Head Gasket Replacement V6
[Saab 95]
Removal
| STEP 1 | Note: These instructions are for the front and rear cylinder heads. There are different steps you have to take depending on which cylinder head gasket your replacing. The steps apply to both unless noted |
| STEP 2 | Place fender protectors or towels over the fenders for protection and remove engine cover. Note radio code where applicable. Detach vent hose and remove the battery |
| STEP 3 | Open the cap on the coolant expansion tank to release the pressure |
| STEP 5 | Remove the bottom engine cover and drain the coolant from the radiator |
| STEP 6 | Front cylinder head only remove the turbo bracket, minding the protective plate for the crankshaft position sensor mounted on the same bracket |
| STEP 7 | Insert two wedges (saab #8395238) between the oil sump and subframe and between the gearbox and subframe |
| STEP 8 | Front cylinder head only detach the turbo delivery pipe from the intercooler leaving on the clamp and lower the car |
| STEP 9 | Remove the mass air flow sensor and hose |
| STEP 10 | Detach the power steering hose from the holder |
| STEP 11 | Remove the right-hand engine attachment with bracket and engine mount |
| STEP 12 | Undo the retaining bolts from the coolant pump pulley and power steering pump pulley |
| STEP 13 | Release the belt from tension |
| STEP 14 | Remove the two pulleys |
| STEP 15 | Remove the belt tensioner and alternator air intake |
| STEP 16 | Remove the timing cover and unhook the throttle cable |
| STEP 17 | Remove the vacuum hoses and unplug the pressure sensor connection on the upper intake manifold |
| STEP 18 | Rear cylinder head only detach the oxygen sensor connectors from the holder on the rear SAI valve by releasing the catch and pushing them down. Undo the SAI pipe mounting fromt the cylinder head. Detach the connectors on the exhaust manifold |
| STEP 19 | Remove the vacuum hose and two water hoses from the throttle body. Remove the turbo delivery pipe with bypass pipe and valve from throttle body and unplug the pressure/temp sensor. Unplug throttle body connections and detach purge valve hose from underneath throttle body |
| STEP 20 | Unplug the connectors from the ignition discharge module and injectors |
| STEP 21 | Detach the fuel lines |
| STEP 22 | Undo the upper intake manifold and move it aside. Remove the middle intake manifold |
| STEP 23 | Remove the lower intake manifold and plug the holes with paper |
| STEP 24 | Undo the coolant bridge and move it aside being careful with the gaskets |
| STEP 25 | Remove the crankshaft pulley |
| STEP 26 | Zero the engine. The markings on the crankshaft sprockets and timing cover must be aligned, use saab tool KM-800-20, as must the crankshaft marking. Fit saab locking tool KM-800-1 and KM-800-2 for the camshaft sprockets and locking tool KM-800-10 for the crankshaft |
| STEP 27 | Undo the tensioning pulley ans adjusting rollers. Use saab tool 8394983 as a counterstay on the adjusting rollers |
| STEP 28 | Mark direction of rotation on the belt. The belt can also be marked with the respective camshaft markings and crankshaft marking to help in refitting. Remove tool KM-800-10 from the crankshaft. Leave locking tools KM-800-1 and KM-800-2 in place. Remove the lower adjusting roller making sure the washer is also removed. Remove the timing belt |
| STEP 29 | Front cylinder head only undo the adjuster roller bolts |
| STEP 30 | Remove the ignition discharge module |
| STEP 31 | Remove the camshaft cover. Make sure the o-rings stay in place and don't fall into the engine |
| STEP 32 | Rotate the crankshaft to 60 degrees BTDC. Note the marking |
| STEP 33 | Remove the camshaft sprockets |
 | The jaws of the open-ended spanner used as a counterstay when removing the camshaft sprockets must not be too long. There is a risk of damaging the metal so that the tappets become locked! |
| STEP 34 | Remove the coolant pump |
| STEP 35 | Remove the inner timing cover |
| STEP 36 | Front cylinder head only remove the front exhaust manifold heat shield |
| STEP 37 | Front cylinder head only remove the hose connections to the front SAI vavle by pressing together the clip and pulling backward |
| STEP 38 | Front cylinder head only remove the SAI pipe with valve from exhaust manifold |
| STEP 39 | Front cylinder head only undo the crankshaft ventilation pipe between the turbo intake pipe and the cylinder head as well as the hose from the oil trap. Bend aside the pipe |
| STEP 40 | Front cylinder head only undo the turbo intake pipe and bend aside |
| STEP 41 | Front cylinder head only undo the turbo outlet hose to the intercooler |
| STEP 42 | Front cylinder head only detach the water hose from the thermostat housing |
| STEP 43 | Front cylinder head only detach the front exhaust manifold from the turbo |
| STEP 44 | Front cylinder head only remove the turbo's water pipes and oil pipes |
| STEP 45 | Rear cylinder head only raise the car and detach the front exhasut pipe from the rear exhaust manifold |
| STEP 46 | Undo and remove the exhaust camshaft. Undo the bolts in stages, 1/2 to 1 turn at a time. Note the markings on the bearing caps. It is important to finish removal at the bearing cap where the tappets are under load. Remove the stuffing box |
| STEP 47 | The intake camshafts do not have to be removed |
| STEP 48 | Remove the tappets using a magnetic tool. Keep the tappets organized |
