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Home >> Saab >> 2001 >> 9-3 Base, 2D Hatchback, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Turbocharger System, Petrol >> Adjustment Replacement >> Turbo (B235R, B205L/R) >> To Fit

To Fit

IMPORTANT: It is essential that there is oil in the turbocharger bearing housing when the engine is started, especially after a new turbocharger has been fitted.

Fill the turbocharger oil inlet with oil from an oil can. Spin the compressor wheel a number of times to lubricate the bearings.

NOTE: Apply a thin coat of Molykote 1000, part no. 30 20 971, or equivalent to the studs. Make sure the sealing surfaces are clean before fitting. NOTE: new gaskets must be used.
  1. Fit a new gasket and carefully lift the turbocharger in place from below.
    Fig 1: Illustration For Steps 1-3-4
    G03504446Courtesy of SAAB-SCANIA OF AMERICA, INC.
  2. Lower the car to the floor.
  3. Fit the nuts securing the turbocharger to the exhaust manifold.

    Tightening torque: 24 N.m (18 lbf ft) 

  4. Fit the coolant pipe to the turbocharger. Use new gaskets.

    Tightening torque: 25 N.m (18 lbf ft) 

  5. Fit the coolant pipe with new banjo bolt and new gaskets to the cylinder head and to the pressure sensor mounting.

    Tightening torque: 25 N.m (18 lbf ft) 

    Fig 2: Illustration For Steps 5-6-7-8-9-10-11-13-14
    G03504447Courtesy of SAAB-SCANIA OF AMERICA, INC.
  6. Fit the oil pipe to the turbocharger with new sealing washers.

    Tightening torque: 20 N.m (15 lbf ft) 

  7. Fit the coolant pipe from the coolant pump to the turbo. Fit the wastegate, 2 bolts and 1 clip.
  8. Release the front exhaust pipe and move it to its correct location. Tighten the 2 top nuts on the joint to the turbocharger.

    Tightening torques: 

    Lock nuts: 24 N.m (18 lbf ft) 

    IMPORTANT: The nuts must be tightened alternately when fitting the front exhaust pipe to the turbocharger so that the flange is not deformed. The exhaust pipe flange must not be in contact with the turbocharger flange.
  9. Remove the plug in the turbocharger air intake. Check O-rings and apply acid-free Vaseline, part no. 30 06 665, or equivalent. Fit the turbocharger inlet pipe without tightening the V-clamp.
  10. Connect the hoses to the solenoid valve, noting the markings on the hoses and connections, and fit the solenoid valve on the engine lifting eye.
  11. Fit the engine lifting eye.
  12. Tighten the turbocharger's intake pipe, V-clamp.
  13. Connect the purge hose to the T-connection.
  14. Fit the crankcase ventilation pipe to the turbocharger inlet pipe with new sealing washers.

    Tightening torque: 24 N.m (18 lbf ft) 

  15. Fasten the crankcase ventilation pipe to the camshaft cover.
    Fig 3: Illustration For Steps 15-16-17-18-19
    G03504448Courtesy of SAAB-SCANIA OF AMERICA, INC.
  16. Fit the heat shield over the exhaust manifold.
  17. Fit the bypass pipe and valve, using a new O-ring lubricated with Vaseline, for the connection to the turbocharger inlet pipe.

    Tightening torque: 8 N.m (6 lbf ft) 

    IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressures, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 30 15 815 Cleaning agent to wipe clean inside the ends of the hoses. Clean also the connecting pieces. If hose clips are rusty or damaged, they must be replaced with new ones to maintain the correct clamping force.
  18. Fit the connecting hose between the mass air flow sensor and the turbocharger inlet pipe.
  19. Spray the solenoid valve connector with Kontakt 61, part no. 30 04 520, and plug it in.
  20. Raise the car.
  21. Remove the plug from the charge air cooler inlet pipe.
  22. Connect the charge air cooler inlet pipe to the turbocharger.

    Tightening torque: 8 N.m (6 lbf ft) 

    Fig 4: Illustration For Steps 22-23-24-25-26-27
    G03504449Courtesy of SAAB-SCANIA OF AMERICA, INC.
  23. Fit the oil pipe from the turbocharger to the oil filter adapter with new copper washers.

    Tightening torque: 25 N.m (18 lbf ft) 

    IMPORTANT: It is extremely important to make sure that the connection is straight when tightened. Tighten the connection by hand initially to avoid misalignment and/or cross-threading. If necessary, slightly loosen the oil pipe from the turbocharger.
  24. Fit the oil return pipe from the turbocharger to the cylinder block.
  25. Fit the coolant pipe on the turbocharger with new sealing washers.

    Tightening torque: 25 N.m (18 lbf ft) 

  26. Fit the bottom nut on the joint between the turbocharger and the front exhaust pipe.

    Tightening torques: 

    Lock nuts: 24 N.m (18 lbf ft) 

  27. Fit the turbocharger stay.

    Tightening torque: 24 N.m (18 lbf ft) 

  28. Check that the cooling system's drain plug is closed.

    Lower the car to the floor.

  29. Fill up with coolant. For the correct mixture, see COOLANT .

    Close the filler cap.

  30. Bleed the system as follows:
    NOTE: AC/ACC should be OFF.
    • Fill the system to the MAX level. Close the cap, start the engine and warm it up unladen at varying speeds until the radiator fan cuts in.
    • Switch off the engine and top up as necessary to the MAX level.
  31. Screw on the expansion tank cap.
  32. Raise the car to check for any oil or coolant leaks.
  33. Lower the car and top up the oil and/or coolant as necessary.
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