Professional Documents
Culture Documents
SERVICE MANUAL
,...
The basic and derived units used throughout the Service Manual
are in accordance with the SI system.
For users not familiar with the SI units, some non-Continental units
are given in brackets after the respective SI unit.
The following symbols and abbreviations are used:
S~
unit
inch (in)
pound (Ib)
pound-force (Ibf)
pound-force foot (Ibfft)
pound-force per square inch (lbf/in 2 )
(Also abbreviated: psi)
US liquid quart (Iiq qt)
(Also abbreviated: qts)
US gallon (USgal)
mm
kg
N
Nm
bar
I (litre)
OF
Convellsion factolls
1in=25.4mm
1Ibf=4.45N
11bfft = 1.36 Nm
1 psi = 0.07 bar
1Iiqqt=0.951
1 US liq qt = 0.83 UKqt
'.
1 mm = 0.039 in
1N = 0.231bf
1Nm=0.74Ibfft
1 bar = 14.5Ibf/in 2
1'j = 1.051iq qt
1 USgal = 0.83 UKgal
Austria
FR
France
AU
BE
CA
GB
GR
Great Britain
OK
Australia
Belgium
Canada
Switzerland
Germany
Denmark
ES
Spain
EU
FE
FI
Europe
CH
DE
Far East
Finland
Saab-Scania AS 1987
Production: Technical Publications, Saab-Scania, Trollhiittan, Sweden
IS
Greece
Iceland
IT
Italy
JR
Japan
Middle East
Netherlands
ME
NL
NO
SE
US
Norway
Sweden
USA
Engine 022-1
Type: 8201
8202
Cylinder bore
mm (in)
90 (3.54)
Stroke
mm (in)
78 (3.07)
Swept volume
cm (in
Firing order
(No.1 cyl inder at rear)
1985 (121)
1-3-4-2
kg (Ib)
140 (309)
8202
kg (Ib)
150 (331)
Saab 900
022-2 Engine
I?erformance, compression vatio, fuel
octane Il1lllJmber, etc.
Engine
Variant
Model
YeaII'
Octane
Suitable
Requirement sion foil' leadRON (AKW<
fll'ee'uel
Compresll'atiokW
Torque
(hp)/Il'pm
Rating (D!N),
Nm (Ibitt)/
rpm
9.5
73(100)/5200
162(120)/3000
9.5
79(108)/5200
164(120)/3300
9.5
. 87 (118)/5500
167(124)/3000
Single
81-84
Mtlll:96
car.IJurettor
85-
Min95
Twin,
81-84
Min96
ca row r:etrtar.
B2([)>:1l.i,
8:1-84
Min96
g5).
Min95
81;-
r'Vlin 91(87)
9.25
81(110)/5250
161(119)/3000
B202iwith
catalytic
converter
86-
Min91
Rec 95(91)
10.1
96(130)/5500
173(128)/3000
B201 Turbo,
(N/AAPC)
81-82
Min98
7.2
107(145)/5000
235(174)/3000
B201 Turbo
(N/AAPC)
with
cata I,y,:tli c.
convener
81-82
Min 95 (91)
7.2
99(135)/4800
217(160)/3500
B20:tTurbo
withAPC
82-84
Min91
Rec98
8.5
107(145)/5000
235(174)/3000
1B2([))1ii wirttli
cata I')ffi:([;:
converter.
B201 Turbo
85
Min91
Rec98
86-
Min91
8.5
114(155)/5000
240(178)/3000
with,APC
Rec98
8-201 Turbo
wilJi,APC and
8286
Min 91 ~87l
Rec95 91
8,5
99(135)/4800
217 (160)/3500
catalYtic
converter
87-
Min 91 (87)
Rec 95 (91)
8.5
103(140)/5000
235(174)/2500
B202Turbo
84-
Min91
Rec98
9.0
129(175)/5300
273(200)/3000
B202Turbo
with catalytic converter
85-
Min91(87)
Rec 95 (91)
9.0
118(160)/5500
255(188)/3000
B202Turbo
SPG USA**
87-
Min95 (91)
9,0
121(165)/5500
265(195)/3000
AKI = MON
+ RON
*)
2
**) Uprated B202 Turbo with catalytic converter
(US &CA)
Premium = 91 AKI
Regular = 87 AKI
Saab 900
Engine 022-3
mm (in)
mm (in)
92.35
mm (in)
mm (in)
Saab 900
022-4 Engine
Tightening sequence
I
.........
57835
ligll1telrning tOll'Cjjues
The specified torques applied to lubricated bolts
and washers and to new head gaskets.
Nm (Ibfft)
60 (44)
Stage II
Nm (Ibfft)
80 (59),
Stage III
Stage IV
Nm (Ibfft)
Stage V
7516529
00'
75(5211)
Stage I
Nm (Ibfft)
60 (44)
Stage II
Nm (Ibfft)
80 (59)
Stage III
Stage IV
StageV
Nm (Ibfft)
60 (44)
Stage II
Nm (Ibfft)
80 (59)
Stage III
Saab 900
Engine 022-5
Standard (A)
mm(in)
Standard (8)
mm (in)
First oversize
mm (in)
90.50 (3.563)
Second oversize
mm(in)
91.00 (3.583)
Make
m/s (ft/s)
.'
0",.,
'.
'
Pnsttoll'Ds
The type of piston used varies with the compression ratio of the engine.
Piston
Mode!
year
Piston
dia, mm (in)
Pt., mm (irn)
8201, Carbo
1981-
58 (2.28)
0.4 (0.016)
480-492 (17.2-17.7)
8201i
1981-
58 (2.28)
0.4 (0.016)
480-492 (17.2-17.7)
8202i
1986-
64 (2.52)
1.0 (0.04)
8201, Turbo
1981
70 (2.76)
6.6 (0/~60)
492-504 (17.7-18:1)
1982-
70 (2.76)
2.65 (0.104)
497-506 (17.8-18.2)
8202, Turbo
1984-
64 (2.52)
4.7. (0.185)
514-526 (18.5-18.9)
8202, Turbo
1986-
64 (2.52)
3.85 (0.152)
519-531 (18.7-19.1)
Engine
Saab 900
weight, g (OI)
~.
504-516 (18.1-18.6)
022-6 Engine
Piston diameter
Measured at right angles to gudgeon pin and:
Mahle: 16 mm above lower edge
- Schmidt: 26 mm above lower edge
N.B.
Pistons of different makes must not be fitted in
the same engine.
