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Home >> Saab >> 2011 >> 9-3X Standard >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Turbocharger System >> Repair Instructions >> Turbocharger, 4WD >> To fit

To fit

  1. Fit a new gasket.
  2. Apply 90 513 210 Universal paste to the studs of the turbo and exhaust manifold.
  3. Lift up and fit the turbo (B). Tightening torque 24 Nm (18 lbf ft).
    Fig 1: Lift Up And Fit Turbo
    G00468912Courtesy of SAAB-SCANIA OF AMERICA, INC.
  4. Fit new sealing washers, screw in the bolt for the turbo oil delivery pipe on the engine block (A) without tightening it.
  5. Connect the pipe (using a new O-ring, lightly coated with non-acidic Vaseline) to the connection hole in the engine block (C). Attach the turbo oil return pipe to the turbocharger using a new gasket (B). Tightening torque, oil return pipe to turbo 15 Nm (15 lbf ft).
    Fig 2: Attach Turbo Oil Return Pipe To Turbocharger Using New Gasket
    G00468913Courtesy of SAAB-SCANIA OF AMERICA, INC.
  6. Fit the coolant pipe between the turbo and the thermostat housing using new sealing washers (A). Tightening torque 20 Nm (15 lbf ft).
  7. Fit the stay (D) between the turbo and engine block. Fit the bolts by hand, start by tightening the bolts in the turbo. Tightening torque, bolt in turbo 32 Nm (24 lbf ft), Tightening torque, screw in block 48 Nm (35 lbf ft).
  8. Lower the car.
  9. Fill with plenty of engine oil in the hole for the oil delivery connection on the turbo while turning the turbine wheel.
  10. Fit the oil delivery pipe to the turbo and tighten the connection using new sealing washers. Grip the pipe so that it does not rotate. (A). Tightening torque 28 Nm (21 lbf ft).
    Fig 3: Fit Oil Delivery Pipe To Turbo And Tighten Connection Using New Sealing Washers
    G00468914Courtesy of SAAB-SCANIA OF AMERICA, INC.
  11. Position and fit the coolant pipe (B) to the turbo and tighten the pipe mounting on the cylinder head.
  12. Connect the hose to the bypass valve (C).
  13. Raise the car.
  14. Tighten the oil delivery pipe connection on the engine block. Tightening torque 28 Nm (21 lbf ft).
  15. Raise the catalytic converter (A) and attach the catalytic converter to the turbo connection.
    Fig 4: Raise Catalytic Converter And Attach Catalytic Converter To Turbo Connection
    G00468915Courtesy of SAAB-SCANIA OF AMERICA, INC.
  16. Fit the catalytic converter bolts to the engine block and catalytic converter (B).
  17. Lower the car.
  18. Coat the turbocharger studs with 90 513 210 Universal paste.
  19. Fit the catalytic converter with new nuts (A) so that it rests evenly against the turbo. Tightening torque 25 Nm (18 lbf ft).
    Fig 5: Fit Catalytic Converter With New Nuts So It Rests Evenly Against Turbo
    G00468916Courtesy of SAAB-SCANIA OF AMERICA, INC.
  20. Raise the car.
  21. Tighten the catalytic converter nuts and bolts a last time. Tightening torque, bolt 22 Nm (16 lbf ft) (A) Tightening torque, nut 25 Nm (18 lbf ft) (B).
    IMPORTANT: Make sure cables to the oxygen sensor are not twisted or damaged.
    Fig 6: Tightening Catalytic Converter Nuts And Bolts
    G00468917Courtesy of SAAB-SCANIA OF AMERICA, INC.
  22. Apply a thin coat of 90 513 210 Universal paste to the threads and fit the lower oxygen sensor. Tightening torque 40 Nm (30 lbf ft) (C).
    IMPORTANT: Make sure the cables are not exerted to chafing.
  23. Lift up the oxygen sensor cables.
  24. Fit Rear catalytic converter, 4WD.
  25. Fit the turbocharger pressure pipe (A). Tightening torque 25 Nm (18 lbf ft).
    Fig 7: Fit Turbocharger Pressure Pipe
    G00468918Courtesy of SAAB-SCANIA OF AMERICA, INC.
  26. Fit the Spoiler shield, front. See SPOILER SHIELD .
  27. Lower the car.
  28. Apply a thin coat of 90 513 210 Universal paste to the threads and fit the upper oxygen sensor (A). Fit the coolant reservoir. Tightening torque 40 Nm (30 lbf ft).
    Fig 8: Fit Upper Oxygen Sensor
    G00468919Courtesy of SAAB-SCANIA OF AMERICA, INC.
  29. Plug in and secure the oxygen sensor connectors (A).
    Fig 9: Plug In And Secure Oxygen Sensor Connectors
    G00468920Courtesy of SAAB-SCANIA OF AMERICA, INC.
  30. Fit the vacuum box (A) to the turbo.
    Fig 10: Fit Vacuum Box To Turbo
    G00468921Courtesy of SAAB-SCANIA OF AMERICA, INC.
  31. Position the control rod (B) to the control arm and fit the lock clip.
  32. Fit the pipe for the crankcase ventilation (C).
  33. Fit the solenoid valve hoses (D) to the turbo.
  34. Fit the turbocharger heat shield (A).
    IMPORTANT: To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, 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 the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.
    35. Fig 11: Installing Air Cleaner Case & Crankcase Ventilation Hose
    G00468922Courtesy of SAAB-SCANIA OF AMERICA, INC.
  35. Fit the air cleaner casing and connect the inlet hose to the turbo. Fit the filter and the air cleaner casing cover (B).
  36. Fit the crankcase ventilation hose to the camshaft cover and turbo as well as the hose from the solenoid valve (C).
  37. Fill with coolant to approx. 20 mm above the mark on the expansion tank.
  38. Check for coolant leaks.
  39. Check the oil and coolant level and top up as necessary.
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