Saab 9-5

since 1997 of release

Repair and car operation



Saab 9-5
+ Saab 9-5 Cars
+ Governing bodies and operation receptions
+ Settings and routine maintenance of the car
- Engine
   General information and preparatory operations
   Check of kompressionny pressure
   Engine check by means of the vacuum gage
   + Repair of 4-cylinder petrol engines
   - Repair of 6-cylinder petrol engines
      Reduction of the piston of the first cylinder in situation VMT and replacement of a belt of a drive of auxiliary units and its natyazhitel
      Removal and installation of the inlet pipeline, belt of a drive of GRM and heads of cylinders
      Dismantling and assembly of the klapanny mechanism
      Replacement of epiploons of a cranked shaft
      Removal and installation of the pallet of a case and maslootrazhatelny plate
      Replacement of the oil pump and its valves
      Replacement of the perepuskny valve of system of greasing of the engine
      Removal and installation of the power unit
   + Repair of 6-cylinder diesel engines
+ Systems of cooling of the engine, heating, ventilation and air conditioning
+ the Power supply system and production of the fulfilled gases
+ Systems of electric equipment of the engine
+ Manual box of gear shifting
+ Automatic transmission
+ Coupling and power shafts
+ Brake system
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment





Removal and installation of the inlet pipeline, belt of a drive of GRM and heads of cylinders

Removal

 PERFORMANCE ORDER

  1. Lay on wings protective covers.
  2. For removal of a forward head of cylinders remove the battery; for removal of a back head – disconnect from the battery a negative wire.
  3. Open a cover of a broad tank of system of cooling of the engine.
  4. To Poddomkratta the car also establish it on props.
  5. Remove the bottom cover of the engine and lower OZh from a radiator.
  6. Remove a turbokompressor arm, paying attention of that on the same arm the protective plate of the CKP sensor is fixed.
  7. Establish wedges between a stretcher and the case pallet, and also between a stretcher and transmission.
  8. At removal of a forward head of cylinders disconnect submitting tube of a turbokompressor from an interkuler, having left on it a collar.
  9. Execute the actions described in in item 4-8 Undressed Reduction of the piston of the first cylinder in situation VMT and replacement of a belt of a drive of auxiliary units and its natyazhitel, a pulley of a cranked shaft yet do not remove.
  1. Unhook a cable of a drive of a butterfly valve (18 on an illustration). Remove vacuum hoses and separate the socket of the sensor of pressure from the top inlet pipeline (19).
  1. Disconnect from the throttle case a vacuum hose, 2 hoses of system of the cooling, submitting and perepuskny tubes. Separate the socket of the case of a throttle and disconnect a hose of the valve of a purge from below throttle cases (20 on an illustration).
  1. Separate the socket of modules of ignition and injectors (21 on an illustration).
  1. At removal of a forward head of cylinders separate the socket of the sensor of pressure/temperature and remove the turbokompressor valve.
  2. At removal of a back head of cylinders:
    • Liberate sockets a lambda probes from holders on the back SAI valve. For this purpose wring out a clamp and press sockets;
    • Remove an arm of a tube of SAI from a head of cylinders. Separate sockets on a final collector. Disconnect a hose from the SAI valve, having compressed clamps and having pulled the socket up;
  1. Disconnect fuel lines. Remove the top section of the inlet pipeline.
  1. Remove average (24 on an illustration) and the bottom (25) sections of the inlet pipeline. To Zakuporta of an opening paper or rags.
  1. Remove a splitter (26 on an illustration) systems of cooling and take him aside.

Do not damage laying.

  1. Remove a pulley of a cranked shaft.
  2. Establish the piston of the first cylinder in the provision VMT of the end of a step of compression and block cogwheels cranked and camshafts by means of special adaptations.
  1. Give fixture of a roller of a natyazhitel of a belt of a drive of GRM and adjusting rollers. Use the special adaptation for fixing of adjusting rollers (29 on an illustration).
  1. Mark the direction of movement of a belt of a drive of GRM (30 on an illustration). For installation simplification (if the removed belt is supposed to be used repeatedly) mark the provision of a belt concerning cogwheels of cranked and distributive shaft. Clean from cogwheels the fixing adaptations established at reduction of the piston of the first cylinder in situation VMT.
  2. Remove the bottom adjusting roller together with a washer located behind it. Remove a driving belt.
  1. Remove assembly of adjusting and tension rollers.
  1. Remove the module of ignition and a cover of a head of cylinders.

Do not allow, that sealing rings of a cover of a head of cylinders fell in the engine.


  1. Turn a cranked shaft in situation 60 a hail. to VMT also note this situation (34 on an illustration).
  1. Remove cogwheels of camshafts (35 on an illustration), the water pump (36) and a back cover of a driving belt (37).
  1. At removal of a back head of cylinders поддомкратьте the car also disconnect forward section of an exhaust pipe from a back final collector.
  1. At removal of a forward head of cylinders execute the following actions described in the item with 29 on 38.
  1. Remove the thermofilter of a forward final collector (38 on an illustration).
  1. Give sockets of fastening of hoses to the forward SAI valve for what compress clamps and pull the socket back (39 on an illustration).
  2. Lift the receiver SAI and the valve from a final collector (40 on an illustration).
  3. Lift the receiver case ventilation between an inlet tube of a turbokompressor and a head of cylinders, and also a hose from an oil separator. Take a tube aside.
  4. Remove an inlet tube of a turbokompressor and take her aside (42 on an illustration).
  5. Disconnect a final hose of a turbokompressor to an interkuler (43 on an illustration).
  1. Disconnect a water hose (44 on an illustration) from the thermostat case.
  1. Disconnect a forward final collector from a turbokompressor (45 on an illustration).
  2. Remove cooling tubes (46 on an illustration) and supply of oil (47) from a turbokompressor.
  1. Give fixture and remove a camshaft of inlet valves (48 on an illustration). Give bolts on a half of turn for an approach. Pay attention to labels on covers of bearings. The last should uncover the bearing, near to the loaded pushers of valves. Remove epiploons.