B
C
lEali'KueD' C~alssDfucation
"
TUlirbo (Mahie)
mm (in)
89,960-89,970 (3.5417-3.5421)
StandardAB
mm(in)
89,970-89,976 (3.5421-3.5424)
Standard B
mm (in)
89,976-89,986 (3.5424-3.5428)
Standard C
mm (in)
89,986-90,002 (3.5428-3.5434)
mm(in)
90,460-90,475 (3.5614-3.5620)
mm (in)
90,960-90,975 (3.5811-3.5817)
mm(in)
0,024-0,050 (0.0009-0.0020)
Saab 900
Engine 022-7
Other engines (Schmidt)
Standard A (not spare part)
mm (in)
89,972-89,980 (3.5422-3.5425)
StandardAB
mm (in)
89,980-89,986 (3.5425-3.5428)
Standard B
mm (in)
89,986-89,994 (3.5426-3.5431)
Standard C
mm (in)
89,994-90,010 (3.5431-3.5437)
mm (in)
90,472-90,487 (3.5619-3.5625)
mm (in)
90,972-90,987 (3.5816-3.5822)
mm(in)
0,014-0,040 (0.0006-0.0016)
mm(in)
89,960-89,970 (3.5417-3.5421)
Standard AB
mm (in)
89,970-89,978 (3.5421-3.5424)
Standard B
mm (in)
89,978-89,986 (3.5424-3.5428)
Standard C
mm (in)
89,986-90,002 (3.5428-3.5434)
mm (in)
90,460-90,475 (3.5614-3.5620)
mm (in)
90,960-90,975 (3.5811-3.5817)
mm (in)
0,02-0,050 (0.0009-0.0CJ20)
New c~assDficatuiDlI1
11l.BIi'bo
lurbo
+ calli'buli'ettm (MaJh~e)
mm (in)
89,978-89,988 (3.5424-3.5428)
Standard AB
mm (in)
89,988-89,996 (3.5428-3.5431)
Standard B
mm (in)
89,996-90,004 (3.5431-3.5435)
Standard C
mm (in)
90,004-90,020 (3.5435-3.5441)
mm (in)
90,482-90,497 (3.5623-3.5629)
mm (in)
90,982-90,997 (3.5820-3.5826)
mm (in)
0,004-0,032 (0.0002-0.0013)
mm (in)
89,977-89,985 (3.5424-3.5427)
StandardAB
mm(in)
89,985-89,991 (3.5427-3.5430)
Standard B
mm (in)
89,991-89,999 (3.5430-3.5433)
Standard C
mm (in)
89,999-90,015 (3.5433-3.5439)
mm (in)
90,477-90,492 (3.5621-3.5627)
mm(in)
90,977-90,992 (3.5818-3.5824)
mm (in)
0,009-0,035 (0.0004-0.0014)
Saab900
".;;
",.t
022-8 Engine
~eslLB~tgD1lg
pistoll1 Cletalli'3B'1lCeS
lEa~!ieR' ciasslfocation
Piston/cyl i[1der
Clearance,
Schmidt
NA
ABIA
ABIB
BIA
BIB
20-38
14-30
24-40
6-24
1J1000mm
Turbo
30-50
24-40
35-50
14-34
8-34
New classificaltloiil
Piston/cyl inder
"
Clearance,
Non-turbo
(Schmidt)
AlA
ABIA
ABIB
BIA
BIB
CIB
12-32
4-22
14-32
6-24
1J1000mm
Turbo
Carburettor)
Non-turbo
(Hepolite)
30-50
22-40
32-50
14-32
24-42
8-34
15-33
0-25
19-35
1-19
11-29
Top compression
ring
Width (til ickness),
mm (in)
Side clearance in
groove
mm (in)
mm (in)
Scraper
ring
1.73-1.75
1.98-1.99
2.63-2.73*
(0.0681-0.0689) (0.0780-0.0783) (0.1035-0.1075)
. 0.050-0.082
0.040-0.072
(0.0020-0.0032) (0.0016-0.0028)
0.35-0.55
0.30-0.45
0.38-1.40**
(0.0138-0.0217) (0.0118-0.0177) (0.0150-0.0551)
Second
compression ring
Engine 022-9
Diameter:
mm (in)
23.996-24.000 (0.9447-0.9449)
Fit
mm (in)
Diameter of big-end
mm (in)
56.000-56.019 (2.2047-2.2055)
Diameterofsmall-end bush
mm (in)
24.005-24.010 (0.9451-0.9453)
(fitted)
Connecting rods
Maximum permissible
weight variation per set
g (oz)
9 (0.32)
Crankshaft
Maximum variation in straightness
mm (in)
0.10 (0.0039)
End float
mm (in)
0.08-0.28 (0.0031-0.0110)
Maximumjournalout-ofround
mm(in)
0.05 (0.0020)
mm(in)
0.05 (0.0020)
mm (in)
2.2-2.5 (0.0866-0.0984)
mm (in)
0.020-0.062 (0.0008-0.0024)
mm (in)
0.026-0.061 (0.0010-0.0024)
Thick
Standard
Red
Blue
First undersize
Yellow
Green
Second undersize
White
Brown
Saab900
022-10 Engine
Crankpin diameter:
Standard
mm (in)
51.981-52.000 (2.0465-2.0472)
First undersize
mm (in)
51.731-51.750 (2.0367-2.0374)
Second undersize'
mm(in)
51.481-51.500 (2.0268-2.0276)
Thir.d urldersize
mm (in)
51.237-51.250 (2.0172-2.0177)
Fourth undersize
mm(in)
50.987-51.000 (2.0074-2.0079)
Standard
mm (in)
57.981-58.000 (2.2827-2.2835)
First undersize
mm (in)
57.731-57.750 (2.2729-2.2736)
Second undersize
mm (in)
57.481-57.500 (2.2630-2.2638)
Third undersize
mm (in)
57.237-57.250 (2.2534-2.2539)
Fourth undersize
mm(in)
56.987-57.000 (2.2436-2.2441)
Turbo
On checking:
inlet
exhaust
0.15-0.30
0.40-0.50
0.15-0.30
0.35-0.50
On adjusting:
inlet
exhaust
0.20-0.25
0.45-0.50
0.20-0.25
0.40-0.45
,.
,\ .
I
mm
Exhaust valve
8201:7,960-7,975
8202:6,969-6,975
8201:42'
8202:32
-1
Saab900
Engine 022-:11
N.B.
The exhaust valves have a stellite coating and
should therefore not be machined. Grinding
using valve grinding paste is the only recommended method. The exhaust valves in engines with
fuel injection are sodium filled and the sodium
must therefore be removed before the valves are
scrapped.
Valve guides
B201
8202
Length
mm (in)
46.65 (1.837)
49..\0
Outer diameter
mm(in)
13.040~13\.o5.:1
(0.5134~O.5113'8)
1L2..:Q3:9-:12.iG5V
(0..47:40 J (j)..4714'4)
1'2.l0Q:Q-.12.r018
,(0.4'7:24-0.4731)
(~L.929.1,~
Boreforvalve guides
in cylinderhead
mm(in)
13.000-13.018
(0.5118-0.5125)
Maximum clearance
between valve stem
and valve guide
mm (in)
I i+'-'-~1liI1 .....
