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(210-2321) Adjustment of casting, rear engine mounting

MODIFICATION INSTRUCTION
Bulletin Nbr: 210-2321
Date: ........... December 2001
Market: SE, DK, GB, IE, ZA
Adjustment of casting, rear engine mounting

Service Campaign 157 08

Cars in stock must be rectified before delivery.

Cars already delivered must be rectified in connection with a scheduled visit to the garage for service or repairs.

Cars affected

Saab 9-5 MY02 RHD with 4-cylinder petrol engine and manual gearbox within VIN range 23000428 - 23011818.

Background

The rear engine mounting casting has a lug that touches the pipe to the steering gear. This can cause unwanted noise and corrosion.

Parts required

(16) 30 15 906 Zinc spray. Sufficient for approx. 50 cars.

Procedure

Check box C2 on the modification identity plate before taking any action. Continue as follows if the box is not marked.


1. Cover the wings and remove the upper engine cover and battery cover. Make a note of the radio code, if necessary.


2. Disconnect the negative battery lead.

3. (Man.) Remove the stay supporting the gear linkage from the rear engine mounting bracket.

4. Remove the engine mounting's upper retaining nut and the bolts securing it to the subframe.

5. Remove the bypass pipe and valve.


Note

There is an O-ring where the bypass pipe is attached to the turbocharger intake pipe.


6. Remove the exhaust manifold heat shield.

7. Unplug the oxygen sensor connectors. Cut the cable tie and pull out the cables.

8. Fit 83 94 850 Lifting beam .


9. Undo the two upper nuts securing the joint between the turbocharger and front exhaust system.


10. Raise the car.

11. Undo the third nut holding the turbocharger and front exhaust system together.

12. Undo the upper bolt on the stay securing the catalytic converter to the engine.

13. Undo the pipe joint between the front and rear exhaust systems.

14. Remove the clips and carefully pull off the rubber mountings.

15. Lower and lift away the front exhaust system.

Note

The flexible section on the front exhaust system must not be bent more than 5° from its neutral line, i.e. if the front exhaust system is left suspended, it must not be bent to a greater degree than is caused by its own weight. Excessive strain on the pipe will cause permanent deformation of the components. This can result in noise and leaks, and eventually to breakage.



16. Remove the engine mounting bracket from the gearbox.


17. Remove the engine mounting.

18. Grind or saw off the section of the lug on the engine mounting that is shown in the illustration.


19. Apply (16) 30 15 906 Zinc spray to the section of pipe to the steering gear that is chaffed.


To fit


1. Position the engine mounting and thread the retaining bolts for the engine mounting bracket.


2. Fit the engine mounting bracket to the gearbox.

Tightening torque 84 Nm (62 lbf ft)

3. Fit the front pipe with rubber mountings and clips.


4. Fit the nuts for the rear pipe joints.

Tightening torque 22 Nm (16 lbf ft)

5. Fit the lower nut on the turbocharger.

6. Fit the stay securing the front pipe to the engine.

Tightening torque 25 Nm (19 lbf ft)

7. Feed up the oxygen sensor cables and lower the car.

8. Release the strain on the lifting beam and remove it.

9. Tighten to torque the bolts retaining the engine mounting.

Tightening torque 26 Nm (19 lbf ft).


10. Fit the gear linkage to the engine mounting bracket.

11. Fit the engine mounting's upper retaining nut.

Tightening torque 47 Nm (35 lbf ft).

12. Fit the two upper nuts to the exhaust system.

Tightening torque 24 Nm (18 lbf ft)


13. Pull out the oxygen sensor cables and plug in the connectors.


14. Secure the cables with a cable tie.

15. Fit the upper engine cover and the heat shield over the exhaust manifold.

16. Lubricate the O-ring on the bypass pipe with acid-free petroleum jelly and fit the pipe with the valve and vacuum hose.

Tightening torque 8 Nm (6 lbf ft)

17. Connect the negative battery lead and fit the cover over the battery.

Calibrate the ACC. Set the clock and, were applicable, enter the radio code.


Marking the modification identity plate

Mark box C2 on the modification identity plate after completing this procedure. If the work was carried out by the importer, mark the box with a "7". If done by a dealer, mark it with an "8".

Time/Warranty information

See separate information.