Saab 9000 User manual

Saab 9000
SERVICEMANUAL
2: I Basicengine B234
News supplement
M 1990-
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Saab9000
SERVICE
MANUAL
2:1 Basic engine B234
News supplement
M 1990-
022 Technical data
102 Special tools
200 Technical description
201 Powertrain
210 Engine
211 Cylinder head
Pistons, connecting rods and cylinder
212 bores
214 Valve gear
215 Timing chain
216 Crankshaft assembly
220 Lubricating system
232 Induction system
234 Fuel pump and fuel tank
LH 2.4.1 fuel-injection system,
240 diagnostics
254 Exhaust emission control
321 Alternator
331 Starter motor
340 Ignition system
400 Transmission
299 Alphabetical section guide
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Units
The basic and derived units used throughout the Service Manual
are in accordance with the SI system.
For users not familiar with the SI units, some non-Continental units
are given in brackets after the respective SI unit.
The following symbols and abbreviations are used:
SI unit
mm
kg
N
Nm
bar
I (liter)
ºC
Conversionfactors
1in=25.4mm
1Ibf = 4.45N
1 lbfft = 1.36 Nm
1 psi= 0.07 bar
11iq qt = 0. 95 I
1 USliq qt= 0.83 UKqt
°F = °Cx 9/5
+
32
© Saab-Scania AB 1990
Equivalentunit and symbol
inch (in)
pound (lb)
pound-force (lbf)
pound-force foot (lbfft)
pound-force per square inch (lbf/in
2)
(Also abbreviated: psi)
US liquid quart (liq qt)
(Also abbreviated: qts)
USgallon (USgal)
ºF
1 mm= 0.039 in
1N=0.23Ibf
1Nm=0.741bfft
1 bar= 14.5 lbf/in
2
11 = 1.05 Iiq qt
1 USgal
=
0.83 UKgal
°C = (°F- 32) x 5/9
Production: Technical Publications. Saab-Scania. Trollhattan , Sweden
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Block and cylinder head
Pistons
Crankshaft
Valve gear
Camshafts
Balance shafts
General data
Engine type
Cylinder bore
Stroke
Swept volume
Firing border
Approximate weight
Technical data 022-1
Technicaldata
. 022- 2
022- 3
022- 6
022-
7
022- 9
. 022-10
mm(in)
mm(in)
kg (lb)
Tightening torques
Belt tension
Lubricating system
Engine performancegraph
Engine number . . . . .
Transverse 4-cyl inder, 4-stroke
16-va Iveengine with twin overhead
camshafts and twin balance shafts.
90 (3.54)
90 (3.54)
2290 (139.
7)
1-3-4-2
160 (350)
Saab 9000
022-11
022-12
022-13
022-14
022-15
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022-2 Technical data
Performance, compression ratio, fuel
octane number, etc.
Engine Model
variant year
B234i 1990
* AKI = (MON
+ RON)/2
Octane Suitable
requirement, for
RON(AKI)* unleaded
fuel
Min: 91 (87) Yes
Recommended:
95 (91)
Premium= 91AKI
Regular= 87 AKI
Blockand cylinderhead
Cylinder head
Cylinder bores
Standard (A) mm (in)
Standard (B) mm(in)
First oversize mm(in)
Second oversize mm (in)
Cylinder head
Height of new cylinder head mm(in)
Minimum after regrinding mm (in)
Compression DIN Torque.
ratio rating, Nm (lbfft).
kW (bhp) at at 3,800 rpm
5,500 rpm
10.1 110 (150) 212 (156)
90.000- 90.012 (3.5433- 3.5438)
90.003- 90.020 (3.5434- 3.5441)
90.500- 90.512 (3.5630-3.5635)
91.000- 91.012 (3.5827 - 3.5831)
140.5 ± 0.1 (5.53 ± 0.004)
140.1 ± 0.1 (5.52 ± 0.004)
Saab 9000
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Tightening torques
The specified torques apply to lubricated bolts
and washers and when a new head gasket is fit-
ted.
