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Official instructions from the Saab WIS (Workshop Information System) for removing and fitting the oil
sump on a Saab 9-5 B235 engine.

To remove

1. Remove the upper engine cover.

2. Remove the dipstick and place a rag in the tube. Remove the oxygen sensor cables.

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3. Remove the turbo bypass pipe and the heat shield over the exhaust manifold.
4. Undo the two upper nuts on the exhaust pipe.

5. Raise the car and remove the lower engine cover.

6. Remove the remaining mountings and remove the front exhaust pipe.
7. Remove the cover plate from the gearbox.
8. Drain the engine oil.

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9. Disconnect the crankcase breather hose from the oil sump.
10. Remove the bolts on the oil sump and lower the sump.

To fit

1. If the sump is changed, transfer the splash guard and pipe to the new sump. Use
new O-rings.

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2. Ensure the oil sump contains no dirt or contaminants. Clean the sealing surfaces on
the engine and sump with a gasket scraper and benzene.
3. Apply an even, 2 mm thick bead of flange sealant, part no. 93 21 795, to the sealing
surfaces of the oil sump.
4. Check that the pipe to the oil adapter is securely in place and that it positioned
correctly in the oil sump. Change the O-rings if necessary.
5. Lift up and position the oil sump. Thread all the bolts.

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6. Tighten the oil sump bolts. Tightening torque 22 Nm (16 lbf ft)
7. Fit the crankcase ventilation hose.
8. Fit the gearbox cover plate.
9. Clean the joints, grease the studs of the turbocharger with Molycote 1000, part no.
30 20 971, and fit the exhaust pipe.

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10. Check that the oil plug has been tightened and lower the car.
11. Tighten the upper bolts on the exhaust pipe.

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12. Plug in the oxygen sensor cables.
13. Fit the heat shield over the exhaust manifold and turbo bypass pipe.
14. Fill with engine oil and put back the dipstick.
15. Fit the upper engine cover.
16. Run the engine until warm, raise the car and check the integrity around the sealing
surfaces.
17. Fit the lower engine cover.
18. Lower the car, check the oil level and top up as necessary.

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