| | ENGINE OIL IN THE COOLANT ON SAAB 2.5 & 3.0L ENGINES | Engine Oil in Coolant For
1995-2000 Saab 2.5 & 3.0L Engines
The AERA Technical Committee offers the following information regarding engine oil in the coolant on 1995-2000 Saab 2.5 & 3.0L engines. This addition of oil to the cooling system often causes engine overheating as it reduces the effectiveness of the system. Excessive crankcase engine oil level reduction may also cause engine damage. Vehicle owners adding oil or experiencing higher than normal coolant temperatures should investigate to reasons why.
The cause of engine oil entering the coolant in most instances has been a faulty engine oil cooler, located underneath the intake manifold. In some cases, vehicle owners did not even realize the engine used an oil cooler.
Replacement oil cooler can be purchased from the dealer under Part #4770988. The washers used to seal the plumbing to and from the oil cooler should also be replace with Part #4620324. Those washers are steel with a rubber inner seal; previous washers were a copper design.
The AERA Technical Committee | | ABNORMAL COMBUSTION | Abnormal Combustion On
Saab 2.0L B201 & B202 Engines
AERA members have reported engine damage from abnormal combustion in Saab automobiles equipped with the 2.0L B201 and B202 engines. The resulting damage has ranged from premature head gasket failure to piston damage shortly after remanufacture of the engine.
After machining the deck surface of the cylinder head, it is important to chamfer the combustion chamber edges. If left unchamfered, the sharp edges may act as a heat sink during the normal combustion process and start to glow. This glowing or hot spot may increase the possibility of abnormal combustion, in
particular premature ignition of the air/fuel mixture, leading to a component failure.
Removing burrs, nicks and sharp edges from the combustion chamber
will result in longer engine service.
The AERA Technical Committee | | REVISED HEAD GSKT & PROCEDURE ON 900 & 9000 SERIES | Revised Cylinder Head Gasket & Retorque Procedure
on 1981-88 Saab 900 & 9000 Series Engines
Saab-Scania of America has released a new cylinder head gasket and installation procedure for all 1981-88 Saab 900 & 1986-88 Saab 9000 series engines. This new procedure applies to 8 and 16 valve cylinder head engines produced after 1981.
The revised cylinder head gasket no longer requires retorquing of the cylinder head bolts after the engine has been started and warmed up for the first time. Furthermore, retorquing of the cylinder head bolts after the first 1000 miles of service has also been eliminated.
Use the following chart to determine if the cylinder head needs to be retorqued:
Engine Series Part Number * Procedure
1981-88 900 Series 8-Valve 75-85-037 do not retorque
1981-88 900 Series 16-Valve 75-61-301 do not retorque
1986-88 9000 Series 16-Valve 75-61-301 do not retorque
before 1981 900 Series 8-Valve 75-05-217 retorque
before 1981 900 Series 16-Valve 75-16-529 retorque
* Saab-Scania cylinder head gasket part number
Engines manufactured before 1981, using head gasket part #75-05-217 or #75-16-529, must be retorqued as before.
The AERA Technical Committee | | CYLINDER HEAD TORQUE SPECIFICATION | Cylinder Head Torque Specification For 1991-93 Saab 2.1L VIN E Engines
The AERA Technical Committee offers the following information concerning cylinder head torque specifications for 1991-93 Saab 2.1L VIN E engines. Information contained within the Saab head gasket sets shows inaccurate torque values.
The torque procedure cards included in the B212 cylinder head gasket kit, Part # 93-21-597 and B212 cylinder head gasket, Part # 87-87-111 should be ignored if it does not match the steps listed below. To correctly torque the cylinder head to the block, Saab offers the following information for the cylinder head torque. Refer to Figure 1 below for the tightening sequence.
Step 1: Torque all bolts in sequence to 44 ft/lbs. (60 Nm).
Step 2: Torque all bolts in sequence to 59 ft/lbs. (80 Nm).
