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Home >> Saab >> 2002 >> 9-5 Linear, 4D Wagon, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Basic Engine, V6) >> Adjustment/Replacement >> To dismantle the engine

To dismantle the engine

WARNING: This page is about a different variant/trim than selected.
  1. Remove the bracket for the engine wiring harness.
    Fig 1: Removing Engine Wiring Harness Bracket
    G03549547Courtesy of SAAB-SCANIA OF AMERICA, INC.
  2. Remove the support bearing bracket with pipe and inboard drive shaft universal joint.
    Fig 2: Illustration For Steps 2-3, 5-6
    G03549548Courtesy of SAAB-SCANIA OF AMERICA, INC.
  3. Disconnect the starter motor and remove same.
  4. Remove the plastic plug under the starter motor and remove the torque converter bolts.

    Advance the torque converter gradually by turning the crankshaft with the pulley.

  5. Prevent the torque converter from moving by means of 87 92 574 HOLDER  .
  6. Remove the gearbox.
  7. Remove the front exhaust pipe with heated oxygen sensor, power steering pump and power unit from the subframe.
  8. Fit Holder part no. 83 94 751 HOLDER, ENGINE  to the power train and lift over the power train to 78 74 878 FLOOR STAND  .
    Fig 3: Illustration For Steps 8-9
    G03549549Courtesy of SAAB-SCANIA OF AMERICA, INC.
  9. Remove the belt tensioner and disconnect and remove the generator.

    Do not forget to remove the lead to the oil pressure sensor from the generator.

  10. Detach the vacuum hose and water hoses from the throttle. Also unplug the throttle's connector.
    Fig 4: Illustration For Steps 10-11
    G03549550Courtesy of SAAB-SCANIA OF AMERICA, INC.
  11. Detach the temperature sensor on the coolant bridge.
  12. Remove the upper intake manifold.
    Fig 5: Illustration For Steps 12-14
    G03549551Courtesy of SAAB-SCANIA OF AMERICA, INC.
  13. Disconnect the leads to the injectors. Remove the middle intake manifold.
  14. Remove the lower intake manifold. Plug the induction orifices.
  15. Disconnect the lead to the oil pressure sensor.
    Fig 6: Illustration For Steps 15-16
    G03549552Courtesy of SAAB-SCANIA OF AMERICA, INC.
  16. Drain the oil and tighten the drain plug.

    Tightening torque: 25 N.m (18.5 lbf ft). 

