To fit

IMPORTANT: The oxygen sensor cable must not be of twisted type. Twisted cables exposed to vibration can break.
The oxygen sensor is sensitive to impacts and jolting and must be handled with care.

NOTE: Smear the studs and gaskets sparingly with Molycote 1000, part No. 30 20 971, or similar, to prevent them baking on.

NOTE: Spray the connector with Kontakt 61, part no. 30 04 520, before plugging in.

Fit a new gasket for the front exhaust manifold.

Fig 1: Illustration For Steps 2
Courtesy of SAAB-SCANIA OF AMERICA, INC.
Fit the front exhaust manifold with turbo.
Tightening torque: 20 Nm (15 lbf ft)

IMPORTANT: It is essential that there is oil in the turbo bearing housing when the engine is started. An extra check should be made when fitting a new turbo.

Fill the turbo oil inlet with oil from an oil can. Rotate the compressor wheel by hand many times to ensure that oil enters the bearings.
Raise the car.
Fit a new gasket between the front pipe and the rear exhaust manifold.

Fig 2: Illustration For Steps 5-7
Courtesy of SAAB-SCANIA OF AMERICA, INC.

NOTE: To facilitate fitting the front exhaust system, sling a strap, 83 95 212 STRAP , around the front pipe.
Fit the front exhaust pipe to the rear exhaust manifold.
Tightening torque: 40 Nm (28 lbf ft) .
Fit the pipe joint between the front and rear exhaust systems.
Tightening torque: 22 Nm (16 lbf ft)
Use a cable tie to secure the oxygen sensor cable. Carefully run the cable back to the oxygen sensor connector.
Fit the oil pipe to the oil filter adapter. Fit new gaskets and sealing washers.

Fig 3: Illustration For Steps 8-10
Courtesy of SAAB-SCANIA OF AMERICA, INC.

Tightening torque: 20 Nm (15 lbf ft)
Fit the turbo mounting bracket.
Tightening torque: 24 Nm (18 lbf ft)
Fit the turbo's oil return pipe.
Tightening torques:

M6 bolt: 14 Nm (10 lbf ft)
Lower the car to the floor.
Plug in the oxygen sensor connector.

Fig 4: Illustration For Steps 12-16
Courtesy of SAAB-SCANIA OF AMERICA, INC.
Bolt the front exhaust pipe to the turbo.
Tightening torque: 24 Nm (18 lbf ft)
Fit the dipstick tube.
Fit the turbo coolant pipe. Use new sealing washers.
Tightening torques:

Banjo screw, turbo: 25 Nm (18 lbf ft)

Retaining screw, cylinder head 14 Nm (10 lbf ft)
Remove the hose pinch-off pliers from the inlet and coolant return hose to the turbo.
Fit the radiator fan. See RADIATOR FAN, V6 .

Fig 5: Illustration For Steps 17
Courtesy of SAAB-SCANIA OF AMERICA, INC.

Tightening torque: 8 Nm (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 93 160 907 Motip Dupli 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.
Fit the hose between the turbo and the charge air cooler.

Fig 6: Illustration For Steps 18-20, 22
Courtesy of SAAB-SCANIA OF AMERICA, INC.

Tightening torque: 8 Nm (6 lbf ft)
Fit the turbo's intake pipe.
Tightening torques:

V-clamp: 3 Nm (2 lbf ft)

U-clamp, cylinder head 14 Nm (10.3 lbf ft)
Fit the crankcase breather pipe between the cylinder head and turbo intake pipe. Change the sealing washers. Connect the hose from the oil trap.
Tightening torques:

Banjo screw, intake pipe: 24 Nm (18 lbf ft)
Remove the plug from the charge air cooler outlet.
Fit the front exhaust manifold's heat shield.
Tightening torques:

Locknut 24 Nm (18 lbf ft)

Stud: 22 Nm (16 lbf ft)
Fit the turbo pressure hose together with the turbo bypass pipe and valve.

Fig 7: Illustration For Steps 23, 26
Courtesy of SAAB-SCANIA OF AMERICA, INC.

Tightening torque: 8 Nm (6 lbf ft)
Start the engine and check for oil and coolant leakage.
Switch off the engine and check oil and coolant levels. Top up as necessary.
Fit the upper engine cover.