4.1.9. Removal and installation to the place of a head of cylinders

Removal

 PERFORMANCE ORDER

1. Open a cowl and clear the surface of the engine around a head of cylinders.
2. Cock the emergency brake and a poddomkratta the car in front and behind, having established it on axial props (address Poddomkrachivaniye's Section, towage and change of wheels). Remove the right forward wheel.
3. Give screws and remove a molding of a forward wing and a loker of an arch of a wheel under the right forward wing.
4. Remove the central panel under a radiator, make draining of the cooling system according to the instructions provided in the Head Routine maintenance. Establish into place and tighten a drain stopper.
5. Give and remove the lower fixing bolt of a casing of the electric fan of the cooling system.
6. Disconnect a negative wire of the battery and shift it far away from the battery plug.
7. On early models weaken clips and disconnect hoses from a broad tank on the right side of a motive compartment. Give a fixing bolt, release a trosikovy clip and separate a connector. Take a broad tank from a motive compartment.
8. Otboltite also remove a jet bar (and where it is necessary, a support) in the right top end of the engine.
9. If necessary remove screws of the tank of system of hydrostrengthening of a wheel and shift the tank aside. Weaken trosikovy clips of hoses.
10. On early models remove a separate driving compressor belt of the air conditioning system (see the head Routine maintenance). On late models take off an auxiliary driving belt (see the head Routine maintenance).
11. Disconnect the plug from the compressor of the air conditioning system (where it is available), then give a bolt of a support and remove the compressor from a bracket.
12. Cover a radiator beam with a piece of fabric, then disconnect the lower hose from the water pump and put the compressor and a hose on a beam.
13. Otboltite.
14. Remove a bracket of a support of the compressor of the air conditioning system from a head of cylinders.
15. Where is available, disconnect wires from a lambda sensor, and the contact plug under the inlet pipeline. Release wires from clips on a head of cylinders and put them aside on a body stretcher.
16. On the models which are not equipped with system of a turbo-supercharging give fixing nuts of the lower pipe of the exhaust system to a final collector and lower a pipe.
17. On the models equipped with system of a turbo-supercharging remove a turbocompressor (see the head Toplivnaya and exhaust systems). Remove the electromagnetic valve of system of a turbo-supercharging and place it away from the measuring instrument of an air stream. Weaken hose clips and pick up the feeding phone of system of a turbo-supercharging. Weaken hose clips and remove an inlet hose of system of a turbo-supercharging from the compressor, also disconnect hoses of the electromagnetic valve. On hoses marking in a look "With" has to be put from the compressor and "W" from an exit.
18. Disconnect wires of the electric fan of the cooling system, then give nuts of the top support and remove assembly of the fan behind a radiator.
19. Weaken a collar and disconnect the top hose of a radiator from a thermostat casing in the left end of a head of cylinders.
20. Disconnect a hose of a sapun of a case and a hose of the control unit of vacuum (where it is established), shift hoses aside.
21. Give screws and remove a viewing cover or the block of ignition of system of direct ignition in the center of a cover of a head of cylinders.
22. Where are available, disconnect high-voltage wires from spark plugs.
23. Where it is established, remove the distributor (see the Head Sistemy of start and a charge) and put it aside.
24. Disconnect wires from temperature sensor on a thermostat casing.
25. Weaken a collar and disconnect a heater hose from a thermostat casing.
26. Give bolts of fastening of a support to a bracket of the regulator of pressure of fuel and turn a bracket together with the sensor and hoses aside.
27. Otboltite from the block of cylinders a jet bar of a bracket of the right support of the engine.
28. Where are established, unscrew the top bolts of a persistent bar of the inlet pipeline on each party of the pipeline.
29. On the models equipped with the two-section inlet pipeline disconnect a hose of the valve of system of the air conditioner and a hose of a sapun of a case and (where is available) you otboltit a bracket of a tube of the measuring probe. Disconnect the inlet pipeline from hoses, then reject it aside and fix hoses by trosikovy collars.
30. Give bolts of fastening of the inlet pipeline to a head of cylinders and shift assembly of the pipeline in a set in a back part of a motive compartment. Remove laying. Leave all wires, hoses and ropes (if are available) connected to assembly of the inlet pipeline.
31. Otboltite also uncover a head of cylinders, remove the special split rubber traffic jams from a head of cylinders. In case the cover stuck to a head, for its release not strongly clap on it a palm.
32. By means of the face key which is put on a bolt of a pulley of the crankshaft turn the engine so that the tag of the top dead point of a flywheel / a driving disk or a pulley of the crankshaft coincided with a distributive tag on the case of transmission or a cover of a distributive chain, and the N1 piston (closest to a distributive chain) appeared in the top point of a step of compression. If necessary address the Section Provision of the Top Dead Point (TDP) of the 1st Piston. Make sure also that tags of the top dead point on the ends of cam-shafts which asterisks are put on coincided with the corresponding tags of the top dead points on covers of bearings of cam-shafts.
33. Give and remove a natyazhitel of a distributive chain of a back part of a head of cylinders.
34. Holding permanently each cam-shaft by means of the wrench which is put on special lysk from the back party of the cam-shafts (turned to a flywheel / to a driving disk) give bolts and remove asterisks, having left their lying in guides of a distributive chain. Alternatively, remove asterisks after drawing identification tags of their situation. Pay attention that on B204/B234 engines the distributive chain is not removed from a crankshaft asterisk as under an asterisk there is a holder. On B202 engines fix a chain on an asterisk having tied up it in guide top.
35. Give and remove 2 bolts of fastening of a cover of a distributive chain to a head of cylinders. Bolts are screwed in in the lower part of a head.
36. Working as it should be, the return offered in fig., on progressing weaken 10 bolts of a head of cylinders half way for 1 time until there is possible an unscrewing of bolts manually.
37. Untwisting of bolts requires application of a replaceable head like "Torx" as heads have 6 external shliyets.
38. After removal of all bolts of a head of cylinders make sure that the distributive chain is located in such a way that the boot of a natyazhitel of a chain does not prevent removal of a head of cylinders. Remove a head of cylinders from the top part of the block of cylinders up and place it on a workbench. If necessary use the help of the assistant - a head of cylinders quite heavy. In case the head of cylinders stuck to the block of cylinders, try to shake it slightly for office it from laying - at all do not try to insert the screw-driver or any other tool between the block and a head as it can lead to damage of contact surfaces. The head of cylinders is established on the directing plugs therefore do not try to shift a head by its side percussion.
39. Remove laying from the top part of the block of cylinders, having paid attention to two guides of the plug. If the directing plugs are inserted freely, take them from the block of cylinders and postpone them together with the block of cylinders. Do not throw out laying, it can be useful for identification.
40. If the head of cylinders is removed for carrying out capital repairs, remove cam-shafts as it is described in the Section Removal, survey and installation of a cam-shaft (cam-shafts) and hydraulic pushers of valves.