Iott-="""'-+l
'min 21,8,mm'
(Q ,8583 in)
r'
'(l,04.l2.in)
min 31,4 mm
0" 2362 'in)
~
orl
N
til
"min 't9,6 mm
'(0,7717 in)
,Jllin 24 mm
'(0,9449 in)
'C
mi~ iil,4 mm
(I,U8i in)
18201
18202
mm(in)
39.5 (1.56)
37.0 (1.4567)
Free length
mm (in)
45.7 (1.88)
45
mm (in)
load of 595-645 N
(131-141Ibf)
mm (in)
Saab 900
28.4 (1.12)
022-12 Engine
Cam fo~~oweli's
8201
8202
Diameter
mm (in)
37.87-38.98
(1.4909-1.4953)
32.959-32.975
(1.2976-1.2982)
Height
mm(in)
33 (1.2992)
26 (1.0236)
mm (in)
38.000-38.016
(1.4961-1.4967)
33.000-33.016
(1.2992-1.2998)
(a1
ex
lEn
B~
Diameter
mm (in)
15.5 (0.6102)
Thickness
mm (in)
1.77-2.89 (0.0697-0.1138)
23 shims available within the range,
at intervals of 0.05 mm (0.002 in)
Camshaft
No. of bearings
8201
8202
Bearing diameter
mm (in)
28.94
(1.1394)
28.922-28.935
(1.1387-1.1392)
End float
mm (in)
0.08-0.25
(0.0031-0.0098)
0.08-0.35
(0.0031-0.0138)
InletValves
Exhaust Valves
B201 carburettor
1981-
mm (in)
10.8 (0.425)
11.0 (0.433)
B201i
1981-
mm(in)
10.8 (0.425)
11.0 (0.433)
B201 Turbo
-1982
mm (in)
9.1 (0.358)
10.5 (0.413)
.1981-
mm (in)
10.8 (0.425)
11.0 (0.433)
B202Turbo
B202 Turbo with
cat. converter
-1985
mm (in)
8.65/6.65
8.65
(0.341/0.262)
(0.341)
B202i
B202Turbo
B202 Turbo with
cat. converter
198619868.65 (0.341)
8.65 (0.341)
-1986
1987-
mm (in)
Saab900
B~
Engine 022-13
Valve timing
(at design clearance: 0.35 mm, inlet; 0.55 mm,
exhaust)
Inlet Valves
Open
Close
8TOC
A80C
Exhaust Valves
Close
Open
ATOC
880C
10
54
46
18
8201i 1981-
10
54
46
18
8202i 1986-
16
44
61
13
12
40
62
10
54
46
18
10
56
56
16
16
56
~.-
Saab90D
61
... -..
",,:,~
13
"
022-14 Engine
L.-
ag e Ha g
es
[
Torque, Nm
Torque,lbfft
Dimension
Main bearings
110
81
M12
Big-end bearings
55
41
Ml0
8201
15
11
M8
8202
15
11
M8
8201
3.7
M6
8202
15
11
M~.
Crankshaft pulley
190
i41
20
14.8
Flywheel
59
44
Ml0
Oil pump
5.9
M6
Spark plugs
28
20.7
M14xl.25
M16
:'-'M8'
Chain tensioner,
B201
12
8.9
M6
Chain guide,
8201
12
8.9
M6
Chaintensioner,
8202
63
46.6
Ml0
Camshaft sprocket,
8201
20
14.8
M8
Camshaft sprocket,
8202
63
46.6
Ml0
Engine to gearbox
25
18.5
Inlet manifold
18
13.5
M8
Thermostat housing
18
13.5
M8
Throttle housing
18
13.5
M8
25
19
allother models
20
Timingcover
Distributor,
B201
14.8
B202
.,
20
t
\
M8
.:
M8
3.7 .
M6
14.8
M8
AI
Oil filter
10
7.4
3/4"-16 UNF
10
7.4
114":"18 NPTF
At
EGRvalve
15
11
M14xl.5
55
40.7
3/8" BSP
ac
NE
3d
22.2
M 14xl.5
M82earlier
5.9
M830nwards
20
14.8
Knock detector,
Si
Mi
:..
At
.1.
I\IE
Dimension
Tighteningtorque
Ibfft
Nm
M5
3.6
M6
10
7.2
Mi
M8
20
14.4
At
\' Ml0
404
23.8
NE
Al
Saab 900,
Engi ne 022-15
A~temidltoll'
,
Single belt
Minimum
After
adjusting
Newbelt
Minimum
After adjusting
New belt
Dual belts
Measuring of
one belt
Measuring of
both belts
N (Ibf)
265 (60)
200 (45)
4~Rj95)
N (Ibf)
N (Ibf)
355 20 (80 5)
535 45 (120 10)
310 20 (70 5)
535 45 (120 10)
645
N (Ibf)
I\J (Ibf)
N (Ibf)
Minimum
After adjusti ng
Newbelt
220(50) ,
310 20 (70 5)
445 45 (100 10)
245 (55)
" 355 20 (80 5)
-, Jj35 45 (120 10)
.'
20 (145 5)
022-16 Engine
icatingsyste
Oil
Oil capacity, including oil cleaner,
8201
8202
3.8 (4.0)
4.0 (4.2)
Turbo: The oil cooler holds an
additional 0.51tr (0.52Iiq qt)
1.0 (1.05)
Recommended grade,
Viscosity:
on pressure
Oil pump pressure-reducing valve
opens at: 8201
8202
bar (psi)
bar (psi)
bar (psi)
0.3-0.5 (4.4-7.2)
bar (psi)
Minimumof2.7 (39)
OiD pump
End float between rotor and housing
mm (in)
Saab900
0.03-0.08 (0.001-0.003)
Engine 022-17
'I
i
To;
J I
:i
i
,. O-norw; "SOD]
~ !)JK 10010
::l~
:::
-:
s'
lOOD rota
i i, !
;;>"
!=!EVI..
.-
, >Ill
,t
\.
~.
If
I.~.~:
g=gI~
.:
I
I
".n,
.
U
-:
i
::
=' . q
=
'~~
:: I SlOO r;ra
.< ,
~
I"
:,
J
=j, ;\
".
:~
l'
.R
~.
oj
j.
'e:
z:=o
, I
,I '
I: I
' J
9~OOJ
K DID 10020
~:
'r
: . ' )000
ria
,
~i
OJ
o-aorq
.,
~ I
.,
'
..
~
, O-nons '1500]
p 0111 1OOZO
81 kW
118 bhD
I 5500 rOQ
.LL
..-
.:. ,
lj
J .
'1 ~ :
..
I.'
: ..
:.~
.'.2,.
T ,.
""
u.
:=
"...........I'l'I1D.-JlUn_
"
'
It:I;:i;I
:tX::Ql
,.."""'~n_
n=."
l~
f:
~~
022-18 Engine
II
!i
~
1;
, I
i
H O~nol'T.l
V SODl
HOW loolo
Z"D ~
24 5 k.pt:l I JOOD r~
h-. . .
..
..
..
p O-n ra \'50 1
I
I
:~~ ~~
!
I 5000
rD:'
1+I
,i a~
o.
o
i,
-I
~J
~
i
:5
j
.~
"
.
~.
R 'j
tafl i
'"'"
'"'i
;1
.~ ff
I
.. .
.
'0'
1 'JOIJ rom
1-;
r! q
.i
a~
.~
'
213 aT.'lCDrI'
1.1.
7-r
P 01'1 00::0
...
8202 Turbo
" B0/1269/[((
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000 rp:.
:1
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Saab900
Engine 022-1'9
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3000 roo
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.II'VT"~""I" ~IIW101U"_
Saab 900
7860794
7860877
Bench stand
7860885
Vice stand
8392169
8393951
7860802
-.......
7861479
Mobile stand
7860794)
8390478
(alternative
to
Saab900
8392409
.. -
-~
,..
'I-
~;"".
m
(f)
, ,
7862014
8393332
8393209
8393340
8394215
8391849
8392540
8392987
lt
8392961
8393639
8392300
8393050
8391997
7862287
8390130
at
at
s.
im-
Saab 900'
S 2051
8391401
8392326
Compressed-air
spark plug hole
8393910
adaptor
8392193
8392201
8392219
7861057
7861065
for
Saab90n
8393928
8393936
8393944
,.