  17. Remove the dipstick.
    Fig 7: Illustration For Steps 17-21
    G03549553Courtesy of SAAB-SCANIA OF AMERICA, INC.
  18. Remove the turbo's water and oil pipes.
  19. Remove the turbo's bracket.
  20. Remove the crankshaft position sensor.
  21. Remove the oil filter and the oil pipes from the oil filter adapter.
  22. Remove the rear exhaust manifold's heat shield. Remove the rear exhaust manifold.
    Fig 8: Illustration For Step 22
    G03549554Courtesy of SAAB-SCANIA OF AMERICA, INC.
  23. Remove the front exhaust manifold.
    Fig 9: Removing Front Exhaust Manifold
    G03549555Courtesy of SAAB-SCANIA OF AMERICA, INC.
  24. Detach the coolant pipe and remove the thermostat housing with thermostat.
    Fig 10: Illustration For Steps 24-26
    G03549556Courtesy of SAAB-SCANIA OF AMERICA, INC.
  25. Remove the coolant bridge, being careful not to damage the gaskets.
  26. Remove the crankcase breather housing.
  27. Disconnect the leads to the ignition discharge modules and remove the engine wiring harness. Remove the ignition discharge modules.
    Fig 11: Illustration For Steps 27-28
    G03549557Courtesy of SAAB-SCANIA OF AMERICA, INC.
  28. Remove the spark plugs using Spark plug socket part no. 83 95 485 SPARK PLUG SOCKET ASSEMBLY WITH LOCATING SLEEVES  , and also remove the camshaft covers with gaskets.
  29. Remove the coolant pump pulley and crankshaft pulley.
    Fig 12: Illustration For Steps 29-30
    G03549558Courtesy of SAAB-SCANIA OF AMERICA, INC.
  30. Remove the timing cover.
  31. Zero the engine. Mark the direction of rotation on the timing belt and undo the belt tensioner. Remove the timing belt. Rotate the crankshaft to 60° BTDC.
    Fig 13: Illustration For Steps 31-33
    G03549559Courtesy of SAAB-SCANIA OF AMERICA, INC.
    WARNING: The camshafts must not be rotated as the valves may collide with the pistons or each other and be damaged. The crankshaft may be rotated only between 0° and 60° before top dead center when the camshafts on both cylinder heads are secured with a locking tool.
  32. Remove the bracket with tensioning roller and the upper adjuster roller.
  33. Remove the lower adjuster roller.
  34. Hold the camshafts with a spanner and remove the camshaft sprockets.
    Fig 14: Illustration For Steps 34-36
    G03549560Courtesy of SAAB-SCANIA OF AMERICA, INC.
    WARNING: The jaws of the open-ended spanner used as a counter stay when removing the camshaft sprockets must not be too long. There is otherwise a risk of damaging the metal so that the tappets become locked.
  35. Remove the coolant pump, taking care not to damage the O-ring.
    NOTE: There is quite a lot of coolant left in the engine so always place a receptacle under the engine to collect it.
  36. Remove the inner timing cover.
  37. Remove the exhaust camshaft bearing caps by undoing the bolts in steps of 1/2 to 1 turn. It is important to conclude removal at the bearing cap where the tappets are under load. Lift out the camshafts and remove the stuffing boxes. Note the marking on the camshaft bearing caps.
    Fig 15: Illustration For Steps 37, 39
    G03549561Courtesy of SAAB-SCANIA OF AMERICA, INC.
    IMPORTANT: The camshafts must come away from the bearing seats evenly.
    NOTE: The intake camshafts can remain in place.
  38. Remove the tappets and keep them in 83 93 787 VALVE STAND  so that they are kept in order. Fit Protective collars part no. 83 95 022 PROTECTIVE COLLAR, V6  .
  39. Undo the cylinder head bolts in the order shown in steps of 1/4 - 1/2 a turn. Remove the cylinder heads. Exercise care when putting them down as the intake camshafts are still in place and the valves could easily be bent through carelessness.
  40. Detach the pipes from the heat exchanger, being careful with the gaskets. Remove the heat exchanger cover complete with the heat exchanger.
    Fig 16: Illustration For Steps 40-41
    G03549562Courtesy of SAAB-SCANIA OF AMERICA, INC.
    IMPORTANT: Not the fitting position.
  41. Mark the pistons with the cylinder number.
  42. Turn the engine. Remove the oil sump, oil suction pipe and antislosh baffle.
    Fig 17: Removing Oil Sump, Oil Suction Pipe And Antislosh Baffle
    G03549563Courtesy of SAAB-SCANIA OF AMERICA, INC.
  43. Fit Counter stay 83 95 063 COUNTER STAY, CRANKSHAFT BELT PULLEY, V6  and remove the camshaft belt sprocket from the crankshaft. Remove the oil pressure sensor.
    Fig 18: Illustration For Steps 43-45
    G03549564Courtesy of SAAB-SCANIA OF AMERICA, INC.
  44. Remove the oil pump and gasket.
  45. Remove the front crankshaft seal.
  46. Remove the drive plate. Carefully pry out the rear crankshaft seal.
    Fig 19: Illustration For Step 46
    G03549565Courtesy of SAAB-SCANIA OF AMERICA, INC.
    IMPORTANT: Do not damage the sealing surface.
  47. Undo all big-end bearing caps and press or carefully tap the pistons out of the cylinders in pairs. Start with 1 and 2.
    Fig 20: Illustration For Steps 47-48
    G03549566Courtesy of SAAB-SCANIA OF AMERICA, INC.
  48. Remove the main bearing member by first undoing the middle bolts on the long sides and unscrewing the adjusting sleeves about 1/2 a turn.
    NOTE: If the adjusting sleeves are tight-fitting, they need not be unscrewed.
  49. Remove the rest of the bolts. Note the position of the main bearing member for subsequent reassembly.
  50. Remove all main bearing caps and lift out the crankshaft.
    Fig 21: Illustration For Steps 50-52
    G03549567Courtesy of SAAB-SCANIA OF AMERICA, INC.
  51. Remove the slotted ring.
    IMPORTANT: Observe the utmost care when handling the slotted ring.
  52. Remove all bearing shells for both the main bearings and big-end bearings.
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