Give bolts of fastening of a back head to sequences, return specified illustrations. It is not required to remove a camshaft of inlet valves.

  1. Take pushers of valves and arrange them so that then to establish on former places.
  2. Give bolts of fastening of a head of cylinders. At first give bolts on a turn quarter, and then on a half of turn. Remove a head of cylinders, trying not to bend valves.

Installation

 PERFORMANCE ORDER

  1. Make control measurements of a head of cylinders and compare them to requirements of Specifications.
  2. Make sure that the camshaft is in situation 60 a hail. to VMT.
  3. Clear interfaced surfaces of the remains of sealing materials and lay on the block of cylinders new laying by "OBEN/TOP" inscription up.
  4. Establish pushers of valves on their former places.
  5. Establish into place a head of cylinders and tighten it new bolts with demanded efforts and in the sequence specified an illustrations below.

Bolts of fastening of a forward head of cylinders tighten in sequence, return specified illustrations.

  1. Grease with a thin layer of impellent oil a final camshaft and lay it in a head of cylinders.
  1. Soriyentiruyte of a label on camshafts according to an illustration (A – a forward head of cylinders; B–back).
  1. Establish covers of bearings of camshafts, paying attention to the labels put on covers and on a head of cylinders. Put on a surface of a head of the cylinders, interfaced to covers of forward bearings of camshafts (C on illustrations) a thin layer of hermetic (No. 74 96 268 according to the Saab catalog). Tighten bolts of fastening of covers of bearings with effort of 8 N • m.
  1. Establish a back cover of a belt of a drive of GRM and cogwheels of camshafts according to the labels put on wheels and on a cover.

Number on a cogwheel should coincide with number on a shaft. Tighten bolts of fastening of cogwheels with demanded efforts.

  1. Make sure that pure dry sealing rings of a cover of a head of cylinders are laid by it on the places and establish a cover of a head of cylinders.
  2. Establish the ignition module.
  3. At installation of a forward head of cylinders establish the components listed on illustrations, in sequence, return to an order of dismantle of components.
Removal of hoses of a turbokompressor.
Removal of the SAI components and turbokompressor hoses.
  1. At installation of a back head of cylinders establish the SAI components and connect forward section of an exhaust pipe to a back final collector.
  1. Establish the water pump and assembly of tension and adjusting rollers.
  2. Establish fixing adaptations on cogwheels of camshafts.
  1. Turn a cranked shaft almost to a label «0» and establish on it the special adaptation. Then turn a cranked shaft till the moment when the lever the adaptation will rest against a flange of the water pump and remove the adaptation.
  1. Lay on cogwheels a belt of a drive of GRM according to the labels made at removal. Establish the bottom tension roller, but yet do not tighten its fixture. Make sure that the washer is on a place. Adjust a hand the provision of a roller (counter-clockwise) so that the belt did not move. Make sure that labels on a driving belt and on cogwheels of camshafts and a cranked shaft coincide.
  2. Establish on a belt of a drive of GRM a tension measuring instrument. Slightly tighten the central bolts of fastening of adjusting rollers. Turn the bottom adjusting roller so to receive a belt tension from 275 to 300 N • m then tighten a bolt of fastening of a roller. Again check a tension of a driving belt if necessary again adjust it.

Adjustment of a tension of a driving belt at this stage is preparatory procedure and its result cannot be used as check at a final tension of a belt.


  1. Make sure that the adjusting nut on the top adjusting roller rotates freely and is not tightened. Correct the provision of a tension roller by means of a prutkovy key on 5 mm so that labels on it coincided and tighten a bolt of fastening of a tension roller.
  1. Clean fixing adaptations from cogwheels of 1 and 2 camshafts. Establish the special adaptation and turn the top adjusting roller counter-clockwise so that labels on cogwheels of camshafts coincided with the corresponding labels on the special adaptation. Tighten a nut of fastening of the top adjusting roller.
  2. Remove all special adaptations.
  3. Turn the engine on two complete revolutions that the cranked shaft slightly did not reach a label «0». Establish on a camshaft the special adaptation and turn a shaft till the moment when the lever of the adaptation will rest against a flange of the water pump. Remove the adaptation, establish a control template of situation VMT and make sure that labels on it are located opposite to labels on cogwheels of camshafts. Make sure that the belt of a drive of GRM lies aflush with cogwheels, and the label And is approximately on 2 mm above B label. If the last condition is not executed, adjustment of phases GRM should be made at first.
  4. Establish a splitter of system of cooling, and then and all other acting in film components in sequence, return to an order of dismantle of components. Tighten fixture with demanded efforts.