Step 3: Rotate all bolts in sequence an additional 90°.
AERA is currently not aware of an aftermarket supplier for this head gasket.
The AERA Technical Committee | | OIL CONSUMPTION | Oil Consumption On
Saab 2.0L 16 Valve DOHC Engines
The AERA Technical Committee has become aware of another possible cause for abnormally high oil consumption on Saab 900 DOHC application. Usually, oil consumption can be traced to piston ring, valve guide and/or valve seal wear. An additional cause may be a reversed one way check valve for the crankcase ventilation system on turbo charged engines.
It is also possible for oil to enter the PCV system because of a slight distortion of the camshaft bearing cap to bolt mating surfaces. At operating temperature, it is possible for oil to spray from underneath the bolt into the PCV system inlet. Oil is then drawn into the PCV system and engine air intake system.
Although engine oil passes only through one of the camshaft bearing cap bolts, a sealing washer, Part #91-14-885, should be installed under all bolts to maintain equal pressure on the bearing cap. Each bolt should be torqued to 11 lbs.ft. during assembly.
The AERA Technical Committee | | EXCESSIVE OIL CONSUMPTION | Excessive Oil Consumption On
1986-94 Saab 2.0L DOHC Engines
AERA members have reported excessive oil consumption on 1986-94 Saab
2.0L DOHC engines. The source of this oil consumption has been traced to the engine's positive crankcase ventilation system (PCV). Apparently the original camshaft cover allows excessive amounts of oil to enter into the induction system.
A modification was made to the camshaft cover Part #8788135 during the 1994 production year to reduce the amount of oil mist reaching the PCV system. The part number for the cover, however, did not change. The identification of the revised cover, requires removing it from the head and inspecting it for the additional tube shown in the illustration below.
The AERA Technical Committee | | FLYWHEEL SPECIFICATIONS | Flywheel Specifications
The AERA Technical Committee suggests referring to the following
flywheel specification chart when re-surfacing flywheels.
Type of
Manufacturer Flywheel Specs Comments
_________________________________________________________________
Allis Chalmers Cup 1.437 D17,D19,190XT
Tractors
AMC Cup .125 2.5L (GM engine)
Alpha Romeo Cup .878
BMW Step .013-.015 320i
Caterpillar Cup 2.937 +/-.005 #9N2646 Cast Number
Chrysler/Mitsubishi Cup .600-.605 2.0L DOHC, #9801
Cast Number
Chrysler Cup 1.00 3.7L engine
Cummins Cup 2.925
Cummins Cup 2.937 2 piece clutch
DDC Flat 1.582 8.2L, Minimum
thickness
Fiat, Spider Step .018 1600 engine
Ford, Falcon Cup 1.00 6 Cylinder engines
Ford, Courier Cup .285
Ford Cup .310
Ford, Ranger Cup .003 V6 Cylinder engines
Ford Truck Cup 1.500 534 CID Truck
Ford Truck Flat .965 New Thickness
Ford Cup 1.140-1.160 Model A
GM, OHC Brazilian Flat .750 New Thickness
GM Cup .125 2.5L, & Vega
GM, Buick Cup .125 V6 Engines
GM, Spirit Cup .195
GM, Sprint Cup .1969 Chevrolet/Suzuki
Honda Cup .030 Small cup
Honda Cup .030 #K4SC16AG Cast
Number
Honda Cup .100-.104
Honda Cup .785 Long alignment pins
Honda Cup .900 Short alignment pins
Honda, Accord Cup .615 1986
Hyundai, Excel Flat Mitsubishi engine
Isuzu Cup .010-.017 Trooper, Pup
Isuzu, Diesel Cup 1.691-1.695 6BD1, 6BDT engines
Mack Midliner Flat 1.260 Min. Measure from
crank/mount to disc
Mazda Cup .062 RX2 Rotary engines
Mazda, RX7 Cup .310