8392268
8392631
8391633
8391450
8392250
8394157
~re
1GB)
)uitside
alve
45
"~,"';~-L'.
jia.,
ralve
8394173
, __
Compressed-air adaptor
Saab900
:..LUL-b
~peclal
83,94181
83:94207
8393357
fools
Socket
TooLfor fitting valve collets
7840622
Dial indicator
8392185
Key for crankshaft bolt (for turning crankshaft for valve adjustment)
00000000
00000000Ii==rn=::::::rii==;m=::::;::r==;=r=:;::r====rs;:::::=='it
~;l;;i;;;;~~~~~;!=;;;;1;;!;;;;;;;;;;!;;;!=,..!lI
8393746
Protective collar
gUides (set of 16)
for
tappet
Saab900
8393787
Valve stand
Ul
S 2/360
8393761
KD-tools 308 valve spring compressor for use with special anvi I
8393779
8393779
8393795
8393803
mIst-
8393753
S 2/173
8394140
8393589
Saab900
S 2/368
'"
l=?emoval
Fittin~
I
I
L
8393902
8393803
(1)
8393811
(2)
8393829
(3)
8393837
(4)
8393845
(5)
8390379
(6)
Mandrel
The above tools (2 - 6) are for use
with valve guide tool 8393803
(1)
8393571
t
8
SaabSOO
8393910
8393175
Ith
8393985
Belt-tension meter
8791394
lch
5aOO900
E
E
t
'J
1t::::\.;IIIII\.;dl
Engine.
. ....
Engine mountings 8201
200-1
200-7
Lubricating system
E gn e body
Gell1eli'a~
Saab 900
Ue:::llalfJlIUrJ
LUU-l
200-5
LUU-L
I echnical Description
Cy~inidlev block
The crankshaft drives the oil pump which is interposed between the timing cover and the
crankshaft pulley.
Saab900
'1e
Pistons
Connecting rods
The pistons are made of light alloy and are provided with grooves for two compression rings and
one oil scraper ring. The top compression ring is
flat with a chromium finish. The second compression ring has oil-control properties and is
slightly wider than the top ring. The actual oil
scraper is a three-piece ring.
He
ul-
Cylinder head
The cylinder head is a precision, light-alloy casting and the steel valve seats are press-fitted in
the head. The head is bolted to the block.
The valves. are made of steel and have
chromium-plated stems. The heads on the inlet
valves are induction hardened and those on the
exhaust valves stellited.
Saab900
1
2
3
4
5
Storage chamber
Leakage orifice
Check valve
High-pressure chamber
Spring
2)
The lubricating system forthe engine has forcedflow circulation. The oil pressure is generated by
a gear-type pump consisting of a pinion and an
eccentric ring gear. The pump is driven by the
crankshaft and is interposed between the timing
. cover and the crankshaft pulley. A relief valve in
the timing cover limits the oil pressure and diverts surplus oil to the inlet side of the pump.
Saab 900
G
T~
tr
al
rc
T~
b(
m
Oil filter
Tt
rc
01
IE
T~
m
til
ar
H,
he
vi
Sl154
TI
C
Saab 900
d
g
s
The engine mountings are designed to absorb
the movement of tile engine while it is running
and also to limit tile transmittance of engine vibration and noise to the body.
The damping action of the engine mounting rubbers is progressive - the greater the load on the
mounting rubbers the greater the resistance.
Thus, the engine mountings protect the surrounding components from excessive movement
ofthe engine.
Saab900
.'.\:
,....
_.
T
b
tl
c
d
b
ti
n
d
T
d
c
1<
d
tl
n
gine is idling.
Improved sound-insulation properties between the engine and body.
As from chassis No. F1033151, hydrau Iic engine
mountings are fitted at the two rear mounting
points in Turbo 16 models (with manual gearbox) .
As from M86, cars with manual gearboxes have
hydraulic engine mountings fitted all round.
As frq,m M86, cars with automatic transmission
have hydraulic engine mountings at the two rear
mounting points.
Saab 900
1
2
3
4
Saab 900
Upper chamber
Lower chamber
Port
Diaphragm
201-1
201-26
201-47
o~g
2 1
The following procedure for removal and refitting
applies to the M88 8201 Turbo engine equipped
with intercooler, catalytic converter and watercooled turbocharger.
Various departures from the method described
will have to be made on account of differences in
different model years and engine variants.
10l1'emove
1 Disconnect the linkages for the bonnet
hinges, disconnect the washer hose and remove the bonnet.
Stand the bonnet where it will not be damaged, e.g. leaning securely against a wall.
Saab 900
201-49
3 Disc:crrrrr.recttJot!il,battery"leads.
Removethe battery (Turb'o cars only),
4 Unb'Q.liIl "th'e:, exhaust: pipe from the exhaust
manifofdL.
5 Slacken the
whe'~l!oolts on
the RH wheel.
Automatics:
<'>
Saab 900
d Undo the clips on the gaiters over the inboard drive-shaft joints and pull the gaiters off the driver cups.
Saab900
N.B.
Label the hoses to ensure they are reconnected
properly.
b Expansion tank
c Thermostat housing
o'"
"'OJ
~
Saab 900
iI
~
,J
Saab 900
\,
'"....
,~
,i;I
c Disconnectthe fuel hoses from the warmup regulator (use two spanners).
'"o
10
Saab 900
f Disconnect the fuel pipes from the injection valves (use two spanners).
Saab900
I,
i
l'
Saab900
N.B.
Note the arrangement of the leads.
b Cold-start valve
c Thermostatic switch (Lambda system)
d Thermostatic time switch
e Temperature sensor
f Hall generator
g Auxiliary air valve
h Thermostatic switch
i Earthing points on engine lifting lug
N.B.
Note the arrangement ofthe leads.
j Warm-up regulator
k Knock detector
I Starter motor (disconnect the positive (+)
feed from the battery at the same time.
m Oi I pressure sensor
n Alternator
Saab900
Saab 900
"',
"
r~
LH engine mounting
RH engine mounting
Saab900
36 Remove the oil pressure sensor and disconnect the oil cooler (air cooled) hoses from
the oil filter.
37 Lift the power train out ofthe car, taking particular care not to damage the radiator orthe
solenoid valve.
Fit covers over the driver cups.
.
N
'"
, (II
.,
---
,.
5 Detach the lifting sling and, when applicable, remove the lifting lug from the water
pump (AC only).
6 Cars with AC only:
Fit the AC compressor.
Fit and adjust the tension ofthe compressor
drive belt.
Saab900
the~manifold,
but do
9 Raise the carto a suitable height and recon-nect the ball joint to the lower wishbone.
c Speedometer drive.
-.':.
Automatic gearbox:
Connect the cable to the gear selector rod and
clip the cable to the gearbox.
Check the gear positions and adjust as necessary (see section 444 of the Manual).
Saab 900
cover.
o
Saab900
16 Lift the wiring loom back into position and reconnect the leads to the following components in the order given:
a Throttle-position sensor
RD/VT
N.B.
Note the configuration of the leads on the throttle-position sensor and at the earthing points on
the Iifting lug.
.1
. I
b Cold-start valve
Saab900
j Warm-up regulator
k Knock detector
Starter motor
(connecting the positive lead from the
battery at the same time)
m Oil pressure sensor
n Alternator
Saab900
Cl
Saab900
Saab900
22 Fit the rubber socket connector for the mixture control unit.
23 Fit the turbo discharge pipe between the intercooler and the throttle housing.
24 Connect the coolant hoses to:
b Expansion tank.