| STEP 49 | Undo the cylinder head bolts in order shown. First loosen them a 1/4 turn and then a 1/2 turn. Remove the cylinder head and be careful when putting it down because the intake valves could accidentally be bent. |
Installation
| STEP 50 | Ensure the crankshaft is at 60 degrees BTDC |
| STEP 51 | Be sure you have the correct gasket for the job (Thinner for LEV engines). Clean all mating surfaces and position the gasket. Pay attention to the guides for the gasket and make sure its marked Open/Top |
| STEP 53 | Place the cylinder head into position and using new bolts tighten in the order shown. Step 1: 25Nm (18.5 lbf ft). Step 2: Tighten a further 90 degrees. Step 3: Tighten a further 90 degrees. Step 4: Tighten a furhter 90 degrees. |
| STEP 54 | Place the exhasut camshaft into position. Check that its position is correct. Lubricate generously with oil. Cylinders 2-4-6 (Front). The locating pins for the intake camshaft should be in line (downwards) with the inside bolts for the camshaft bearing caps. The guide pins for the exhaust camshaft should point striaght up from the cylinder head plane. Note the markings on the bearing cap and cylinder head. Apply a very thin layer of thread lock to the front contact surface of the bearing cap with the cylinder head. Install the stuffing box and bearing caps and tighten the bolts in steps of 1/2 to 1 turn. Torque to 8Nm (6lbf ft) |
| STEP 55 | Fit the inner (rear) timing cover |
| STEP 56 | Install the camshaft sprockets correctly in relation to the locating pins. Check the position against the markings in the timing cover. The number in the sprocket hub should match the number on the camshaft. Torque bolts to 50Nm (37lbf ft) + 60 degrees |
| The jaws of the open-ended spanner used as a counterstay when removing the camshaft sprockets must not be too long. There is a risk of damaging the metal so that the tappets become locked! |
| STEP 57 | Check that the O-rings are in the camshaft cover and wipe clean. Lubricate with soap solution and place part # (10) 8152381 in the corners at the camshaft bearing caps. Torque to 8Nm (6lbf ft) |
| STEP 58 | Install the ignition discharge module |
| STEP 59 | Fit the turbo oil pipes. Torque to: oil pipe-turbo: 20Nm (15lbf ft). Oil pipe-oil filter adapter: 20Nm (15.5lbf ft). Oil return pipe: 14Nm (10lbf ft) |
| STEP 60 | Install the turbo water pipes. Torque to: water pipe: 25Nm (18.5lbf ft). Cylinder head retaining bolt 14Nm (10lbf ft) |
| STEP 61 | Connect the water hose to the thermostat housing |
| STEP 62 | Install the front exhaust pipe to the turbo. Torque to 24Nm (18lbf ft) |
| STEP 63 | To avoid turbo delivery hoses from coming loose due to low friction at high pressure, the hoses and connecting pieces must be cleaned using a rag and safe cleaning agent. Wipe the inside of the hose and replace any damaged hose or pipe. |
| STEP 64 | Install the hose between the turbo and intercooler |
| STEP 65 | Install the crankcase breather pipe to the turbo intake pipe paying attention to the gasket. Torque to 24Nm (18lbf ft) |
| STEP 66 | Install the turbo intake pipe. Torque to: V-clamps 3Nm (2.2lbf ft). U-clamp-cylinder head 14Nm (10.3lbf ft) |
| STEP 67 | Install the SAI pipe to the front exhaust manifold using new gaskets |
| STEP 68 | Install the hose connection to the valve and check the connection |
| STEP 69 | Fit the crankcase ventilation pipe between the cylinder head and the turbo intake pipe. Connect the hose from the oil trap. Torque the banjo screw, intake pipe to 24Nm (17.7lbf ft) |
| STEP 70 | Install the coolant pump. Torque to 25Nm (18.5lbf ft) |
| STEP 71 | Install the bracket with tensioning roller and the upper adjuster roller |
| STEP 72 | Fit locking tool KM-800-1 on No.1 and No.2 camshaft sprockets and locking tool KM-800-2 on No.3 and No.4 camshaft sprockets |
| STEP 73 | Rotate the crankshaft to just before the 0 degree mark and fit tool KM-800-10. Carefully rotate the crankshaft in the direction of rotation of the engine until the arm is lying against the coolant pump flange and remove tool |
| STEP 74 | Install the camshaft belt following the markings on the belt and the indicated rotation direction. Use saab adjustment tool for cam sprocket and timing belt KM-800-30 to hold the belt in place. Fit the lower tensioning pulley loosely. Make sure the washer is in place. Adjust the tensioning pulley by hand so the belt does not disengage. Adjust anticlockwise, saab adjustment tool 8395006. Check carefully to see that the markings on the camshaft belt match the corresponding markings on the camshaft sprocket and the crankshaft. Remove tool KM-800-30. Fit locking tool KM-800-10, mount a length of the camshaft timing belt and fit a belt tensioner gauge to measure the belt tension. Tighten the center bolts of the adjuster rollers lightly. Adjust the lower adjuster roller anticlockwise until a tension of 275-300Nm is obtained. Tighten the adjuster roller's bolt. Use saab tool 8394983 as a counterstay. Check the belt tension once more and adjust as necessary. Torque to 40Nm (30lbf ft). Remove the belt tension meter and piece of the belt |
| STEP 75 | Ensure the adjusting nut on the upper adjusting roller rotates freely and is not tight. Adjust the tensioning pulley with a 5mm allen key until the two lines on the tensioning pulley correspond with each other. Torque to 20Nm (15lbf ft). |
Pricing for HEAD GASKET SETS & RELATED (engine seals & gaskets)
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