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From The Saab Tech Wiki
3. Lubricate and fit the main bearing caps in their correct positions, making sure that they are the right way round.
'''Tightening torque: 110 Nm (81.4 lbf ft).'''
4. Rotate the compression rings so that their gaps are displaced 120 degrees from each other and in line with the gudgeon pin bosses. Also make sure that the gaps in the three-part scraper ring are staggered and not in line with each other.
6. Lubricate and fit all big-end bearing caps in their original positions, making sure they are the right way round (number to number, groove in shell to groove in shell).
'''Tightening torque 48 Nm (35.5 lbf ft).'''
7. Apply a bead of Loctite flange sealant about 1 mm thick on the mating surface of the end plate and fit the end plate. Mind the gasket.
8. Fit the flywheel or driver disc but do not tighten it. Use thread locking compound on the bolts. Use flywheel locking segment (SAAB tool No. 83 94 868) and tighten the bolts.
[[file:Engine_Assy_05.gif|thumbnail|none|]]
'''Tightening torque 80 Nm (59.2 lbf ft) and 95 Nm (70.3 lbf ft).'''
9. Align the mark (0°) on the flywheel or driver disc with the mark on the end plate.
Warning: It is extremely important for the correct torque to be applied when fitting the chain tensioner.
'''Tightening torque: 10 Nm (7.4 lbf ft)'''
16. Inspect the balance-shaft chain and fit it and the idler sprocket so that the setting marks behind the balance-shaft sprocket and on the bearing housing are in line with each other. Tauten the chain between the crankshaft and balance shafts. Fit the idler sprocket last. Hold the bolt in place with your thumb, mesh the teeth of the sprocket with the chain and roll the sprocket along the chain into position.
19. Fit the timing cover.
'''Tightening torque: 22 Nm (16 lbf ft).'''
20. Fit the oil pump.
22. Make sure the mating surface on the oil sump is completely clean and apply an even coat of flange sealant to it. Invert the engine and fit the oil sump.
'''Tightening torque: 22 Nm (16 lbf ft).'''
23. Invert the engine in the stand, rotate the crankshaft through 45 degrees and fit the cylinder head, using a new gasket. Check that it is correctly seated in the locating sockets and that the chain is not trapped.
Tighten the cylinder head bolts in three stages:
'''Stage I 40 Nm (30 lbf ft)'''
'''Stage II 60 Nm (44 lbf ft)'''
'''Stage III Tighten a further 90 degrees (1/4 turn)'''
Tighten the bolts in the sequence shown.
24. Fit the two bolts between the timing cover and the cylinder head.
[[file:Engine_Assy_13.gif|thumbnail|none|]]
'''Tightening torque: 22 Nm (16 lbf ft).'''
25. Check that the camshafts are in alignment with their setting marks and turn the crankshaft back to the 0° mark.
28. Fit the chain tensioner, using a 27 mm socket.
'''Tightening torque: 63 Nm (47 lbf ft).'''
29. Fit the plug for the chain tensioner with push rod and spring.
'''Tightening torque: 22 Nm (16 lbf ft).'''
30. Check that the chain is correctly seated in the guides. Rotate the crankshaft two complete turns and check that the timing marks on the flywheel and camshafts are still in alignment.
31. Tighten the camshaft sprocket bolts.
'''Tightening torque: 63 Nm (47 lbf ft).'''
32. Clean the flanges of the camshaft cover, using benzine.
33. Apply soap to the open end of the camshaft cover and fit the cover, starting at the open end. Then tighten the bolt located furthest to the front at the timing end. Then continue all the way round, on both the inside and outside.
'''Tightening torque: 15 Nm (11 lbf ft).'''
34. Fit the spark plugs.
'''Tightening torque: 28 Nm (20.7 lbf ft).'''
35. Fit the ignition discharge module or ignition cables and the cover plate.
'''Tightening torque: 11 Nm (8 lbf ft).'''
36. Fit flywheel locking segment and tighten the crankshaft pulley.
[[file:Engine_Assy_16.gif|thumbnail|none|]]
'''Tightening torque 175 Nm (129.5 lbf ft).'''
Remove the locking segment.
37. Fit the exhaust manifold and fit a new gasket. If the exhaust manifold is of two-piece type, fit the outer section before the inner section. Check that the contact surfaces for the front pipe are level with each other. Note that spacer sleeves are fitted on the outer studs only.
[[file:Engine_Assy_17.gif|thumbnail|none|]]
'''Tightening torque: 25 Nm (18.5 lbf ft).'''
38. Fit the adapter housing with oil filter. Fit the crankshaft position sensor and the thermostat housing cover.
40. Fit the turbocharger.
[[file:Engine_Assy_18.gif|thumbnail|none|]]
'''Tightening torque: 22 Nm (16 lbf ft).'''
41. Connect the water and oil pipes (turbo).
45. Align the intake manifold gasket and fit the intake manifold.
[[file:Engine_Assy_19.gif|thumbnail|none|]]
'''Tightening torque: 22 Nm (16 lbf ft).'''
46. Refit the intake manifold steady bar and connect the crankcase breather nipple.
49. Fit the torque converter (automatic transmission) retaining bolts. Use thread locking compound on the bolts.
'''Turning torque 30 Nm (22 lbf ft).'''
50. Fit a lifting sling to the engine and lift it off the stand. Remove the fixture and lower the engine onto a trolley.