Saab 900
c Thermostat housing.
Saab900
ef i
g~
2 2
Stand the bonnet where it will not be damaged, e.g. leaning securely against a wall.
Saab 900
d Undo the clips on the gaiters over the inboard drive-shaft joints and pull the gaiters off the driver cups.
Saab 900
Saab900
LUl-L~
"I
Saab 900
e_m_o:..:v~a::l..':a~n~d~r~e:!lfi~tt~i~ng~
201-30
R
__
~Re:m~ov~a~1O~f~~~~."a~
_____________________
"
'
N.B.
If necessary, use a small screwdriver to release
the catches on the connectors.
Saab900
Saab900
Saab 900
Removal of the main wiring loom from the lefthand side of the engine bay, 8202
Saab900
37 Disconnect the fueJ hoses from the fuel injection manifold amt'the fuel pressure regulator.
LH engine mounting:
lflme bolt is a through-bolt and is equipped
wi1illliGl. spacer.
Cars,1itI:US spec.:
Remmze the bump stops on the front and RH
mountings.
RH engine mounting
LH engine mounting
Saab 900
42 Remove the oil pressure sensor and disconnect the oil cooler (air cooled) hoses from
the oil filter.
Saab 900
Saab900
Saab 900
c Speedometer drive.
11 Lower the car to a suitable height and connect the battery earth (-) lead to the timing
cover.
Clip the positive lead to the engine.
Saab 900
I
Wheel bolt tightening torque M87 and earlier:
90 - 110 Nm (66 - 811bf ft)
WheelllJolt tightening torque MBS IDll1waIli'ds:
105 -125 Nm (77 - 92 Ibf ft)
Saab 900
1"_",
Reconnecting the main wiring loom on the lefthand side of the engine, 8202
"
r ;'-
21 Reconnect the coolant hoses to the expansion tank and the heat exchanger valve.
!
II
I
I
i
\
I
I
a AC compressor
(Fig. g)
thermostatic
switch
't
,I
. .,
--------------------------------------Saab 900
Reconnecting the main wiring loom incorporating the loom for the LH fuel injection system,
8202.
Saab 900
aJ!l'i1cdJ
Saab 900
8 Carefully lift the engine away from the gearbox (as shown), removing the release-bearing sleeve at the same time.
Cautoo~
Make. sure that the two guide sleeves are fittam! iim:tJhe gearbox.
IB.
The release bearing and sleeve must be held in
position against the clutch when the engine is
lifted onto the gearbox.
Saab 900
.11.
mmmnJ.
Stud in gearbox
"El
...
Saab900
[g.
~ Takl~
Saab900
Engine 210-1
To dismantle, 8201
210-3
To assemble, 8201
210-8
.;I'
-~
til
I ~.
_.
Saab900
210-2 Engine
.
@
, '0
~f)fJJ
(f;JJP,
~,
'!!lO
.
1\l
Engine 210-3
Saab900
210-4 Engine
8 Remove the oil pump.
SaabSOO
Engine 210-5
13 Remove the pivoting chain guide.
/.
Saab900
210-6 Engine
17 Remove the oil filter adaptor.
N.B.
Note the markings on the can rods. Keep the
bearing shells in order so that they can be refitted in their original p.ositions.
Saab 900
Engine 210-7
20 Remove the bolt from the engine bracket and
remove the end plate.
I
22 Lift out the crankshaft. Keep the bearing
shells and thrust washers in order so that
they can be refitted in their original positions.
'
./
210-8 Engine
o eassembls, 2 1
1 Placethe bearing shells in the seats and lubricate them with engine oi I.
.
"
Saab 900
Engine 210-9
4 Lubricate the bearing shells and refit the
bearing caps.
Note the mallrkings!
N.S.
I~
saab900
..
._._-_.~
..
_-~
210-10 Engine
Place the gUide to tool 8392540 on the
flywheel flange and fit the end plate and
bolts.
Saab900
Engine 210-11
Tightening torque for flywheel:
59 Nm (44Ibfft)
1 Compression rings
2 Scraper ring
/'
Saab 900
210-12 Engine
Make sure that the notch in the top ofthe
piston points towards the timing end, and
the mark on the big-end towards the
exhaust side ofthe block.
0000
CEI 0
Saab900
~~
Engine 210-13
8 Refit the fixed chain guide.
,
I
Saab900
210-14 Engine
12 Fit new gaskets to the timing cover, using
dabs of grease to hold the gaskets in place.
13 Fitthetiming eaveI'.
Saab900
Engine 210-15
16 Fill the passage between the oil pump and
adaptor with engine oil.
.'
Saab 900
210-16 Engine
23 Remove the locking segment
8392987) from the flywheel.
(tool
Saab900
e
Cylinder hea"d, 8201
Cylinder head, 8202
ea
211- 1
211-21
. . . 211-31
..
Saab 900
Saab900
N.B.
Because of the design of the slot for the distributor dog, NO.1 cylinder must be at top dead
centre for the valve cover to be removed.
Saab900
Saab900
I, '
~
..
..
Saab 900
'
, '"
..
To refit
1 Fit a.new cylinder head gasket on the block.
'.
.,
.~
.'
~
10
<t
Saab 900
N.B.
Never move the camshaft or crankshaft with the
timing chain removed, as a fUlly open valve can
collide with the piston at top dead centre.
Saab900
N.B.
TORX bolts are precoated with lubricant and do
not normally require further lubrication the first
time they are refitted. The bolts can usually be
refitted up to five times before the coating wears
off. Thereafter, remove all traces of the old coating and lubricate the bolts with Molycote 1000
6 Refit the three camshaft securing bolts complete with plain washers.
Tightening torque: 20 Nm (1.4.8 !bf ft)
~.
.C
saab900
N.B.
One of the bolts (arrowed in picture) is shorter
than the others
Saab900
Saab 900
f Temperature sensor
g Earthing points on engine lifting lug. Note
the corfiguration of the leads.
h Cars v-k 1 AC: j\C compressor.
",
Saab900
20 Refit the distributor cap and HT leads and reconnect the vacuum hose and the connector
forthe Hall generator.
/
I
Saab900
Saab 900
N.B.
Never move the camshaft or crankshaft with the
timing chain removed, as a fully open valve can
collide with the piston at top dead centre.
, ,/
Saab 900
crankcase ventilation
hose and the preheater hose from the
turbo suction pipe.
turbo unit.
Undo and remove the exhaust manifold
nuts.
Saab900
4t
,. f
/'
SaabSOO
valve.
Tightening torque for inlet manifold:
18 Nm (13.3Ibfft)
Saab900
N.B.
Fitthe bracket, oil return pipe and oil supply pipe
to the unit before tightening the manifold.
Fit new gaskets at the oil pipe fittings.
j:
Saab900
N.18.
Place a cover over the chamber for the timing
chain to prevent any bolt, nut or other item dropping inside the timing cover.
./
./
Saab900
2 2
To rremove (engine in
CalII')
Saab900
/
.'.'
7 Re:!!a@'S.e tlJe;
G:.!iilD&..
8,
Saab900
N.B.
Do not alter the setting of the camshaft or
crankshaft after the sprockets have been removed, as rotation of one of the shafts can result
in damage to the valves.
)
Saab900
N.B.
Never stand the cylinder head on its flanges as
open valves will protrude. Stand the cylinder
head on wooden blocks.
Saab9CO
N.B.
