1998 Saab 900 SE ENGINES Saab 2.0L & 2.3L 4-Cylinder
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- Bethanie Leona Anthony
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1 Removal & Installation See VALVE SPRINGS under CYLINDER HEAD under OVERHAUL. CAMSHAFT Removal 1. Rotate crankshaft until "0" mark on flywheel aligns with timing mark on flywheel cover. Remove inspection panel from valve cover. On 900 Series, disconnect ignition leads and vacuum hose from distributor. Remove distributor (if equipped). On 9000 Series, remove ignition cartridge. 2. Remove valve cover. Remove camshaft sprocket retaining bolts. Remove chain tensioner, camshaft sprockets, and timing chain. Remove oil line and camshaft bearing caps. Remove camshafts. Installation 1. Ensure "0" mark on flywheel aligns with timing mark on flywheel cover. Install intake camshaft with bearing caps No. 1 through 5, and exhaust camshaft with bearing caps No. 6 through Tighten bearing cap bolts to specification. See TORQUE SPECIFICATIONS. Rotate camshafts until they are aligned with their respective timing marks. See Fig. 2. Reverse removal procedure to complete installation. Fig. 2: Locating Camshaft Timing Marks Courtesy of SAAB-SCANIA OF AMERICA, INC. Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
2 BALANCE SHAFTS Removal Remove timing chain cover. See TIMING CHAIN. Remove upper chain guide, chain tensioner, and pivoting guide. Remove idler sprocket and balance shaft chain. Pull oil pump drive and balance chain drive sprocket from crankshaft. Carefully pull balance shafts from engine block. Inspection Inspect all parts for wear or damage. Replace bearings and/or balance shafts if bearing clearance exceeds.007" (.18 mm). Installation 1. Ensure "0" mark on flywheel aligns with timing mark on flywheel cover. Lubricate balance shaft journals and bearing housings. Carefully insert balance shafts into their respective bores. Shaft marked INL goes into intake side of engine. Ensure timing marks on balance shaft bearing housings and sprockets are aligned. 2. Install balance shaft chain and idler sprocket, leaving some slack in area of tensioner. Keep chain reasonably taut with upper chain guide. Press plunger on chain tensioner. Maintain plunger in position by inserting paper clip into hole in housing. Ensure plunger is turned to position in which spring acts fully upon it. 3. Install chain guides and tensioner. Remove paper clip to set tensioner. Rotate crankshaft several times. Ensure timing marks align. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS. REAR CRANKSHAFT OIL SEAL Removal (900 Series A/T) Remove engine. See ENGINE. Separate engine and transaxle. See TRANSMISSION REMOVAL & INSTALLATION - A/T article in AUTOMATIC TRANSMISSION SERVICING. Remove torque converter and flexplate. Pry out old seal. Removal (900 Series M/T) Remove clutch. See CLUTCH article. Remove flywheel. Pry out old seal. Removal (9000 Series A/T) Remove transaxle and flexplate. See TRANSMISSION REMOVAL & INSTALLATION - A/T article in AUTOMATIC TRANSMISSION SERVICING. Pry out old seal. Removal (9000 Series M/T) Remove clutch. See CLUTCH article. Remove flywheel. Pry out old seal. Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
3 Installation (All Models) Lubricate sealing surface of new seal with engine oil. Install into position with Seal Installer ( ). Reverse removal procedure to complete installation. Tighten bolts to specification. See TORQUE SPECIFICATIONS. WATER PUMP Removal (900 Series) Drain coolant. Remove drive belt. Remove pulley, water pump retaining bolts, and water pump. Removal (9000 Series) Raise and support front of vehicle. Remove right front wheel assembly. Drain coolant. Loosen drive belt. Remove water pump pulley. Unbolt oil and water line clips. Disconnect coolant hoses. Remove water pump. Installation (All Models) Clean gasket surfaces. Install new gasket. Install water pump, belt tensioner pulley, and drive