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  #1  
Old 27th August 2006
Gazolzwurf Gazolzwurf is offline
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Default Lets install the latest PCV fix!

This is a step by step guide for installing the latest crankcase ventilation kit.
TSB 210-2417 ed.4 - Released around April '06.
Saab part # 55561200

Please be aware that I am not a mechanic and I have installed this kit with very little prior info.

If you believe some part of this guide is incorrect or that something should be added then please let us know.

Tools required:
- 8mm socket
- 10mm socket
- 13mm socket
- zip ties

-------

First the parts

-------

These hoses are not supplied in this latest PCV kit.
Replace as necessary.

Cam cover to oil trap - part# 55560463

Oil trap to sump - part# 55560445

Check valve and hoses - part# 9399973

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This pic shows all of the newly supplied parts of tubing connected together.
The three ends of this tubing will be referred to as;
- oil trap tube - top right of pic
- filler neck tube - centre of pic
- turbo tube - bottom left of pic
Notice the direction of flow on the check valves.



-------

The oil trap.
Same trap as the previous model but diameter of the holes are different.



-------

Cam cover grommet.
The one on the right is the new and the one on the left is the old.
The diameter of the centre hole on both of these grommets is the same so I chose to stay with the old grommet because the lip on the old one holds it more securely inside the cam cover.



Last edited by Gazolzwurf; 16th October 2006 at 11:52 AM.
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  #2  
Old 27th August 2006
Gazolzwurf Gazolzwurf is offline
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Cam cover nipple.
Different part number to the one I already had in place but looked exactly the same. The only reason I installed it was because it was cleaner.



-------

Filler neck.
The one on the right is the new and the one on the left the old.
Notice the tube that is now part of the moulded item.



-------

Also in the bag there are several zip ties and a piece of neoprene, aprox 6" square.

Last edited by Gazolzwurf; 27th August 2006 at 07:08 PM.
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  #3  
Old 27th August 2006
Gazolzwurf Gazolzwurf is offline
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The procedure.

-------

Make sure the engine is cold.

Disconnect the battery.

Remove the plastic cover that covers the filler neck, fuel rail etc

Remove the screw that holds the filler neck in place.



-------

Lift out the old filler neck



-------

Remove the old tube that runs between the pipe to the turbo and the oil trap.



The pipe to the turbo that I'm referring to is shown here in one of Chris' pics.
The shiny pipe that runs around the side of the cam cover.


Last edited by Gazolzwurf; 8th September 2006 at 05:03 AM.
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  #4  
Old 27th August 2006
Gazolzwurf Gazolzwurf is offline
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Install the new filler neck and secure in place with the screw.

Connect the filler neck tube to the filler neck



-------

Connect the turbo tube to the pipe to the turbo inlet.



Closer image of turbo tube
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  #5  
Old 27th August 2006
Gazolzwurf Gazolzwurf is offline
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Replace the grommet and nipple on the cam cover.



-------

Connect the smaller tube to the T piece of the nipple.
This smaller tube routes to the throttle body.
Part# 9399973 (includes check valve and hoses)



-------

Route the oil trap tube around the filler neck and pop it down through the intake manifold directly in front of the block connector on the throttle body.
The block connector I'm referring to is red and is shown towards the top right of the pic.



-------

Pic showing tube passing through intake manifold.


Last edited by Gazolzwurf; 16th October 2006 at 11:43 AM.
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  #6  
Old 27th August 2006
Gazolzwurf Gazolzwurf is offline
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Now you need to get your car off the ground and whichever way you do it, do it safely.

Leave the bonnet (hood) open to let the light in.

If you're under the car looking towards the front then the oil trap is located on the back of the engine to the right hand side of the cat.

The intake manifold stay runs vertically in front of the oil trap screws.
Remove the top fixing of the bar and loosen the lower fixing.
The bar will then swing to the left aiding access to the oil trap.
Alternator cable can also be in the way. Remove if necessary.



-------

Take off the remaining two tubes from the oil trap.

Remove the two screws holding the oil trap in place.

Remove the oil trap.



-------

Fix the new oil trap and secure using the two screws.

