09.07.2006: Saab NG900 Engine Accessories

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09.07.2006: Saab NG900 Engine Accessories

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The installation of manifolds, pumps and other accessories on a Saab B204/B234 family engine. The work was done on a 1995 Saab 900SE turbo, but will also apply to any four cylinder 1994-1998 900 turbo and 1999 9-3. Newer cars using the B205/B235 engine family are also quite similar.

Tools:

22 mm wrench: oil thermostat cap, oil pressure sensor;
19 mm wrench: intake manifold coolant nipple;
17 mm socket: temperature sender;
16 mm socket: engine mount, starter;
13 mm socket: oil filter housing, coolant pump, alternator, exhaust manifold, turbo;
12 mm socket: thermostat, intake manifold, banjo bolts;
10 mm socket: coolant pipes;
8 mm Allen socket: alternator bolts, belt tensioner;
torque wrench;

	09.07.2006 Engine A freshly rebuilt engine just waiting to go back into the car.		09.07.2006 Engine Refer to this document for more detail on the base engine assembly.
	09.07.2006 Oil filter housing Clean the oil filter housing, the oil thermostat, and get a new filter ready.		09.07.2006 Oil filter Install the filter housing (13 mm socket), tighten the thermostat cap (22 mm). Lubricate the O-ring on the filter and screw it on.
	09.07.2006 Thermostat Fit a new seal on the thermostat and clean the thermostat housing.		09.07.2006 Thermostat housing Attach the thermostat housing (12 mm socket).
	09.07.2006 Coolant pump The coolant pump is next. Coat new O-rings with vaseline and put them on the coolant inlet pipe.		09.07.2006 Coolant inlet Fit the inlet into the slot in front of cylinder #1. Make sure the flap on the inlet matches the cut-out on the right.
	09.07.2006 Pump installed Install the coolant pump, check that the outer O-ring on the inlet is not jammed. Tighten the bolts.		09.07.2006 Coolant pipes Attach the pipes leading to the heat exchanger and expansion tank. Renew the O-ring and the short rubber U-bend if needed. Tighten the 10 mm screw on the pump.
	09.07.2006 Coolant pipes Secure the pipes on the far side of the engine -- one screw at the corner, and two more on the thermostat housing.		09.07.2006 Manifold studs Screw in exhaust manifold studs. The factory configuration has longer studs in the outer holes, but the benefit of those is debatable since they are always the first to break, so I'm using short studs instead.
	09.07.2006 Exhaust gasket Position a new gasket on the studs -- soft side to the head, flat side to the manifold.		09.07.2006 Exhaust manifold Install the manifold, fit the washers and tighten the nuts to 18.5 ft-lbs (13 mm socket).
	09.07.2006 Turbocharger Bolt the turbocharger to the exhaust manifold, use a fresh gasket. Install the lower support bar. Connect all coolant and oil lines before tightening the banjo bolts. Renew all banjo bolt washers. More detail on turbo fitting in this article.		09.07.2006 Mount bracket Install the passenger side engine mount bracket (two 16 mm bolts).
	09.07.2006 Inlet pipe Bolt the inlet pipe to the turbocharger and fit three hoses from the boost pressure control valve (BPC). Attach the crankcase vent pipe.		09.07.2006 Lifting eyes Connect the crankcase vent nipple to the valve cover. Install the lifting eyes and the wiring harness bracket above the thermostat housing.
	09.07.2006 Intake gasket Fit the lower part of the oil dipstick tube. Insert two studs into the intake manifold mounting holes (you'll be replacing them with regular bolts later) and position the gasket on them.		09.07.2006 Intake manifold Install the intake manifold and tighten the bolts to 16 ft-lbs (12 mm socket). Fit the coolant temperature sensor and the hose nipple if you took them out previously.
	09.07.2006 Injectors Slide the injectors into their sockets and secure the fuel rail with two screws.		09.07.2006 Oil tube Screw in the oil pressure sensor (22 mm wrench), the upper part of the dipstick tube and bolt on the intake manifold stay.
	09.07.2006 Throttle body Lubricate the rubber gasket and install the throttle body.		09.07.2006 Hoses Fit the vacuum hose to the fuel pressure regulator, and a hose with a check valve from the vent nipple (the arrow on the valve should point to the throttle body). Attach the throttle body warm-up coolant hoses.
	09.07.2006 IAC valve Install the idle air control valve (IAC) and connect its hoses to the throttle body.		09.07.2006 Wiring harness The wiring harness is held by two screws to the fuel rail. Take your time fitting all the connectors. Luckily, they are colored, indexed and rather hard to plug in incorrectly.
	09.07.2006 Temperature sender Attach the temperature sender and the crankshaft position sensor. Plug them into the remaining connectors on the harness.		09.07.2006 Alternator Install the intermediate shaft bracket, the alternator bracket (13 mm socket) and then two long bolts holding the alternator (8 mm Allen).
	09.07.2006 Starter Attach the starter motor to the stud on the endplate. Connect the control wires and the positive line from the battery.		09.07.2006 Pulleys Install the belt tensioner (8 mm Allen) and the idler pulleys. The upper idler pulley on this picture is the aluminium pulley by Wazee. Proceed with engine installation.

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