Preparation for installation into place

 PERFORMANCE ORDER

1. Before installation of a head of cylinders into place the interfaced surfaces of a head and the block of cylinders have to be carefully cleared. For removal of traces of old laying and a deposit use a firm plastic or wooden scraper; also smooth out heads of pistons. During cleaning constantly keep in mind that soft aluminum alloy can be easily damaged. Remember that the deposit should not get to oil and water canals of the engine - especially it belongs to the engine lubrication system as, the scratched-out deposit which got to galleries of maslotok can block supply of oil to engine components. For the prevention of hit in them of a deposit and pollution close up all oil and water openings, and also openings under bolts in the block of cylinders by means of an adhesive tape. For the prevention of hit of a deposit in a gap between pistons and mirrors of cylinders fill gaps with dense lubricant. After cleaning of each piston remove lubricant traces with a deposit from a gap a small brush, then carefully wipe the remains with pure rags.
2. Examine the interfaced surfaces of the block and a head of cylinders regarding detection of agnails, deep scratches and other damages, superficial scratches can be carefully removed with a file, however at detection of deeper damages by the only alternative to replacement of the block or a head machine machining can be.
3. If there is a suspicion on a curvature of the interfaced surface of a head of cylinders, check its planeness by means of a template of the flat line or a metal ruler.
4. Check a condition of bolts of a head of cylinders, special attention paying them to a carving part, make it every time at removal of bolts. Wash out bolts in solvent and dry wipe them. examine bolts regarding detection of signs of wear or damage of a carving part or heads, if necessary replace bolts. Measure length of each bolt and compare it to length of new. In spite of the fact that SAAB does not pay special attention to need of replacement of bolts, authors of this manual strongly recommend replacement of all set of bolts when dismantling the engine working at the car with a considerable run.

