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Re: Part missing, what is it?
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Posted by sam96CS [Email] (#852) [Profile/Gallery] (more from sam96CS) on Sat, 2 May 2009 04:43:31 Share Post by Email
In Reply to: Part missing, what is it?, mishkee, Fri, 1 May 2009 23:38:49
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The plug is part number 9135211, and you can get one from one of the site sponsors.

The plug is a compression fit part. Around its perimeter is a very thin layer of rubber. I don't know for sure, but I think that after exposure to oil and thermal cycles this integrated "gasket" wears away and the plug no longer seals well enough to prevent oil from seeping out.

To install, remove the DI cassette, then remove the valve cover, then from the inside of the engine push out the old plug, then push in the new plug from the outside. There is NO need to loosen the two tamper proof T40 bolts that you'll see when you remove the valve cover.

If the valve cover hasn't been removed recently then after removing the bolts it may be "stuck" on. Smack it a couple of times with a rubber mallet, not too hard. If you're lucky, the valve cover gasket will remain intact (mine's still good at 147K miles) and you won't need to replace it.

At http://www.townsendimports.com/Saab_TSB_Folder/Saab_TSB_pdfs/210_1704_utg2.PDF you'll see on page 4 the order in which the valve cover (called a camshaft cover in the document) bolts are torqued. Put all the valve cover bolts in hand tight, then tighten them to 11 ft. lbs. in the correct sequence. The sequence is counter-intuitive. Also, note that the torque spec for the DI cassette bolts is 8 ft. lbs.

Regarding the DI cassette, keep it upright when you remove it and smear a dab of dielectric grease around the tip of each of the four boots before re-installing it.

Hope this helps.

posted by 71.75.23...

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