Never move the camshaft or crankshaft with the
timing chain removed, as a fully open valvf7.can
collide with the piston at top dead centre. I
Saab900
Saab 900
\
,('
Saab900
I
1
,I
7 Fit the camshaft sprockets, fitting the sproc}<et for the exhaust-valve camshaft first.
Make sure that the chain between the
crankshaft sprocket and the camshaft
sprocket is kepttight and properly located in
the guide channel. Next fit the sprocket on
the inlet-valve camshaft. Keep the cha'ir;J
,tight between the sprockets.
/
.'
Saab900
N.B.
Use a spanner on the flats on each camshaft to
hold the shaft still when tightening the bolts, to
ensure that the set positions do not alter.
Saab900
..i
Saab900
'I
,;/
\
I"
,
To replace pistons, piston rings
and big-end bearings . . . .
212-1
Classification of pistons
and bores
.
212-4
Saab900
Saab900
Karl Schmidt
Hepolite
assificatoo
cylinder bores
AB
B
C
The cylinder class is stamped on the cylinder
plane and is specified for each cylinder.
The cylinder class may be A or B, and both classes may occur in any cylinder block.
Classificat60fil of pistons
See "Technical data".
Cy inder block
See "Technical data".
Saab900
/
1./
011' lJ'e
cy~aU1l[lJe\l'
\
~'
Saab91}O
.~
Piston
Connecting rod
Bearing
Bearing cap
Compression rings
Oil scraper ring
1 Compression rings
2 Scraper ring
-.I .: '.
.;.1
Saab900
./
Saab900
saab9OO'
214-1
214-16
/~
/.
Saab900
214-23
Saab 900
Valve gear
1
2
3
4
5
6
7
8
3 Use the IT 19ntic tool to extract the cam followers allJ store them in the correct sequence.
Saab900
Valve
Valve spring seat
Valve spring
Retainer
Collet
Adjusting pallet
Cam follower
C8mshaft
"""."-,,~
~', ~ .
~-
','
in fixture 8393050.
Saab900
N.B.
I;nsure that the feeler gauge apertures face the
inlet side. Incorrect installation of the camshaft
carrier assembly cuts off lubrication to the valve
gear.
Saab901ll
./
.:/
7 Apply'athin coat of engine oil to the cam followers and refit them.
Saab900
Saab 900
To remove
Before removing the valve guide, flush the cylinder head with hot water. Press out the guide
using tool 8392631.
To fit
Saab900
......'----:""""O'~,,~
.....lo............ s~Q_~.il'
N.B.
Valves with valve-seat inserts cannot be recut,
as the cutter may snag in the insert (carburettor
engines).
Saab 900
N
B
tr
N.B.
The exhaust valve seats are stellited and not
suitable for machine grinding. Lapping is the
only method recommended.
Valve clearance
General
The valve clearances do not vary and adjustment
under normal conditions is only required after
long periods or when work has been performed
on the valves. However, the valve clearance
should be checked in accordance with the Service Programme.
Saab 900
.Ii
N.B.
Because of the design of the slot for the distributor dog, NO.1 cylinder must be at top dead
centre for the valve coverto be removed.
I
3a Rotate the crankshaft until the cam lobe
for the valve to be measured is at 1800 to
the valve stem.
b Check the valve clearance with the feeler
gauge. (See the 'Technical data' section
for the specified values.)
4 Rotate the crankshaft to TOC on the compression stroke for No.1 cylinder and fit the
valve cover.
6'
./
Saab900
.,
I
'
3 Us\ng,the measuring tool, lift the cam follower andread off the valve clearance on the
di,?).... Note the reading.
,1/",'
,., "
.
f
4 Measure and note the clearances of all valves in the same way. Adjust the clearance of
any valve which does n9t lie within the following limits:
Inlet valves:
0.20 - 0.25 mm
(0.008 - 0.010 in)
Exhaust valves: 0.40 - 0.45 mm
(0.016 - 0.018 in)
Exhaust valves
(Turbo):
0.45 - 0.50 mm
(0.018'>0.020 in)
Saab 900
./
,7
6 Measure and note the thickness of the pallets using tool 8391633 or a micrometer.
This thickness plus the valve clearance
equals the total distance between the cam
follower and the cam.
Example
Valve clearance
measured:
Pallet thickness
measured:
Total distance:
The thickness of the adjusting pallet required equals the total distance measured
between the cam follower and the cam, less
the valve clearance specified for the inlet or
exhaust valve.
Example
Total distance:
Less specified
inlet valve
clearance:
r - - ---
,
I
II
Saab900
:::::i,~:~~
~.
Saab 900
0.00 2,64
O,O~ 2,69
0,05 2,69
E 0,07 2,74
O,lD 2,74
0,12 2,79
.....co 0,15 2,79
(.)
0,17 2,84
"0
0,20 2,84
c
0,22 2,89
co 0,25 2,89
"0
0,27
..c
..... 0,30
'3 0,32
0,35
-0
QJ
0,37
::::J
en 0,40
co 0,42
QJ
0,45
E 0,47
QJ
(.)
0,50
c
co 0,52
~ 0,55
-' _0,57
(.)
0,60
QJ
0,62
>
0,65
> 0,68
0,70
0,72
.-
2,59
2,64
2,64
2,69
2,69
2,74
2,74
2,79
2,79
2,84
2,84
2,89
2,B9
2,54
2,59
2,59
2,64
2,64
2,69
2,69
2,74
2,74
2,79
2,79
2,84
2,84
2,89
2,B9
en
III
III
aU!