Mazda, 2.2L, 1987 Cup .785 Hyd. Clutch,
Segmented wheel
Mazda, 2.0L Cup .805 Hyd. Clutch, .020
max/removal
Mercedes, 240D Cup .885
Navistar, 404/446 Flat .750 New thickness
Navistar, 6.9L Flat 1.410 Minimum thickness
Navistar 9.0L Flat 1.585 Minimum thickness
Nissan Flat With groove
Nissan, Maxima Flat With groove, #425
Cast Number
Nissan, (Datsun) Step .003-.005 No groove
Nissan,
(Sentra,Stanza) Step .006-.010 1.6L & 2.0L engines
Nissan, B2000 Cup .807 new Max stock removal
.020
Nissan,(Datsun)240Z Step .010 With groove
Renault Step .021 1.4L Alliance
Saab, 96 Cup .656
Subaru Cup .830 Justy
Subaru Cup .875
Subaru Cup .905 4X4 Brat
Suzuki Cup .070
Suzuki Cup .197 1.0L, 3 cyl
Toyota Step .018-.022 Large alignment pins
Toyota, 22RE Step .018-.022 #627 Cast Number
Toyota Cup .055 Small cup
Toyota Cup .965-.970 Tercel, large cup
Toyota Step .040 Tercel, step
Toyota Step .020 Land Cruiser
VW Cup .945 Air cooled, 6 Volt
VW Cup .913-.918 210MM Clutch
VW Cup .830-.835 Rabbit/Golf/Scirocco
Vanagon Cup .982 Water/Air cooled bus
engine
VW Cup .830 Air cooled engine
VW Cup .885 Air cooled engine
Specifications listed for Step type flywheels refer to the
height of the wear surface above the pressure plate mounting
surface. Specifications for Cup type flywheels refer to the
height of the pressure plate mounting surface above the wear
surface.
The AERA Technical Committee
June 1992 - TB 677R
(Please destroy TB 677)
##END## | | IMPORT ENGINE THRUST BEARING PROBLEMS | Import Engine Bearing Problems
The addition of many aftermarket main bearing sets for import automotive engine applications has caused a frequent complaint that the thrust bearings cannot be installed.
The reason is that in most import engine applications, the flanged bearing length is increased with the undersize of the bearing. This means those grinding the crankshaft must grind the thrust face of the crank to accommodate the increased bearing length and secure proper clearance of the crankshaft end thrust.
A typical example may be found with the 1.5L and 1.7L Saab engine utilizing a common aftermarket main bearing set:
The .010 undersize is .004 oversize length.
The .020 and .030 undersize has a .010 oversize length and
the .040 undersize has a .020 oversize length.
The AERA Technical Committee | | CRANKSHAFT SPECIFICATIONS FOR 1997-2001 CATERA ENGINE | Crankshaft Specifications For
1997-2001 GM 3.0L VIN R Engines
The AERA Technical Committee offers the following information on crankshaft specifications for 1997-2001 GM 3.0L VIN R engines. It has been reported that various forms of published service information supplied incorrect rod journal dimensions.
The correct dimension for the connecting rod journal is 2.1248-2.1256 (53.971-57.990 MM). Casting numbers reported for this engine?s crankshaft include 90499243 and 1255069.
Location Dimension Oil Clearance
Rod Journal 2.1248-2.1256 (53.971-57.990 MM) .0005-.0024 (.013-.061 MM)
Main Journal 2.6763-2.6770 (67.978-67.996 MM) .0006-.0017 (.015-.043 MM)
Stroke 3.3464 (84.999 MM)
NOTE: The main bearing halves in bearing caps 2 and 3 have no oil-ways.
Undersize bearings available for the crankshaft include .010 (.25 mm) & .020 (.50 mm) for both rod and main locations. These bearings are currently available from the vehicle manufacturers network or GM.
Note: This engine is also used in various Saab and Opel vehicles beginning in 1995.
The AERA Technical Committee |
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