Reconnect the lower tube (This routes to the sump)
Part# 55560445



-------

To the lower connection of the oil trap.


Last edited by Gazolzwurf; 16th October 2006 at 11:41 AM.
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  #7  
Old 27th August 2006
Gazolzwurf Gazolzwurf is offline
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Reconnect the right hand tube (This routes to the cam cover)
Part# 55560463



-------

To the right hand connection on the oil trap.



-------

Connect the left hand tube (This is the tube that has just been installed from the filler neck/turbo inlet pipe)



-------

To the left hand connection of the oil trap


Last edited by Gazolzwurf; 15th October 2006 at 06:49 PM.
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  #8  
Old 27th August 2006
Gazolzwurf Gazolzwurf is offline
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This is how it should look.



-------

Reconnect the bar in front of the oil trap and secure in place with screws.

The small sheet of neoprene is to protect the tubes at the back of the fuel rail. Secure it in place with zip ties.

Make sure all of the existing PCV tubing is firm and undamaged.
If any have a mushy feel or are damaged then they should be replaced.
Part#'s at beginning of thread.

Get your car on the ground.

Reconnect the battery.

Replace engine cover.

Make sure no tools left in engine bay.

Job done.


Last edited by Gazolzwurf; 16th October 2006 at 11:49 AM.
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  #9  
Old 29th August 2006
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Outstanding write up.Thank you so much for your details and pictures. I have debated doing this and now the debate is over. I will do it. I cleaned the sump & strainer 2 months ago, not in bad shape.

Where did you get your updated kit from. Is this update better because of new hoses or because of a better design?

I noticed a previous kit included a long thin hose with a fat oval check valve in it. I don't see that in this newest kit.
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  #10  
Old 29th August 2006
Gazolzwurf Gazolzwurf is offline
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My kit came from my local Saab dealer.
You guys over the pond can get it from GenuineSaab for $55

This is the latest PCV fix from Saab. The thin hose you speak of links the T piece on the cam cover to the throttle body (shown above connecting to cam cover)
The one they supplied in an earlier fix was because they decided to reroute it.
Instead of TB to cam cover, it went TB to filler neck. This was the one that was backed out because it drank oil.

You won't see the big white check valve on my set up because I skipped it in favour of the Norgren check valve.
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  #11  
Old 29th August 2006
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Raven18940 Raven18940 is offline
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So if you haven't changed your check valve in...well forever, you'll need a new one when you do this?
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  #12  
Old 29th August 2006
Gazolzwurf Gazolzwurf is offline
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Take it off, clean it (very important) then test it by blowing down each end.
Blowing down the tube towards TB end should be ok, blowing other way should be blocked.

But for total peace of mind, get a new one.
I did have the part # number somewhere, I'll see if I can dig it out.
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  #13  
Old 29th August 2006
rcase13 rcase13 is offline
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For those of us in the States will Saab cover this if the car is under warrenty? Will there be a recall?
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  #14  
Old 29th August 2006
Gazolzwurf Gazolzwurf is offline
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Not covered under warranty, no recall.
It's an easy install, go buy the kit and have some fun with your car
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  #15  
Old 29th August 2006
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I just ordered mine, thanks for the link. I checked other sources and it was not listed and I wanted to make sure I got this "final" solution.
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  #16  
Old 29th August 2006
Gazolzwurf Gazolzwurf is offline
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Check valve here

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  #17  
Old 29th August 2006
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Ian3504 Ian3504 is offline
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Thanks for the detailed instal details Mr G, goin to order the kit tomorrow and get stuck into it at the weekend - hopefully!
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  #18  
Old 3rd September 2006
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sorry for the confusion. wasn't fully awake when trying to make sense of this thing. nothing to see here. carry on.

Last edited by B~P; 3rd September 2006 at 11:58 AM.
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  #19  
Old 3rd September 2006
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Saab put out another bulliten a couple months ago suggesting the PCV system be returned to how it was before.
They found out that this actually made the problem worse.
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  #20  
Old 3rd September 2006
Gazolzwurf Gazolzwurf is offline
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The procedure on this thread is the latest PCV fix for the 9-5.
The site you linked to has not been updated with this latest fix.
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