Stage I Nm (lbf ft)
Stage II Nm (lbfft)
Stage Ill
Tightening sequence
Pistons
Piston speed at 5,000 rpm
Different makes of piston must not
be fitted in the same engine
Piston dimensions
Engine Model year
8234i 1990
mis
mm(in)
Technical data 022-3
60 (44)
80 (59)
Tighten a further quarter-turn (90°)
-
R
0
15
Radius (R) 0 A
257 (10.12) 75 (2.95) 3.05 (0.120)
Saab9000
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022-4 Technical data
Pistondiameter
This is measured at right angles to the piston
boss, 13 mm (0.52 in) from the bottom of the
skirt.
Classificationof pistonsand cylinder
bores
The piston classification code is stamped on the
piston crown. The codes for servicing are:
AB
B
C
The cylinder classification code is stamped on
the block adjacent to each cylinder.
Cylinders are either class A or class B, both of
which may occur in the same block.
Pistonsizes
Standard A (not spare part) mm (in)
Standard AB mm (in)
Standard B mm (in)
Standard C mm (in)
First oversize (0.5 mm) mm (in)
Second oversize (1.0 mm) mm (in)
Piston clearance (nominal) mm (in)
Classlflcatlon,
Piston/cylinder
A/A mmx10-
3
AB/A mmx10-
3
AB/B mm x 10-
3
8/8
mmx 10-
3
0
89.971-89.980 (3.5422-3.5425)
89.980- 89.989 (3.5425-3.5429)
89.989-89.997 (3.5429-3.5432)
89.997 -90.013 (3.5432-3.5438)
90.4 72- 90.488 (3.5619-3.5625)
90.972-90.988 (3.5816-3.5822)
0.007 - 0.037 (0.0003- 0.0015)
Clearance
20-41
11-32
14-40
6-31
13mm
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Piston rings
Width
(thickness)
Side
clearance in groove
Working gap in new
cylinder
mm (in)
mm(in)
mm (in)
* Segment width (thickness): 0.51 mm (0.020)
** Applies to segment
Gudgeon pins
Diameter
Fit
Connecting rods
Diameter of big-end
Diameter of small-end bush
(bush fitted)
Maximum permissible weight
variation per set
Length
mm(in)
mm(in)
mm(in)
mm (in)
g (oz)
mm (in)
Technical data 022-5
Top
compression
ring
Second
compression
ring
Oil-scraper
ring
1.728-1.740 1.98-1.996 2.934-3.052*
(0.0680-0.0685) 0.078- 0.0779) (0.1155-0.1202)
0.040-0.072 0.040-0.072
(0.0016-0.0028) (0.0016-0.0028)
0.3-0.5 0.30- 0.45 0.38-1.40**
(0.0118-0.0197) 0.0118 - 0.0177) 0.0149- 0.0551)
23.996- 24.000 (0.944 7 -0.9449)
0.001-0.010 (0.0001-0.0004)
(sliding fit under gentle thumb pressure)
56.000- 56.019 (2.204 7 - 2.2055)
24.005 - 24.010 (0.9451-0.9453)
6 (0.21)
14 7 (5. 79)
Saab 9000
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022-6 Technical data
Crankshaft
Alignment- max variation
in straightness mm (in)
Endfloat mm (in)
Maximum journal
out-of-round mm (in)
Maximum taper of journals mm (in)
Radius main journalfillet mm (in)
Main bearing clearance mm(in)
Length mm (in)
Colour markings of main-bearing and
big-end bearing shells
Standard
First undersize
Second undersize
Crankpin diameter
Standard mm (in)
First undersize mm (in)
Second undersize mm (in)
Third undersize mm (in)
Fourth undersize mm (in)
Big-end bearing clearance mm (in)
Main Journaldiameter
Standard mm (in)
First undersize mm (in)
Second undersize mm (in)
Third undersize mm (in)
Fourth undersize mm (in)
0.10 (0.004)
0.06- 0.31 (0.002- 0.012)
0.05- (0.002)
0.05- (0.002)
1.65-1.85 (0.065-0.073)
0.020-0.062 (0.0008- 0.0024)
543 (21.4)
Thin Thick
Red Blue
Yellow Green
White Brown
51.981- 52.000 (2.0465-2.0472)
51 .731- 51. 750 (2.0366-2 .0374)
51.481-51.500 (2.0268-2.0276)
51.237 - 51.250 (2.0172-2.0177)
50.987 - 51.000 (2.007 4-2.0079)
0.026- 0.062 (0.0010- 0.0024)
57 .981-58 .000 (2.2827 -2.2835)
57. 731- 57. 750 (2.2729- 2.2736)
57 .481-57 .500 (2.2630-2.2638)
57 .237 -57.250 (2.2534- 2.2539)
56.987 -57.000 (2.2436-2 .2441)
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Technical data 022- 7
Valvegear
29mm
(1.15 in)
980 mm
(0.2738--0 .2748 in)
Exhaust valve
mm
(0.2740--0.2746
in)
32mm
(1.26
in)
Inlet valve
Caution
The exhaust valves are stellited and should
therefore not be machined. Grinding using valve-
grinding (lapping) paste is the only recommen-
ded method.
