Saab B204/B234 engine assembly. This engine is found in all four-cylinder Saab 900 and 9000 from 1994 to 1998, as well as 1999 9-3. Newer cars with B205/B235 engines have certain differences, but the procedure is largely the same.

Tools and supplies:

  • 27 mm socket: crankshaft pulley, timing chain tensioner;
  • 19 mm socket: flywheel;
  • 19 mm wrench: to hold camshafts when tightening;
  • 16 mm socket: spark plugs;
  • 14 mm socket: camshaft sprocket bolts;
  • 13 mm socket: drain plug;
  • 12 mm socket; chain tensioner plug, upper timing cover bolts;
  • Torx E16 socket: head bolts;
  • Torx T40 socket: timing cover, oil pan, valve cover;
  • Torx T30 socket: endplate, DI cassette, timing and balance chain gear;
  • torque wrench (or two - for high and low torque fasteners);
  • large snap ring pliers: oil pump cover;
  • rubber mallet;
  • gasket maker.
02.07.2006
Crankshaft seals

Before starting the assembly, make sure you have all spare parts needed. This picture shows the endplate and oil pump cover with a pack of fresh seals for them.
02.07.2006
Suspended

If you are using an engine stand that bolts on to the gearbox mounting points, you won't be able to attach the endplate. In this case, suspending the engine on a hoist does the job.
02.07.2006
Endplate

Clean the endplate, tap the new seal in and apply a thin bead of sealant to the mating surface.
02.07.2006
Endplate attached

Fit the plate and tighten the screws (Torx T30 socket). Wipe the excess sealant.
02.07.2006
Flywheel

Attach the flywheel, apply some threadlock to the bolts and tighten them to 59 ft-lbs (19 mm socket). Use a flywheel stop or have a helper hold the crank pulley nut on the other end to prevent the crankshaft from spinning.
02.07.2006
Back on the stand

Put the engine back on the stand. It might need some extra washers to clear the flywheel. Turn the flywheel to match the "0" mark on the endplate.
02.07.2006
Balance shaft

Lubricate the balance shafts and carefully insert them trying not to scratch the bearing surfaces inside the block.
02.07.2006
Shafts in

The shafts are the same, but the sprockets are not. The intake shaft has a smaller sprocket marked "INL", while the exhaust side is marked "EXH". Tighten the screws (Torx T30).
03.07.2006
Chain and guides

Prepare a new timing chain and plastic guides.
03.07.2006
Timing chain

Fit the timing chain sprocket and hang the chain off it so the colored link matches the notch on the sprocket (there are two other colored links on the other end of the chain that will match the camshafts).
03.07.2006
Chain guard

Attach the chain guard (two Torx T30 screws).
03.07.2006
Guides

Fit the guides. The fixed guide is held by two long T30 screws, while the swivel guide just sits on a big pin.
03.07.2006
Balance shaft

Turn the balance shafts so the notch matches the mark on the housing.
03.07.2006
Balance chain

Fit the balance chain sprocket, the small swivel guide and the balance shaft chain.
03.07.2006
Tensioner

Push the piston on the balance chain tensioner in and lock it with a pin or a paper clip.
03.07.2006
Tensioner fitted

Attach the tensioner and tighten the screws to 7.4 ft-lbs (the factory manual makes a big deal about it).
03.07.2006
Idle sprocket

Fit the balance chain idler sprocket (Torx T40).
03.07.2006
Upper guide

Attach the upper balance chain guide with two more T30 screws (the engine is upside down, so it's at the bottom) and release the tensioner. Turn the crankshaft and check if the shaft notches are still in sync with a "0" mark on the flywheel after a few revolutions.
03.07.2006
No chain

If you choose to build the engine without a balancing chain, you can leave the shafts and sprockets in to preserve the proper oil flow. Just replace the swivel guide with a spacer so it doesn't rattle inside the engine.
03.07.2006
Timing cover

Clean the mating surfaces of the timing cover and apply a bead of sealant.
03.07.2006
Timing cover

Fit the cover and tighten the bolts to 16 ft-lbs (Torx T40 socket).
03.07.2006
Oil pump

Lubricate and insert the oil pump gears making sure that the marking on the oil pump ring gear is facing out and the pump gear with flange facing in.
03.07.2006
Oil pump cover

Tap a new seal into the oil pump cover, put the cover on and secure it with a snap ring.
03.07.2006
Oil tube

Fit the oil feed tube and refresh the O-rings on it. Screw in the reducer valve.
03.07.2006
Oil pan

Attach the pickup screen and the splash guard inside the oil pan, apply a bead of sealant to the flange.
03.07.2006
Pan fitted

Tighten the oil pan screws to 16 ft-lbs (Torx T40). Fit a fresh drain plug washer.
03.07.2006
Crankshaft pulley

Slide the crankshaft pulley on (mind the oil seal in the oil pump cover) and tighten the 27 mm bolt to 130 ft-lbs.
04.07.2006
Top of the block

Turn the block upright and clean the upper surface.
04.07.2006
TDC mark

Turn the crankshaft pulley to match the TDC mark.
04.07.2006
Head and gasket

Prepare the head with a fresh gasket. Clean the head flange thoroughly.
04.07.2006
Gasket

Put the gasket on top of the block, make sure it clears the locating dowels.
04.07.2006
Head

Set the camshafts to zero (see the markings on the #1 cap) and put the head carefully on the block.
04.07.2006
Head bolts

A new set of head bolts is needed to attach a head. The old bolts are already stretched and won't provide a proper clamping force.
04.07.2006
Head bolts

Tighten the bolts to 44 ft-lbs in the order shown. Then do a second pass and tighten them to 59 ft-lbs. Grab a bigger wrench and do a third pass, turning every bolt an extra 90°.
04.07.2006
Camshafts

Fit camshaft sprockets, starting with the intake side. Check that both camshafts and the crankshaft remain at their "0" mark. Screw the sprocket bolts in but not tighten them yet.
04.07.2006
Tensioner

Take apart the timing chain tensioner and clean it. Press on the catch and compress the piston completely.
04.07.2006
Tensioner

Install the tensioner with a new washer while keeping it in a compressed state. Tighten to 47 ft-lbs (27 mm socket). Insert the spring and tighten the plug to 16 ft-lbs.
04.07.2006
Sprocket bolts

Rotate the crankshaft clockwise and ensure that zero marks on the camshafts and crank pulley are still in sync after a few revolutions. Tighten sprocket bolts to 47 ft-lbs (14 mm socket), tighten the two upper timing cover bolts to 16 ft-lbs (12 mm socket).
04.07.2006
Valve cover

Clean the valve cover and renew the upper timing chain guide. Apply some soap to the valve cover gasket so it sticks to the groove.
04.07.2006
Valve cover

Fit the valve cover, make sure the gasket fills the half-moon openings correctly and is not jammed anywhere. Tighten the bolts to 11 ft-lbs in the order shown (Torx T40).
04.07.2006
Spark plugs

Gap the spark plugs and tighten them to 20 ft-lbs. NGK BCPR7ES are the plugs most recommended for this application.
04.07.2006
DI cassette

Install the ignition module and tighten the screws to 8 ft-lbs. Congratulations, you've built yourself an engine!

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