TECHNICAL SERVICE BULLETIN

TSB No.
Distr.

210-2418 ed. 4

Date

April 2006

9-3 (9400)

all

Oil leakage from engine

Cars affected

Parts required

Saab 9-3 (9400) M99 - M03 with engine variants

B205 and B235

55 561 200 Renovation kit, crankcase ventilation,

consists of:

Background
The flow through the crankcase ventilation may be
inadequate in certain operating conditions, and oil
leakage may then arise. Most common is leakage at
the joint between the timing cover, the cylinder block
and the cylinder head as well as leakage at the
crankshaft seal. Well functioning crankcase ventilation is also very important for avoiding increased oil
consumption. Gasket replacement/resealing must
only be carried out if the oil leakage does not cease
after the following procedure.
In the case of customer complaint, the following procedure must be carried out.

Symptom description
Oil leakage from the engine.

Nipple
Insulation
Hose kit (x 2)
Oil filler pipe
Oil trap
Cable tie (x 2)
Bushing
If the hoses and/or check valve must be replaced:
55 560 445 (CA: 30566431) Hose to oil pan
55 560 463 (CA: 30581025) Hose for camshaft cover
93 99 973 (CA: 30585634) Hose with check valve
If the throttle body O-ring must be replaced:
42 26 833 (CA: 30553310) O-Ring, throttle body
B205 M99-00
49 40 698 (CA: 30571893) O-ring, throttle body
B205 M01-03, B235 M99-02

Saab Automobile AB Bulletins are intended for use by professional Saab technicians only, NOT a do-it-yourselfer. They are designed
to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service
of a vehicle. Saab trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a
condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have the condition. See your
authorized Saab Dealer for information on whether your vehicle may benefit from the information.
2005 Saab Automobile AB. All rights reserved.

ENG

2 210-2418 ed. 4
Procedure
1 Disconnect the battery's negative cable.
2 Remove the upper engine cover.
3 Install a new oil filler pipe.
4 Remove the hose from the pipe connection on the
turbo's intake manifold.

5 Remove the hoses from the nipple in the camshaft

cover. Check the condition of the hoses, replace if
necessary.
6 Remove the old nipple and bushing from the camshaft cover and install the new nipple and bushing.
7 Raise the car.

D254B021

8 Remove the oil trap's two upper hoses.

9 Remove the lower hose to the oil trap. Remove the

stay to the intake manifold and the oil trap. If necessary, remove the generator positive cable.

9
9
9
9

D254B010

210-2418 ed. 4 3
10 Install the new oil trap, the lower hose to the oil trap
(replace hose if necessary) and the stay for the intake
manifold. If the positive cable was removed, connect
it to the generator.
11 Lower the car.

10
10
10
10

D254B011

12 Check the function of the check valve on the small circuit with 30 14 883 Pressure/Vacuum pump, replace
if necessary. The arrow must point toward the throttle
body.

12

Note
Arrow's direction on the check valve.
13 Man: Remove the vacuum pipe from the turbocharger delivery pipe.

D254B022

14 Remove the upper turbocharger delivery pipe from

the throttle body and cylinder head. Move the turbocharger delivery pipe aside.

14

13

14

14

D254B012

4 210-2418 ed. 4
15 Unplug the temperature sensor connector.

15

15
D254B013

16 Detach and move aside the cable duct from the cylinder head.

16

17 Unplug the throttle body connector.

16

17
16

D254B014

18 Connect the new hose kit (with T-connection)

between the nipple on the oil filler pipe and the connection on the turbo's intake manifold.

18

18

D254B025

210-2418 ed. 4 5
19 Install the insulation under the throttle body coolant
hose so that the insulation's short sides point upward.

19

D254B015

20 Install the crankcase ventilation hose in so that the

check valve is located above the coolant hoses. The
crankcase ventilation hose must follow the route of
the lower coolant hose through the intake manifold
and then on to the oil trap.

20

D254B016

21 Connect the oil trap's upper hoses. If the hose with

part no. 55 560 463 is replaced then the nipple
enclosed with the hose must not be used. Use the
nipple enclosed with the spare parts kit.

22

20
21

D254B024

6 210-2418 ed. 4
22 Connect the new hose kit together at the T-connection.
23 Make sure that the check valve has good contact with
both coolant hoses. Affix a cable tie around the insulation on each side of the check valve.

23

D254B017

24 Plug the connector into the throttle body.

25

25 Fit the cable duct to the cylinder head.

25

24
25

D254B018

26 Plug the connector into the temperature sensor.

26

26
D254B019

210-2418 ed. 4 7
27 Install the turbocharger delivery pipe. If necessary,
replace the throttle body O-ring.

27

28 Man: Install the vacuum pipe.

29 Connect the hoses to the nipple on the camshaft cover.
30 Install the upper engine cover.

28

27

31 Connect the cable to the battery's negative terminal.

32 Set the correct time and date in SID.

27

Warranty/Time Information
In the case of customer complaint and if the car is within
the warranty period, use the following information to fill
out the claim:
Failed Object: 21216
Fault/Reason code: 57
Location code: 09 (US=9)
Warranty Type (US): 01
Repair/Action code: 05
Labour Operation (US): 2121602
Labour Operation (CA): J6025
Time: 0.9 hr

D254B020