Valveguides
Length
Outside diameter
Bore for vaIve guides in
cylinder head
Maximum clearance between
valve stem and valve guide
mm(in)
mm (in)
mm(in)
mm(in)
45.0 (1. 77)
12.039-12.050 (0.4740-0.4744)
12.000-12.018 (0.4 724-0.4731)
0.5 (0.02) Measured on valve head
raised 3 mm (0.12 in) above seat
Saab 9000
l5
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022-8 Technical data
Valvesprings
Length when fitted
Free length
Length when subjected to
compressive
forcm;of595- 645 N (131-141 lbf)
Camfollowers
Diameter
Height
Bore for cam foll ·owers in cylinder
head (camshaft bearing assembly)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
min
19 .6
mm
(0.77
in)
B
min
24
mm
(0.95
in)
C
min mm
(1.12 in)
37.0 (1.46)
45
±
1.5 (1. 77
±
0 .05)
28 .4 (1.12)
32.959- 32.975 (1 .2976-1.2982)
26.0 (1.024)
33.000-33.016 (1.2992-1.2998)
Saab
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Technical data 022-9
Camshafts
Number of bearings 5
Bearing diameter mm (in) 28.922-28.935 (1.1387 -1.1392)
Endfloat mm (in) 0.08- 0.35 (0.003- 0.014)
Cam 11ftat zerovalveclearance
Enginevariant Modelyear Inletvalves Exhaustvalves
8234i 1990 mm (in) 8.65 (0.3406) 8.65 (0.3406)
Valvetiming
(at design clearance: 0.35 mm/0.014 in, inlet; 0.55 mm/0.022 in, exhaust)
Inletvalves Exhaustvalves
Open Close Open Close
BTDC ABDC BBDC ATDC
B234i 1990 13° 53° 50° 16°
9000
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022-10 Technical data
Balanceshafts
Length mm(in) 295. 7 ± 0.5 (11.642 ± 0.020)
Diameter of balance-shaft
journal (larger, outer) mm (in) 39.9 ± 0.08 (1.571 ± 0.003)
Diameter of balance-shaft
bearing (larger, outer) mm(in) 39.988-40.043 (1.574-1.577)
Bearing clearance (larger,
outer) mm (in) 0.08-0.151 (0.003-0.006)
Maximum permissible bearing
clearance when bedded in mm (in) 0.18 (0.007)
Diameter of balance-shaft
journal (smaller, inner) mm (in) 19.94 7 -19.960 (0. 785-0. 786)
Diameter of balance-shaft
bearing (smaller, inner) mm (in) 20.000-20.021 (0. 787 -0. 788)
Bearing clearance (smaller,
inner) mm (in) 0.040-0.07 4 (0.0016-0.0029)
Saab 9000
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Technical data 022-11
Tighteningtorques
Torque, Nm Torque, lbfft Bolt
dimension
Main bearings 20 (+tightening 15 (+ tightening M12
through a further through a further
quarter-turn/90°) quarter-tu rn/90°)
Big-end bearings 20 (+tightening 15 (+tightening M10
through a further through a further
quarter-turn/90°) quarter-turn/90°)
Camshaft bearing caps 15 11 MB
Camshaft cover 15 11 MB
Crankshaft pulley 190 140 M16
Flywheel 60 44 M10
Oil pump 8
6
M6
Timing chain tensioner 63 47 M22
Camshaft sprocket 65 48 M10
Inlet manifold 22 16 MB
Thermostat housing 22 16 MB
Throttle housing 22 16 MB
Exhaust manifold 18 13 MB
Timing cover 20 15 MB
Knock detector 20 15
Balance-shaft
chain tensioner 12 9 M6
Balance-shaft
bearing holder 12 9 M6
BaIanee-shaft
chain guides 12 9 M6
Balance-shaft sprokets 63 47 M10
Balance-shaft idler-wheel
sprocket 22 17 MB
Tighteningtorquesfor other bolts
Bolt dimension Torque, Nm Torque, lbf ft
M5 5 3.7
M6 10 7.4
MB 20 15
M10 40 30
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022-12 Technical data
Drive-belttension
Minimum value on checking N (lbf) 170 (38)
Saab 9000
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Lubricatingsystem
Oil capacity including that
in oil filter
Volume between MAXand MIN
marks on dipstick
Grade of oil
Viscosity
Drain plug tightening torque
Note
Iitres (Iiq qt)
I
itres
(I
iq qt)
Nm (lbfft)
The recommended grades of oil contain all ne-
cessary additives and the use of additional addi-
tives should therefore be avoided.
