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;

 

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09.07.2006: Engine
A freshly rebuilt engine just waiting to go back into the car.

 

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09.07.2006: Engine
Refer to this document for more detail on the base engine assembly.

 

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09.07.2006: Oil filter housing
Clean the oil filter housing, the oil thermostat, and get a new filter ready.

 

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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.

 

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09.07.2006: Thermostat
Fit a new seal on the thermostat and clean the thermostat housing.

 

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09.07.2006: Thermostat housing
Attach the thermostat housing (12 mm socket).

 

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09.07.2006: Coolant pump
The coolant pump is next. Coat new O-rings with vaseline and put them on the coolant inlet pipe.

 

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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.

 

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09.07.2006: Pump installed
Install the coolant pump, check that the outer O-ring on the inlet is not jammed. Tighten the bolts.

 

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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.

 

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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.

 

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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.

 

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09.07.2006: Exhaust gasket
Position a new gasket on the studs -- soft side to the head, flat side to the manifold.

 

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09.07.2006: Exhaust manifold
Install the manifold, fit the washers and tighten the nuts to 18.5 ft-lbs (13 mm socket).

 

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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.

 

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09.07.2006: Mount bracket
Install the passenger side engine mount bracket (two 16 mm bolts).

 

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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.

 

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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.

 

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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.

 

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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.

 

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09.07.2006: Injectors
Slide the injectors into their sockets and secure the fuel rail with two screws.

 

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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.

 

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09.07.2006: Throttle body
Lubricate the rubber gasket and install the throttle body.

 

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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.

 

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09.07.2006: IAC valve
Install the idle air control valve (IAC) and connect its hoses to the throttle body.

 

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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.

 

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09.07.2006: Temperature sender
Attach the temperature sender and the crankshaft position sensor. Plug them into the remaining connectors on the harness.

 

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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).

 

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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.

 

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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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