belt. Reverse removal procedure to complete installation. Tighten bolts to specification. See TORQUE SPECIFICATIONS. OIL PAN Removal 1. Remove dipstick. Stuff rag into opening. Raise and support front of vehicle. Drain engine oil. Remove right front wheel and inner fender panel. Remove front and rear engine mount nuts, HO2S sensor, and front section of exhaust pipe. Remove torque strut through-bolt. Lift engine slightly. Remove lower oil pan-to-transaxle bolt. 2. Disconnect wiring from oil level sensor. Remove turbocharger brace and oil return line (if equipped). Fold down splash plate. Remove rubber plugs from transaxle housing to gain access to rear oil pan bolts. Remove oil pan retaining bolts. Tap guide sleeve into engine block. Remove oil pan. Remove guide sleeve. Installation Clean gasket surfaces. Apply silicone sealant to gasket surfaces. Install rubber seal for oil strainer into groove in oil pan. Reverse removal procedure to complete installation. Tighten bolts to specification. See TORQUE SPECIFICATIONS. OVERHAUL CYLINDER HEAD Cylinder Head Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
4 Measure cylinder head height after resurfacing. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Cylinder head warpage information is not available from manufacturer. Valve Springs 1. Remove camshafts. Remove valve lifters with magnet. Install Lifter Bore Sleeves ( ) to protect lifter bores. Position Valve Retainer Remover ( ) squarely on valve head and tap firmly with hammer. Remove keepers with magnet. Remove springs and caps. 2. To assemble, install valve spring and cap over valve stem. Position retainers into groove in spring cap. Using Valve Retainer Remover ( ) and Valve Retainer Installer Sleeve ( ), carefully tap retainers into groove of valve stem. Length of valve spring when installed should be 1.46" (37 mm). To complete assembly, reverse disassembly procedure. Valve Stem Oil Seals Remove seals using Pliers ( ). Ensure protective sleeves for lifter guides are in place. Install seals using Installer ( ). Remove shank from installer. Insert seal into installer. Insert Installer into guide. Tap seal into position with plastic mallet. Valve Guides 1. To check for valve guide wear, pull valve approximately.12" (3.0 mm) from its seat and check side play with a dial indicator. If side play exceeds.020" (.50 mm), replace valve and/or valve guide. 2. To replace guide, flush hot water through head and pull valve guide from top of head using Guide Puller ( ), Spacer ( ), and Nut ( ). To install, flush hot water through head and press in new valve guide from bottom side. Valve Seat Grind intake and exhaust valve seats to an angle of 45 degrees. Valves Grind intake valves to an angle of 44.5 degrees. DO NOT grind exhaust valve face. Use only lapping compound to finish face. Valve Seat Correction Angles Using a 75-degree cutter, adjust exhaust valve seat width so valve contact surface extends to edge of head. Using a 75-degree cutter below, and an 11- or 12-degree cutter above, adjust intake valve seat contact area to center of valve head. Valve seat width should be approximately.06" (1.5 mm) after refinishing. See Fig. 3 and Fig. 4. Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
5 Fig. 3: Refinishing Exhaust Valve Seat Courtesy of SAAB-SCANIA OF AMERICA, INC. Fig. 4: Refinishing Intake Valve Seat Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