Technicaldata 022-13
4.3 (4.5)
1.0 (1.05)
ToAPIService SF/CC,SF/CDor SG
SAE10W-30 or 10W-40. Where these
are unavailable, 15W-40 maybe used.
In climates with temperatures
regularlybelow-20°C (-4°F) use 5W-30
25 (19)
Saab 9000
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022-14 Technical data
011
pressures
Oil pump reducing valve
opens at:
Warning light comes on
at:
Oil pressure at 2,000 rpm,
engine temp. of 80°C (170°F)
and 10W-30 oil
Endfloat between pump rotor
and housing
Engine oil cooler thermostat
opens at:
bar (psi) 3.5 (50)
bar (psi) 0.3- 0.5 (4.4- 7.2)
bar (psi) 2. 7 (38.9) minimum
mm (in) 0.03-0.08 (0.0012-0.0031)
ºC
ºF 80 (176)
Engineperformancegraph
I
I I
I
I
I
I I
I
I
Power
I
I
I
70020
I
5500
rpm
I I
hp
I
I
110
•
I
•
•
•
110
100
I
•
•
•
•
•
•
,.
IO
•
•
·•
• ·
•
• -
I
I
-.
·• ,
•
0-norm
212 Nm rpm
6
J
I
00 10
:
10
I
I
:
50
,o
I
0
0
000 2000 3000
7000
82341
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Engineno.
Example:
Pos. 1 Enginetype
B = Petrol engine
Pos. 2 &3 Swept volume--------------·
23
=
2,290 dm3
Pos.4 Cyllnderhead
4
=
Cylinder head with twin camshafts and
twin balance shafts
Pos. 5 Version
I= Fuel injection
Technical data 022-15
M
oo
L
000001
Pos. 6 Exhaustemission controlspecification
4
=
Saab 9000to Swedish RegulationA12 and
USfederal register FTP-75
Pos. 7 Transmission
A= Automatic transmission
M = Manual gearbox
Pos. 8 &
9 Variant
Variant codes:
00 = Basic model (i.e. no variant)
01 = Engine adapted to meet future
ELCOrequirements
02 = Specially equipped for improved cold starting
05 = Special inlet valves
06 = Special inlet valves meeting future
ELCOrequirements
Pos. 10 Model-yearcode as perFMVSS115
L= 1990
Pos. 11- 16 Serlal number
Saab 9000
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Special tools 102-1
Specialtools
83 93 746 Protective collar for tappet guides
(set of 16)
83 93 761 KO-Tools 308 valve spring compres-
sor for use with special anvil
8393 779
83 93 779 Special anvil for use with valve
spring compressor 83 93 761
83 93 753 Valve-clearance measuring tool
7
83 94 454 Engine bracket for use with floor
stand
83 93 787 Valve stand
83 93 795 Cylinder head bracket for use with
floor stand 78 614 79
Saab 9000
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102-2 Special tools
83 93 993 Flywheel locking attachment
\
I.
83 93 803 Tool for fitting valve guide seal
83 94140 Adaptor for checking expansion tank
pressure cap
83 90 494 Tool for fitting/removal of valve
guide
3
!J
4
5
6
83 93 811 Pull rod for removal/fitting of the
(2) valve guide
83 93 829 Sleeve for removal of valve guide
(3)
83 93 837 Depth gauge for fitting of valve guide
(4)
83 93 845 Nut for removal/fitting of valve guide
(5)
83 90 379 Mandrel
(6) The above tools (2 - 6) are for use
with guide tool 83 90 494
Saab9000
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