o
o
co
2,48
2,54
2,54
2,59
2,59
2,64
2,64
2,69
2,69
2,74
2,74
2,79
2,79
2,84
2,84
2,89
2,89
2,43
2,48
2,48
2,54
2,54
2,59
2/j9
2,64
2,64
2,69
2,69
2,74
2,74
2,79
2,79
2,84
2,84
2,89
2,89
2,38
2,43
2,43
2,48
2,48
2,54
2,54
2,59
2,59
2,64
2,64
2,69
2,69
2,74
2,74
2,79
2,79
2,B4
2,84
2,B9
2,B9
2,33
2,38
2,38
2,43
2,43
2,48
2,48
2,54
2,54
2,59
2,59
2,64
2,64
2,69
2,69
2,74
2,74
2,79
2,79
2,84
2,84
2,B9
2,B9
2,28
2,33
2,33
2,38
2,38
2,43
2,43
2,48
2,48
2,54
2,54
2,59
2,59
2,64
2,64
2,69
2,69
2,74
2,74
2,79
2,79
2,B4
2,B4
2,B9
2,B9
2,23
2,28
2,28
2,33
2,33
2,38
2,38
2,43
2,43
2,48
2,48
2,54
2,54
2,59
2,59
2.64
2,64
2,69
2,69
2,74
2,74
2,79
2,79
2,84
2,84
2,89
2,B9
2,18
2,23
2,23
2,28
2,28
2,33
2,33
2,38
2,38
2,43
2,43
2,48
2,48
2,54
2,54
2,59
2,59
2,64
2,64
2,69
2,69
2,74
2,74
2,79
2,79
2,B4
2,84
2,B9
2,B9
2,13
2,18
2,18
2,23
2,23
2,28
2,28
2,33
2,33
2,38
2,}8
2,43
2,43
2,48
2,48
2,54
2,54
2,59
2,59
2,64
2,64
2,69
2,69
2,74
2,74
2,79
2,79
2,B4
2,B4
2,B9
2,08
2,13
2,13
2,18
2,18
2,23
2,23
2,28
2,28
2,33
2,33
2,38
2,3B
2,43
2,43
2,4B
2,48
2,54
2,54
2,59
2,59
2,64
2,64
2,69
2,69
2,74
2,74
2,79
2,79
2,84
2,03
2,08
2,08
2,13
2,13
2,18
2,18
2,23
2,23
2,28
2,28
2,33
2,33
2,3B
2,38
2,43
2,43
2,48
2,48
2,54
2,54
2,59
2,59
2,64
2,64
2,69
2,69
2,74
2,74
2,79
1,98
2,03
2,03
2,08
2,08
2,13
2,13
2,18
2,18
2,23
2,23
2,28
2,2B
2,33
2,33
2,38
2,38
2,43
2,43
2,48
2,48
2,54
2,54
2,59
2,59
2,64
2,64
2,69
2,69
2,74
1,93
1,98
1,98
2,03
2,03
2,08
2,08
2,13
2,13
2,18
2,18
2,23
2,23
2,28
2,28
2,33
2,33
2,38
2,38
2,43
2,43
2,48
2,48
2,54
2,54
2,59
2,59
2,64
2,64
2,69
1,88
1,93
1,93
1,98
1,98
2,03
2,03
2,08
2,08
2,13
2,13
2,18
2,18
2,23
2,23
2,2B
2,28
2,33
.2,33
2,3B
2,3B
2,43
2,43
2,4B
2,4B
2,54
2,54
2,59
2,59
2,64
1,82
1,88
1,88
1,93
1,93
1,98
1,98
2,03
2,03
2,08
2,08
2,13
2,13
2,lB
2,lB
2,23
2,23
2,28
2,2B
2,33
2,33
2,3B
2,3B
2,43
2,43
2,4B
2,48
2,54
2,54
2,59
1,77
1,82
1,82
.1,88
1,88
1,93
1,93
1,98
1,98
2,03
2,03
2,08
2,OB
2,13
2,13
2,18
2,lB
2,23
2,23
2,28
2,28
2,33
2,33
2,3B
2,3B
2,43
2,43
2,48
2,48
2,54
1,77
1,77
1,82
1,82
1,88
1,88
1,93
1,93
1,98
1,98
2,03
2,03
2,08
2,oB
2,13
2,13
2,18
2,18
2,23
2,23
2,28
2,2B
2,33
2,33
2,38
2,38
2,43
2,43
2,4B
1.77
1,77
1,82
1,82
1,88
1,88
1,93
1,93
1,98
1,98
2,03
2,03
2,08
2,08
2,13
2,n
2,lB
2,18
2,23
2,23
2,2B
2,2B
2,33
2,33
2,38
2,3B
2,43
1,77
1,7'1
1,82
1,82
1,88
1,88
1,93
1,93
1,~8
1,98
2,03
2,03
2,08
2,08
2,13
2,13
2,lB
2,18
2,23
2,23
2,2B
2,28
2,33
2,33
2,38
1,77
1,77
1,82
1,82
1,88
1,8B
I,"'}
1,93
1,9B
1,98
2,03
2,03
2,08
2,oB
2,13
2,13
2,lB
2,18
2,23
2,23
2,2B
2,2B
2,33
1,77
1,77
1,82
l,B2
l,8B
1,BB
1,93
1,93
1,98
1,98
2,03
2,03
2,08
2,08
2,13
2,13
2,18
2,lB
2,23
2,23
k,2B
1,77
1,77
1,82
1,82
I,B8
1,88
1,93
1,93
1,98
1,9B
2,03
2,03
2,OB
2,OB
2,13
2,13
2,lB
2,18
2,23
1,77
1,77
1,B2
1,82
1,88
1,88
1,93
1,93
1,9B
1,98
2,03
2,03
2,oB
2,08
2,13
2,13
2,18
1,77
1,77
1,82
1,82
1,8B
1,BB
1,93
1,93
1,9B
1,9B
2,03
2,03
2,08
2,OB
2,13
1,77
1,77
1,82
l,B2
l,8B
1,8B
1.93
1,93
1,98
1,98
2,03
2,03
2,OB
1,77
1,77
1,B2
1,82
1,BB
1,B8
1,93
1,93
1,98
1,9B
2,03
<
CD
ao.
CD
Q)
.....
OJ
N
for use
The following example illustrates how the table
is used:
<
Q)
Q)
::::J
Q..
OJ
I\,)
~
~
I
(J1
Saab900
1
2
3
4
5
Storage chamber
Leakage passage
Check valve
High-pressure chamber
Spring
Saab900
Saab900
I
2 Remove the oil pipes and the camshaft bearing caps and lift out the camshafts.
N.B.
Do not twist the pipes when removing them as
this is liable to damage the contact surfaces between the pipes and fittings.
/-.f
Saab900
saab900
N.B.
Prior to assembly, thoroughly lubricate all the
parts. Replace any defective valve stem seals
before fitting the vclves.
N.B.
Stand the cylinder head on wooden blocks to
avoid bending the valves as the camshafts are
tightened down.
4 Fit the camshafts and bearing caps.
Bearing cap markings:
1- 5 = Inlet-valve camshaft
6 -10 = Exhaust-valve camshaft.
SUb 900
N.B.
Make sure when refitting the pipes that the outlet holes face the right way. The longer pipes locate in the sfnaight couplings and the shorter
ones in thaeJl:!H!Jws.
After reassemb1ing:tl1e pipes, reconnect the
pipewonk :.J the oilwaJ's in the bearing caps
and cylinderrr.read.
N.B.
Do not twist the pip'es as this is liable to damage
the mating surfaces between the pipes and the
fittings.
Saab900
N.B.
Set aside the parts carefully to avoid confusing
them on refitting.
Saab900
Saab900
To refit
1 Remove the shank from tool 8393803 and
fit the valve seal in the tool with the taper
facing inwards (away from the valve head).
2 Fit the seal on the valve stem. Use a plasticfaced mallet to tap the seal carefully into
position.
/.
Saab900
Saab900
To refit
Saab900
Saab900
I
The timing gear comprises sprockets and a
chain. The chain has two guides, one fixed and
one pivoting. The pivoting guide maintains the
tension in the chain, assisted by an hydraUlic
chain tensioner.
The camshaft sprocket is guided by means of a
dog on the shaft. Each sprocket has 38 teeth and
is secured to the camshaft by a centre bolt.
214-30
Valv~
1 Jackscrew
2 Pull rod
3 Spacer sleeve
5 Nut
1
2
3
4
5
Jackscrew
Pull rod
Spacer sleeve
Nut
Valve guide
To refit
1 Insert the valve guide from above and
the tool from below.
appl~
Saab 900
1 Jackscrew
2
3
4
5
6
Pull rod
Stop
Centring sleeve
Nut
Valve guide
;;
rearyrer,
Saab900
Valves
Inlet valve face angle: 44.5
Valve head diameter: 32 0.1mm
(1.26 0.004 in)
Exhaust valve face angle: 44.5
(The contact surface of the valve has a
0.006-mm (0.0002-in) coating of stellite.)
Valve head diameter: 29 0.1mm
(1.14 0.004 in)
N.B.
Only a limited amount of material can be removed from exhaust valve seats, since the stellite coating must be preserved as far as possible.
