This bulletin applies to all Saab models with 4-cylinder engines (9-3,
900 and 9000). Under certain conditions, the upper engine block surface
may become eroded from prolonged leakage of the head gasket. The
erosion appears as a pitting of the block surface around the coolant
The eroded portion of the block surface can be built up using JB
Weld or similar machineable epoxy. If necessary this repair can be
performed without removing the engine from the vehicle.
1) Remove the cylinder head and the gasket.
2) Clean the surface and apply the epoxy following the
instructions provided with the epoxy. Take great care to apply epoxy
evenly, building up the eroded area above the actual deck height.
3) After the material Is fully set-up, sand the area
with a sandling blockso that the deck surface is even and smooth. Take
care not to remove any metal from the deck.
4) Reinstall the cylinder head and gasket using normal procedures.
Caution: Epoxy filings must not be allowed to enter the cylinders or the coolant and oil passages.
Some or all of this information was provided by the Automotive
Parts Remanufacturers Association (APRA). For more information on
technical bulletins available through APRA call 703-968-2772 or visit www.AutoBulletins.com.