900SAAB.com: Long Block Assembly

Engine Overhaul: Long Block Assembly

Returning to the assembled short block, now that the cylinder head has been overhauled, the long block can be assembled.

In my haste, I failed to capture most of the long block assembly, in photograph. Here's what I did (refer to Platonoff for his pictorial of the verbiage below): Beginning with the assembled short block, the timing cover can be installed. Verify that the flywheel is still at zero degrees, that the timing chain link is still in alignment and that the balance shaft hardware is installed properly. Clean the gasket surfaces with lacquer thinner, apply an even bead of Loctite 518 (anaerobic sealant) to the timing cover and sit it in place. Install the bolts and torque to 16 ft-lbs, working from center to outer edge, in stages. Lubricate the oil pump gears and driver and slide them into position. Fit a new o-ring to the front cover, tap it into place and install it's snap ring.

Clean the head gasket surfaces of both the block and head, with lacquer thinner, set the gasket and lay the head in place. Using new head bolts, thread all into position, finger tight, and then torque. Apply torque in three stages: 30 ft-lbs (40 n-m), 44 ft-lbs (60 n-m) and then an additional 90-degrees.

Verify that the timing marks are aligned on the flywheel and camshafts and fit the cam gears, intake side first. The marks on the gears should center themselves in the copper-colored timing chain links. Install the timing chain tensioner base and torque to 45 ft-lbs. Install the timing chain tensioner piston and torque to 16 ft-lbs. Rotate the engine several rotations and verify all timing marks still properly line up.

Clean the gasket surfaces for the oil-filter adapter, apply a bead of Loctite 518 and bolt in place; torque to 16 ft-lbs in a criss-cross fashion. Install new o-rings on the oil filter feed tube, lubricate the o-rings with Lubriplate 105 and slide the tube into position.

When all the above is complete, you should be here; note that the red oil seen on all the upper end components is camshaft assembly lube:

Fit a new gasket to the valve cover, lay it in place, install the bolts and torque to 11-ft lbs. A dab of Lubriplate 105 at each of the half-moon seals helps to keep them from falling out. Fit new spark plugs and torque to 20 ft-lbs (SAAB's prefer NGK's)

Flip the engine over, clean the gasket surfaces for the oil pan, apply a 1-mm thick bead of Loctite 518, and install (I chose to use new bolts). Torque to 16 ft-lbs, working logically from the inside out. Fit the crankshaft pulley and tighten to 130 ft-lbs. With this, the long block is assembled.

Refer to the "Engine Assembly" page for installation of the accessories and manifolding.