6 Courtesy of SAAB-SCANIA OF AMERICA, INC. CYLINDER BLOCK ASSEMBLY Piston & Rod Assembly 1. Mark pistons for reassembly reference. Rod and cap for each cylinder are stamped with an identification number (1-4). Piston pins are retained by circlips. Remove circlips and press out piston pins. Check pins and bearings for wear or damage and replace as necessary. 2. Install piston and rod assembly with number on rod and cap facing exhaust side of engine. Install piston with notch on top of piston (at outer circumference) facing timing chain end of engine. Fitting Pistons 1. To fit pistons to cylinder bores, use a feeler gauge 1/2" (12.7 mm) wide and a spring scale. Oil cylinder lightly. Insert piston without rings. Attach spring scale to feeler gauge. 2. Insert feeler gauge between piston and cylinder wall at right angle to piston pin. When feeler gauge can be pulled out of cylinder with a force of lbs. ( kg), piston clearance is equal to feeler gauge thickness. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. 3. Repeat test at various bore depths. Standard and oversize pistons are available. See PISTON DIAMETER SPECIFICATIONS table. PISTON DIAMETER SPECIFICATIONS Standard AB ( ) Standard B ( ) Standard C ( ) 1st Oversize ( ) 2nd Oversize ( ) Piston Rings 1. Check piston rings for end gap and side clearance. Use an inverted piston to push ring down into bore. On worn bores, measure at lower end of bore. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. 2. Lubricate pistons and rings. Install rings onto pistons. Stagger ring gaps. Compression ring gaps must be located 180 degrees from each other. Oil ring gaps must be equally spaced from each other. Rod Bearings 1. Using a micrometer, measure rod bearing journal diameter, taper, and out-of-round. Measure bearing clearance with Plastigage. 2. Rod bearings are available in standard and undersize. Thin and thick bearings may be combined to obtain proper clearance. See ROD & MAIN BEARING SIZES table. Rod bearing journals may be ground one undersize without need for hardening of shaft. Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
7 ROD & MAIN BEARING SIZES Standard First Oversize Second Oversize Color Red Yellow Blue Crankshaft & Main Bearings 1. Turn engine upside-down to prevent weight of crankshaft from affecting measurements. Measure bearing clearance with Plastigage positioned to one side of journal centerline. 2. Main bearings are available in standard and undersize. Thin and thick bearings may be combined to obtain proper clearance. See ROD & MAIN BEARING SIZES table. Main bearing journals may be ground one undersize without need for hardening of shaft. Thrust Bearing Center main bearing is thrust bearing. If crankshaft end play exceeds specification, install new thrust washer. Thrust washer oil grooves should face toward crankshaft. See CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS table under ENGINE SPECIFICATIONS. Cylinder Block Check each cylinder for wear, cracks, or damage. Ensure oil passages are clean. Ensure freeze plugs are in good condition. ENGINE OILING ENGINE LUBRICATION SYSTEM The crankshaft drives an oil pump on the timing cover. Oil flows through a full flow filter to oil passages which feed main bearings, rod bearings and valve train. Crankcase Capacity Oil capacity, including filter, is 4.1 qts. (4L) for 900 Series 2.0L and 2.3L engines. Oil capacity, including filter, is 5.1 qts. (4.7L) for 9000 Series 2.3L engine. Oil Pressure Oil pressure is 43 psi (3.0 kg/cm 2 ) at 2000 RPM. OIL PUMP Removal Clean area around pump. Attach Locking Device ( ) to flywheel ring gear. Remove crankshaft pulley Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
8 retaining bolt and pulley. Remove oil pump retaining bolts and pump. Installation Coat gears with oil. Ensure ring gear is installed with mark on visible face. Position NEW sealing ring into groove in pump body. Prime pump with oil and install on engine. Remove oil filter adapter casting and fill passage with oil. Install casting. NOTE: It may be necessary to pull pump gear out slightly to position gear on driving plate. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Ft. Lbs. (N.m) Camshaft Bearing Cap Bolt 11 (15) Camshaft Sprocket Bolt 48 (65) Crankshaft Pulley Bolt 130 (175) Cylinder Head Bolt (1) Step 1 44 (60) Step 2 59 (80) Step 3 (2) Distributor Hold-Down Bolt 15 (20) Exhaust Manifold Bolt 19 (26) Flywheel Bolt 59 (80) Intake Manifold Bolt 16 (22) Knock Sensor (15-26) Main Bearing Cap Bolt 81 (110) Oil Pan Bolt 15 (20) Rod Bearing Bolt 41 (56) Thermostat Housing Bolt 16 (22) Timing Chain Cover Bolt 16 (22) Timing Chain Tensioner Bolt 48 (65) Water Pump Bolt 15 (20) INCH Lbs. (N.m) Belt Tensioner Pulley 71 (8) Oil Pump Bolt 71 (8) (1) Tighten in sequence. See Fig. 1. (2) Tighten bolts an additional 90 degrees. ENGINE SPECIFICATIONS Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
