SAAB WIS ONLINE

Replacement of oil pump

Replacement of oil pump

To remove



1. Drape the wings with protective covers and disconnect the negative cable from the battery.

2. Remove the air cleaner and the mass air flow sensor.

3. Slacken the pulley bolts slightly. Remove the multigroove drive belt, the belt tensioner, the power steering servo pump pulley, the coolant pump pulley and the cover. Remove the power steering pump from the bracket and place it aside.


4. Remove the right-hand front wheel and the cover in the wheel housing. Remove the crankshaft pulley (undo the six bolts but do not remove the centre bolt).


5. Put the No.1 cylinder in the compression position. The markings on the camshaft sprockets and timing cover should be in alignment as should the marking on the crankshaft. Insert the locking tools for the camshaft sprockets on both cylinder heads.


6. Before removing the toothed belt, mark its direction of rotation. To facilitate refitting, the belt can be marked at both the camshaft marking and the crankshaft marking.

7. Release the belt tension and remove the toothed belt.


8. Turn the crankshaft back 60° BTDC.

9. Remove the bracket holding the upper adjusting roller and the tensioning roller.


10. Remove the timing cover retaining bolts. Use a spanner to rotate camshaft sprocket No. 1 so that the cover's retaining bolt behind the sprocket can be removed. Exercise care so that the camshaft does not "snap". Turn the camshaft sprocket back to the zero position. Do the same with camshaft sprocket No. 2. Lock the camshaft sprockets with setting tool 83 95 006 and remove the sprockets. Remove the rear timing cover.


11. Fit lifting beam 83 94 850 and holder 83 9 835 in the lifting eyes.


12. Raise the car. Remove the spoiler sections and the front exhaust pipe.

13. Remove the protective plate.

14. Fit holder 83 95 063 and remove the crankshaft pulley.

15. Remove the subfame.


16. Remove the alternator.


17. Remove the A/C compressor and hang it up.

18. Drain the engine oil.


19. Remove the sump, the oil strainer and the antislosh baffles.

20. Disconnect the cable for the oil pressure switch.

21. Lower the car and place a stand under the front of the engine block.


22. Remove the bracket complete with the engine mounting.

23. Remove the oil pump housing.


24. Remove the cover and extract the two impellers.

25. If necessary, check the oil pressure relief valve and control valve.

Turning torque pressure release valve

28 Nm (21 lbf ft) copper gasket.

20 Nm (15 lbf ft) aluminium gasket.


To fit



1. Position the impellers in the housing and fit the cover. Lock the bolts with 74 96 268.

Turning torque 6 Nm (4.5 lbf ft).

Important

The marks on the impellers should be on the outside when fitting.


2. Position a new gasket, coat it with 93 21 795 and fit the pump housing.

Turning torque 6 Nm (4.5 lbf ft).

3. Fit the bracket complete with engine mounting.


4. Raise the car and remove the stand.

5. Fit the cable for the oil pressure switch.


6. Seal the joints in the parting line with silicone flange sealant 87 81 841. Fit the antislosh baffles, oil strainer and sump. Lock the bolts with 74 96 268.


Tightening torques,

oil antislosh baffles 8 Nm (6 lbf ft).

oil sump 15 Nm (11 lbf ft).

oil suction pipes 8 Nm (6 lbf ft).

7. Fit the A/C compressor.


8. Fit the alternator.

9. Fit the subframe.


Tightening torques

front: 115 Nm (85 lbf ft)

middle: 190 Nm (140.6 lbf ft)

- rear: 110 Nm (81.4 lbf ft) + 75°.

10. Use holder 83 95 063 and fit the crankshaft sprocket.


Tightening torques

250 Nm (184.5 lbf ft) + 45.

11. Remove the holder and fit the cover plate.

12. Fit the spoiler sections and the front exhaust pipe.

13. Lower the car. Remove yoke and lifting sling.

14. Fit the rear timing cover. Fit the camshaft sprockets. Fit the timing cover retaining bolts. Use a spanner to rotate camshaft sprocket No. 1 so that the cover's retaining bolt behind the sprocket can be fitted. Exercise care so that the camshaft does not "snap". Turn the camshaft sprocket back to the zero position. Do the same with camshaft sprocket No. 2.


15. Fit the bracket for the tensioning roller and the upper adjusting roller.

16. Fit setting tool 83 95 006 on camshaft sprockets Nos. 1 and 2, 3 and 4.


17. Turn the crankshaft to just before the 0 point and fit setting tool 83 95 006 on it. Carefully turn the crankshaft in the direction of engine rotation until the arm rests against the coolant pump's flange and tighten it.


18. Fit the toothed belt according to the marked direction of rotation. Use setting tool 83 95 006 to keep the belt in place and adjust the tensioning roller loosely by hand to prevent the belt from jumping off. Adjust anticlockwise. Fit a section of toothed belt and fit tool 83 93 985 to measure the belt tension. Lightly tighten the centre bolts of the adjusting rollers. Adjust the lower roller anticlockwise to a belt tension of 275-300 Nm.


Turning torque 40 Nm (30 lbf ft).

Important

The adjustment of the belt tension is only a preparatory measure and must not be used as a check when the belt is finally adjusted.


19. Adjust the tensioning pulley with an allen wrench until the two marks are aligned. Tighten.

Tightening torque 20 Nm (15 lbf ft).

Remove the locking tool for camshaft sprockets 1 and 2. Adjust the upper adjusting roller counter-clockwise until the No. 2 sprocket moves 1-2 mm clockwise.

Turning torque 40 Nm (30 lbf ft).

Remove the upper locking tool.

20. Turn the engine over two revolutions until just before the zero mark and place the locking tool on the crankshaft. Carefully turn the crankshaft in the direction of engine rotation until the arm rests against the coolant pump's flange and then tighten the arm. Fit setting tool 83 95 006 and check that the markings on the camshaft sprockets are aligned with the markings in the tool.


Important

Also check the tensioning roller to ensure that the marks are in alignment.


21. Fit the crankshaft pulley.


Tightening torque 20 Nm (15 lbf ft).

22. Fit the timing cover, the power steering servo pump, the coolant pump pulley, the power steering servo pump pulley, the belt tensioner and the multigroove belt.

23. Fit the right-hand front wheel and the cover in the wheel housing.


Turning torque, wheels

110 Nm (81 lbf ft)

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


25. Connect the negative lead to the battery. Check all oil and fluid levels, top up as necessary. Check the engine compartment is clean. Remove the wing covers.

26. Start the engine and check all functions. Take the car out on a test drive.