(260-2544) Overpressure at the expansion tank pressure cap or coolant loss due to displacement of the cylinder liners
Symptom: Coolant loss. Coolant is forced out via the expansion tank pressure cap.
Carbon in the expansion tank.
CO2 gas in the expansion tank.
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TECHNICAL SERVICE BULLETIN
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Bulletin Nbr:
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260-2544
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Date:
...........
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Maj 2005
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Market:
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enl. separat lista
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Overpressure at the expansion tank pressure cap or coolant loss due to displacement of the cylinder liners
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Saab 9-5 M02- with engine alternative D308L.
There is a possibility of gas leakage from the combustion chambers to the coolant ducts via the cylinder head gasket. This causes coolant loss by means of the coolant being forced out via the expansion tank pressure cap in cases where the pressure becomes higher than 1.4 bar. In addition, carbon and CO
2
gas could enter the expansion tank. The basic cause is a small displacement that may arise in the cylinder liners.
In the case of customer complaint, the following procedures must be carried out.
Symptom description
Coolant loss. Coolant is forced out via the expansion tank pressure cap.
Carbon in the expansion tank.
CO
2
gas in the expansion tank.
In accordance with action list.
Measuring the height of the cylinder liners in relation to the cylinder block.
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1.
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Remove the cylinder heads in accordance with WIS - Engine - Basic engine V6 (diesel) - Adjustment/Replacement - Cylinder head, both banks (in car).
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2.
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Rotate the crankshaft so that all pistons are below cylinder block level.
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3.
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Inspect the cylinder head gasket and the surfaces of the cylinder head and cylinder block. If gas has flowed past there will be a carbon imprint from the gasket which is a good indication as to the cylinder(s) in which the cylinder liner has moved out of position.
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4.
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Clamp together and remove all guide rings from the cylinder block.
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5.
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Clean the sealing surfaces on the cylinder block.
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6.
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Measure the position of the cylinder liner in relation to the cylinder block at four points on each cylinder as illustrated. Use a 78 40 622 Dial indicator with 87 91 857 Probe tips and an 83 95 550 Measuring jig. Reset the dial indicator to zero against the cylinder block, move the measuring jig so that the probe tip is in contact with the cylinder liner and read off the value on the dial indicator.
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7.
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If any measurement value indicates that the cylinder liners have dropped more than 0.04 mm then the engine must be replaced.
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8.
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If no measurement value indicates that the cylinder liners have dropped more than 0.04 mm then the guide sleeves and new gaskets must be fitted to the cylinder heads.
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Note
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Use new gaskets with the same marking (number of recesses) as those being replaced.
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10.
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Fit the cylinder heads in accordance with WIS - Engine - Basic engine V6 (diesel) - Adjustment/Replacement - Cylinder head, both banks (in car).
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Warranty/Time Information
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In the case of customer complaint and if the car is
within the warranty period
, use the following information to fill out the claim:
Failed Object: 21118
Fault/Reason code: 56
Location code: 09
Repair/Action code: 08
Labour Operation: 2111810 and 2111811
Time: 21118-10 = 2.4 hr. Removal, both cylinder heads for measuring the cylinder liner height before replacing engine assy. Engine assembly replacement is added.
21118-11 = 0.2 hr. Measuring the cylinder liner height in connection with replacing the gaskets. Gasket replacement, cylinder head, is added.