Installation into place

 PERFORMANCE ORDER

1. If removed, establish into place cam-shafts (address the Section Removal, survey and installation of a cam-shaft (cam-shafts) and hydraulic pushers of valves).
2. Absolutely wipe the interfaced surfaces of a head of cylinders and the block of cylinders / case. Make sure that the directing plugs are installed on the places in the block of cylinders.
3. Establish new laying on the surface of the block of cylinders, having made sure that it is established correctly.
4. Make sure that each cam-shaft is in the top dead point - distributive tags are located on the forward ends of cam-shafts and have to coincide with tags on covers of bearings.
5. Make sure that the zero mark of the top dead point in a flywheel / a driving disk is still combined with a distributive tag on transmission.
6. Make sure that the distributive chain correctly sat down in chain guides, then carefully lower a head of cylinders on the block, having put on it the directing plugs.
7. Slightly grease carvings and the lower surfaces of heads of bolts of a head of cylinders. Insert bolts and tighten them by hand.
8. Working in a progressive order, according to fig. tighten bolts of a head of cylinders with effort of the first stage by means of a dynamometer key.
9. Working in the same order, tighten bolts of a head of cylinders with effort of the second stage.  
10. After tightening of all bolts of a head of cylinders with effort of the second stage besides, working in a former order, make a final dozatyagivaniye of bolts on a corner of the third stage of tightening, use for this purpose a face key with the extender.
11. For best accuracy carrying out this stage of tightening application of a goniometer is recommended. In case at your disposal there is no goniometer, then it is recommended by paint to apply landing tags on bolts of a head of cylinders and the case of a head of cylinders, when tightening these tags can be used as reference points for definition of an angle of tightening.
12. Insert and tighten 2 fixing bolts of a cover of a distributive chain to a head of cylinders.
13. Establish asterisks of cam-shafts, having at first dressed an asterisk of a final shaft, and then inlet. Do not tighten completely bolts at this stage. Make sure that the distributive chain correctly sat down on guides and on asterisks.
14. Establish a natyazhitel of a distributive chain (address the Section Removal, survey and installation to the place of a distributive chain and asterisks).
15. By means of the face key which is put on a crankshaft pulley bolt turn the engine on 2 whole revolutions clockwise, then make sure that tags of the top dead point are still correctly combined.
16. Completely tighten fixing bolts of asterisks of cam-shafts with the required effort, holding at the same time cam-shafts by means of the wrench which is put on special lysk.
17. Clear the interfaced surfaces of a head of cylinders and a cover of a head of cylinders. Establish the special cut rubber traffic jams on a head of cylinders, then apply a 4-mm pillow of silicone sealant on corners of a head and on rubber traffic jams.

18. Establish into place a cover of a head of cylinders and insert fixing bolts. Tighten bolts in a progressive order with the required effort, since bolts on the party of the head turned to a flywheel / to a driving disk and the central bolt from a distributive chain.
19. Install the inlet pipeline on a head of cylinders, having used new laying, and tighten adjusting bolts.
20. On models with the two-section inlet pipeline connect the pipeline to hoses, then establish into place a bracket of a tube of the measuring probe and connect a hose of a sapun of a case and a hose of the valve of the air conditioning system.
21. Where is available, insert and tighten the top bolts of persistent bars of the inlet pipeline from each party of the pipeline.
22. Establish a jet bar of a bracket of the right support of the engine on a head of cylinders and tighten bolts.
23. Establish into place a bracket of the regulator of fuel pressure complete with the sensor and tighten adjusting bolts.
24. Connect a hose of a heater to a thermostat casing and tighten a collar.
25. Connect wires to the sensor of measurement of temperature on a thermostat casing.
26. Where is available, establish into place, the distributor (see the Head Sistemy of start and a charge).
27. Where are available, connect high-voltage wires to candles.
28. Establish into place a viewing cover or the block of ignition of system of direct ignition on the center of a cover of a head of cylinders and tighten fixing screws.
29. Connect a hose of a sapun of a case and a hose of the vacuum regulator (where is available).
30. Connect the top hose of a radiator to a casing of the thermostat and tighten a collar.
31. Establish assembly of the electric fan of the cooling system to the place of behind radiator, tighten adjusting nuts. Connect wires.
32. On the models equipped with system of a turbo-supercharging establish into place a turbocompressor with the accompanying components (see the Head Toplivnaya and exhaust systems).
33. On the models which are not equipped with system of a turbo-supercharging establish into place to a final collector a reception exhaust pipe, having used new laying and tighten nuts.
34. Under the inlet pipeline connect into place the plug a lambda sensor. Fix wires in clips on a head of cylinders and fix by a trosikovy collar wires to a lifting earring of the engine.
35. Establish into place a bracket of a support of the compressor and the compressor of the air conditioning system, tighten adjusting bolts. Connect into place a connecting hose of the water pump, tighten a collar. Connect the plug, having made sure that wires are located in such a way that do not touch a compressor pulley.
36. Establish into place an auxiliary driving belt (see the Head Routine maintenance).
37. On early models establish a driving belt of the air conditioning system (see the Head Routine maintenance).
38. If it is required, install into place the tank of system of hydrostrengthening of a wheel, tighten adjusting screws. Fix hoses by trosikovy collars.
39. Establish into place on the right end of the engine a jet bar / support and tighten adjusting bolts.
40. On early models install into place a broad tank in the right part of a motive compartment and tighten a bolt. Connect hoses and fix them by collars. Connect the plug and fix wires by means of trosikovy collars.
41. Connect a negative wire of the battery.
42. Install the central panel under a radiator, and then a loker of an arch of a wheel and a molding of the right forward wheel.
43. Establish into place the right forward wheel and lower the car on the earth.
44. Fill the cooling system (see the Head Routine maintenance).
45. Start the engine, observing the precautions given in the Section Capital repairs of the engine - the general information.