Consequently, if the valve seat is badly pitted,
the valve should be replaced.
Saab900
Saab900
215-1
215-5
N.B.
Never rotate the crankshaft or the camshaft once
the timing chain has been detached.
A fully open valve can come into contact with a
piston at top dead centre.
/,
/'
Saab900
N.B.
The 00 mark on the crankshaft must be in line
with the timing mark.
Saab900
N.B.
Never rotate the crankshaft or the camshaft once
the timing chain has been detached.
A fully open valve can come into contact with a
piston at top dead centre.
Saab900
Saab900
N.B.
The 0 0 mark on the crankshaft must be in line
with the timing mark.
Fit the sprocket bolts complete with plain
washers.
I
Tightening torque for camshaft sprocket:
20 Nm (14.8Ibfft)
Saab900
Saab900
Tension the chain tensioner by fully depressing the piston and then rotating it to
the locked position .
,j
Sub 900
N.B.
Use a blunt instrument - not a screwdriver or
similar.
Sssb900
I
Fit the chain tensioner complete with
gasket and tighten to a torque of 65 Nm
(52Ibfft) .
//
Saab900
6 When undoing or tightening the centrebolts, hold the camshaft still by means of a
spanner fitted over the flats on the camshaft.
'. ,
Saab900
Camshaft setting
Saab900
./
216-1
216-1
216-3
/
Saab900
/'
21-6-4
2.16-9
Big-end bearings
Plastigage strips cannot be used to measure the
out-of-round of big-end bearings with the pistons
fitted in the blOck. Use a micrometer instead.
Saab900
0 (;t'~nose
SUIJ900
1st undersize:
Yellow - thin bearing half, gives Increased clearance.
Green - thicker bearing half, gives reduced clearance.
2nd undersize:
White - thin bearing half, gives increased clearance.
Brown - thicker bearing half, gives reduced clearance.
Example
Try to obtain the correct clearance by fitting two
thin bearing shells. Ifthe clearance is excessive,
reduce it by fitting one thin and one thick, or two
thick shells.
If the clearance is excessive even after two thick
bearing shells have been fitted, the crankshaft
must be ground down to the next undersize and
the appropriate undersized bearing shells fitted.
(See the 'Technical data' section).
N.B.
The journals can be ground down one undersize
(0.25 mm or 0.0098 in) without requiring rehardening. Grinding to further undersize will necessitate Tenifer rehardening.
Saab900
Saab900
Saab900
Saab900
Tightening
torque
55 Nm (40 Ibfft)
70 Nm (52lbfft)
80 Nm (59lbfft)
.
To change: the clutch shaft bearing
1 Removetl1e flyvvheel.
2 Remove the clutch shaft bearing from the
flywl're-el, using drift 83 91997.
Saab900
Belt-tension meter
Saab900
I
rive-belt tension
Alternator drive belt
Single belt
Measuring of
one belt
Dual belts
Measuring of
both belts
Minimum
After
adjusting
N (Ibf)
265 (60)
200 (45)
420 (95)
N (Ibf)
355 20 (80 5)
310 20 (70 5)
645 20 (145 5)
New belt
N (Ibf)
N (Ibf)
220 (50)
After adjusting
N (Ibf)
310 20 (70 5)
New belt
N (Ibf)
Minimum
N (Ibf)
245 (55)
After adjusting
N (Ibf)
355 20 (80 5)
Newbelt
N (Ibf)
,
"
Saab900
t
f
r
t
./
r
f
(
Oil level
The sensor for the oil warning light is located on
the oil filter adaptor.
The oil should be checked two or five minut~s
after thli engine has been switched off having
reached its normal operating temperature. Do
not top up the oil unless the level is lower than
midway between the MAX and MIN marks on the
dipstick.
.
8201
The oil flows through the inlet filter in the sump,
,on through the oil pump and an oilway to the oil
filter adaptor, and thence through the main gallery in the block. Oilways run from the gallery to
the main bearings and a rising oilway runs to the
cylinder head for lubrication of the camshaft a'nd
valve gear.
Saab900
Pressure switch
Adaptor
Saab900
To remove
The oil pump can be removed with the engine in
the car.
1 Clean the area round the oil pump.
2 Remove the crankshaft pulley centre-bolt
and the pulley from the crankshaft. Immobilize the crankshaft by attaching locking
segment 8392987 to the flywheel ring
gear.
3 Remove the oil pump retaining bolts and extract the pump.
Saab900
To check
Use a straightedge and feeler gauge to c~ck the
end fl'oat b'etween the pump body and the gearwheel.
Permissible end float:
0.03-0.08 mm
(0.0012 - 0.0031 in)
To refit
1 Oil the gearwheels,
2 Refit the ring gear with the mark on its face
uppermost.
~?\
4 Refit :;the. pump. Extract the pump gear
slightly and engage the dog on the gear in
the slot in the hub.
Saab900
'.'
.
I'
.,
I.
. '.
~,
..
A = Early de'sign .
B = Latest design
Caution
To remove
-----------------Sa-a-b9-0-G-----------------?~~
'-'.. . ~
+ 2 bolts).
Saab900
Oil filter
./
The oil filter is of the fu!l-;a: ow type, Le. all the oil
from the oil pump passes through the filter.
For production reasons a smaller filter (75-mm
dia.) is fitted at the factory and this should be replaced with the larger model at the 1200-mile
(1000-km) service.
N.B.
Only the larger diameter filter should subsequently be used.
'.
N.B.
Overtightening ofthe filtE;r is liable to distort the
seal, with oil leakage as the result.
Saab900
1
2
3
4
Filter housing
Rubber seal
Oil inlet
Oil outlet
5 Check valve
6 Filter
7 Overflow valve
N.B.
f~
Saab900
215-11
022-13
Crankshaft assembly
Replacing the crankshaft seal
Main bearings
, , , , ,
Measuring bearing clearance
Selecting bearing shells
Technical data
Big-end bearings
"
216-4
216-2
216-1
216-3
022-9
261-2
Lubrication system
220-1
Oil filter
222-1
Oil pump
To remove
To refit , ,
Belt tension
Piston rings
Matching to bores
Technical data . .
Cylinderhead,B201
211-1
211-6
211-13
211-17
022-3
022-4
Cylinderhead,B202
To remove (engine in car)
To remove (engine out of car)
To refit .. , , ..
Technical data . ,
Tightenine: torques
211-21
2.11-24
211-27
022-3
022-4
Engine
To dismantle, B201
To reassemble
Technical data , .
210-3
210-8
022-3
221-1
221-2
022-15,
212-5
022-8
212-4
Pistons
Technical data
Classification
Replacing
022-5
022-6
212-1
Special tools
102-1
200-1
Tightening torques
022-14
215-1
215-5
Engine mountings
200-7
General description
To remove
...
To refit . . . . ..
Checking valve seats
Valve guides ..
Valve guide seals .
022-2
022-17
..f
Engine refitting
-
261-15
201-38
Engine removal
B201
B202
214-3
214-9
214-10
214-10
214-8
Engine
B201
B202
To remove . , ..
Recutting valve seats
Grinding in (lapping)
Valve clearance
Valve guides .. ,
201-47
201-49
Automatic
Manual
214-16
214-19
214-21
214-33
214-30
214-23
022-12
022-10
201-1,,201-26
Saab'900
SAAB
Saab Automobile AS
TrollhiHtan, Sweden