean and fit it into the tool.

Important

Fit the driver in the gearbox until about 20 mm remains and withdraw the tool before the shaft's sealing surface reaches the shaft seal.


15. Push in the rest of the shaft until the circlip snaps into place.

16. Lower the car to the floor.

17. Fit the gearbox mounting.


Tightening torque: 40 Nm (30 lbf ft)

18. Connect the clutch delivery line to the gearbox and fit the clips, check that the pipe mounting on the body is firmly attached.

19. Lift the unit.

Note

Do not lift higher than necessary, it will only make the fitting of the subframe more difficult.


20. Tighten the left engine pad to the body and gearbox, first fit all the bolts and nuts, then tighten the guide bolt first of all to ensure that the correct position is obtained.


Tightening torques:

Engine pad - gearbox: 85 NM (62 lbf ft)

Engine pad - body: 60 Nm (45 lbf ft)

21. Fill the gearbox to the correct level. Use the assembly tool 87 92 590, see Assembly tool . Tighten the level plug, drain plug and filler plug

Tightening torque: 50 Nm (37 lbf ft)

22. Connect the lead to the reversing-light switch.

23. Check that the journals for the radiator assembly are correctly fixated in the radiator member.


24. Unhook the oil cooler.

25. Raise the car and position the lifting trolley with the subframe under the car.

26. Carefully raise the subframe.

Important

Watch out for:

- Hoses to the engine oil cooler.

- The rubber gaiters to the inner driver that can knock against the centre mountings on the subframe before the subframe comes against the body.

- Guide in the front ball joints.


27. Tighten the steering servo delivery line mountings (2 pcs.) before the subframe is fully raised.

28. Guide the radiator assembly journals into the subframe.

29. Guide the AC-lines into their brackets on the subframe.

30. Adjust the subframe so that the bolt holes are aligned with the body. On the lifting trolley there are 2 journals, front left and rear right, which guide the subframe into the correct position.

31. Fit the bolts and the rear support plate that secures the subframe.

32. Roll the lifting trolley out the way.

33. Tighten the bolts for the subframe.


Tightening torque: 100 Nm + 45° (74 lbf ft + 45°)

34. Tighten the bolts for the support plate.

Tightening torque: 60 Nm (44 lbf ft)

35. Fit the two bolts securing the torque rod to the subframe and tighten them.

Tightening torque: 30 Nm (22 lbf ft)

36. Remove the strap that is securing the radiator assembly.

37. Fit the engine oil cooler.

38. Tighten the 2 rear attaching clamps for the steering servo delivery line in connection with the subframe, tighten the nut that secures the oil cooler coil.

39. Tighten down the air filter housing.

40. Tighten down the steering gear.

Tightening torque: 90 (66 lbf ft)

41. Tighten the outer ball joints to the steering swivel member.


Tightening torque: 60 Nm + 90° (44 lbf ft + 90°)

Warning

Check that the journal on the ball joint protrudes above the steering swivel member attachment.


42. Fit the anti-roll bar supports. Hold with a thin, open 17 mm wrench or hold the hexagonal pin with a socket.

Tightening torque, nut with steel lock: 95 Nm (66 lbf ft)

Tightening torque 84 Nm (62 lbf ft)

43. Fit the cover plate between the engine and gearbox (not B235R).


44. Fit the rear engine pad, with the bolts in place, on the subframe and insert the two front bolts.

45. Fit the rear engine mounting, the linkage to the selector mechanism will follow.

Tightening torque: 70 Nm (50 lbf ft)

46. Fit the stay between the engine mounting and engine.

Tightening torque: 22 Nm (16 lbf ft)

47. Fit the front exhaust pipe, by:

• Tightening the flange to the turbo.

Tightening torque: 25 Nm (18.5 lbf ft)

• Fit and tighten the stay to the engine.

Tightening torque: 22 Nm (16 lbf ft)

• Fit the clip for the rubber mounting.

• See also Front exhaust system with catalytic converter, 4-cyl. B205E or Front exhaust system with catalytic converter, B235R .

48. Fit shields and the belt circuit splash guard.

49. Lower the car to the floor.

50. Remove the lifting beam, remove the locating studs and tighten the upper bolts between the engine and gearbox.

Tightening torque: 70 Nm (50 lbf ft)

51. Shake the power train to avoid tension in the engine pads. Tighten the bolts to the rear engine pad from the engine bay side, start with the rear bolts.


Tightening torque: 24 Nm (18 lbf ft)

52. Tighten the nut to the rear engine pad.

Tightening torque: 45 Nm (33 lbf ft)

53. Raise the car.

54. Slacken the bolt to the front torque arm to the gearbox and centre the rubber pad in the arm and tighten.

Tightening torque: 47 Nm (34 lbf ft)

55. Lower the car to the floor.

56. Remove the brake clamp from the clutch pedal. Connect a hose to the bleed nipple, slacken the nipple and allow a small amount of brake fluid to run out. Tighten the nipple and test the clutch. If it does not work bleed the clutch as described in Bleeding the brake system .

Check that there are no system leaks.

57. Fit the selector linkage to the gearbox and tighten.

Tightening torque: 24 Nm (17.5 lbf ft)

58. Remove the locking pin 87 92 335 from the gear lever housing and connect the gear linkage to the selector rod.


59. Select 4th gear and secure with a locking pin 87 92 632. Tighten the clamp on the gear linkage.

Tightening torque: 22 Nm (16 lbf ft)

60. Remove the locking pins, check the gear positions and that the ignition key can be removed. Fit the plastic plug in the gearbox.

Fit the gaiter.

61. Connect the oxygen sensor/s.

62. Fit the battery tray.


63. Fit and connect the battery, also fit the plastic cover.

64. Fit the front wheels, the wheels must hang freely.

Tightening torque: 110 Nm (80 lbf ft)

65. Fit the cover over the throttle body.

66. Fit the grille


67. Test drive the car. Check the position of the steering wheel when driving straight ahead on a level road. Adjust if needed.

68. Set the correct time and radio code.