9 GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Specification 2.0L Displacement 121 Cu. In. (2.0L) Bore 3.54" (90.0 mm) Stroke 3.07" (78.0 mm) Compression Ratio 9.0:1 Fuel System SFI RPM 900 Turbo Turbo SPG 5500 Torque Ft. Lbs. 900 RPM Turbo RPM L Displacement 140 Cu. In. (2.3L) Bore 3.54" (90.0 mm) Stroke 3.54" (90.0 mm) Compression Ratio Non-Turbo 9.0:1 Turbo 8.5:1 Fuel System SFI RPM Non-Turbo 6100 Turbo 5000 Torque Ft. RPM Non-Turbo 4300 Turbo 2000 CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS Crankshaft End Play ( ) Runout.004 (.10) Main Bearing Journal Diameter ( ) Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
10 Journal Out-of-Round.0002 (.005) Journal Taper.0002 (.005) Oil Clearance ( ) Connecting Rod Bearings Journal Diameter ( ) Oil Clearance ( ) CONNECTING RODS CONNECTING RODS Bore Diameter Pin Bore ( ) Crankpin Bore ( ) Length 6.02 (153) Maximum Bend (1) Maximum Twist (1) Side Play (1) (1) Information is not available from manufacturer. PISTONS, PINS & RINGS PISTONS, PINS & RINGS Pistons Clearance ( ) Diameter (89.97) Pins Diameter ( ) Piston Fit (1) ( ) Rod Fit (1) ( ) Rings No. 1 End Gap ( ) Side Clearance ( ) No. 2 End Gap ( ) Side Clearance ( ) No. 3 (Oil) End Gap ( ) Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
11 Side Clearance (2) (1) Sliding fit under gentle thumb pressure. (2) Information is not available from manufacturer. CYLINDER BLOCK CYLINDER BLOCK Cylinder Bore Standard Diameter ( ) Maximum Taper (1) Maximum Out-Of-Round (1) (1) Information is not available from manufacturer. VALVES & VALVE SPRINGS VALVES & VALVE SPRINGS Specification Intake Valves Face Angle 44.5 Degrees Head Diameter 1.29" (33 mm) Minimum Margin (1) Minimum Refinish Length (1) Stem Diameter "( mm) Valve Tip Maximum Refinish (1) Exhaust Valves Face Angle 44.5 Degrees Head Diameter 1.14" (29 mm) Minimum Margin (1) Minimum Refinish Length (1) Stem Diameter "( mm) Valve Tip Maximum Refinish (1) Valve Springs Free Length 1.77" (45.00 mm) Installed Height 1.46" (37.0 mm) Out-Of-Square (1) Pressure In. ( mm) Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
12 (1) Information is not available from manufacturer. CYLINDER HEAD CYLINDER HEAD Specification Cylinder Head Height (Minimum) " ( mm) Maximum Warpage (1) Valve Seats Intake Valve Seat Angle 45 Degrees Seat Width.06"(1.5 mm) Maximum Seat Runout (1) Seat Bore Diameter (1) Exhaust Valve Seat Angle 45 Degrees Seat Width.06"(1.5 mm) Maximum Seat Runout (1) Seat Bore Diameter (1) Valve Guides Intake Valve Valve Guide Bore I.D " ( mm) Valve Guide I.D. (1) Valve Guide Installed Height (1) Valve Stem-to-Guide Oil Clearance.019"(.50 mm) Exhaust Valve Valve Guide Bore I.D "( mm) Valve Guide I.D. (1) Valve Guide Installed Height (1) Valve Stem-to-Guide Oil Clearance (1) Information is not available from manufacturer..019" (.50 mm) CAMSHAFT CAMSHAFT Bore Diameter (1) Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
13 End Play ( ) Journal Diameter ( ) Journal Runout (1) Lobe Height (1) Oil Clearance (1) Lobe Lift.340 (8.64) (1) Information is not available from manufacturer. BALANCE SHAFTS BALANCE SHAFTS Journal Diameter Larger Outer ( ) Smaller Inner ( ) Bearing Diameter Larger Outer ( ) Smaller Inner ( ) Oil Clearance Larger Outer ( ) Smaller Inner ( ) End Play ( ) VALVE LIFTERS VALVE LIFTERS Bore Diameter ( ) Lifter Diameter ( ) Oil Clearance (1) (1) Information is not available from manufacturer. Sunday, May 08, :38:01 PM Page Mitchell Repair Information Company, LLC.
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