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Home >> Saab >> 2004 >> 9-3 Linear, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Basic Engine >> Adjustment-Replacement >> Removing the cylinder block >> To remove

To remove

  1. Place the car on a lift.

    CV:  Remove the chassis reinforcement, front subframe, CV.

  2. Place a receptacle under the car. Use protective gloves. Remove the plug and drain the gearbox oil. Fit the plug.

    Tightening torque, automatic transmission 45 Nm (33 lbf ft) 

    Tightening torque, manual gearbox 50 Nm (37 lbf ft) 

    Fig 1: Illustration For Steps 2
    G03708006Courtesy of SAAB-SCANIA OF AMERICA, INC.
    WARNING: The oil can be very hot if the car was recently driven. Risk of burn injuries.
    WARNING: Exercise caution with oil spills on hot surfaces. Risk of fire.
  3. Remove the drain plug and drain the engine oil. Fit the plug with a new O-ring.

    Tightening torque 25 Nm (18 lbf ft)  .

    Fig 2: Illustration For Steps 3
    G03708007Courtesy of SAAB-SCANIA OF AMERICA, INC.
  4. Remove the engine assembly, see POWER TRAIN REMOVAL  .
  5. Leave the power train on the trolley lift.
  6. Remove the cover to the spark plugs.
    Fig 3: Illustration For Steps 6
    G03708008Courtesy of SAAB-SCANIA OF AMERICA, INC.
  7. Remove the engine wiring harness using the following method:
    IMPORTANT: Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to CONNECTOR .
    1. 7.A. Unplug the connector from the charge air control valve.
      Fig 4: Illustration For Steps 7A-7H
      G03708009Courtesy of SAAB-SCANIA OF AMERICA, INC.
    2. 7.B. Unplug the connector from the coolant temperature sensor.
    3. 7.C. Unplug the engine control module connector.
    4. 7.D. Unplug the engine control module connector.
    5. 7.E. Unplug the connector from grounding point G7.
    6. 7.F. Unplug the bypass valve connector.
    7. 7.G. Unplug the throttle body connector.
    8. 7.H. Unplug the 4 ignition coil connectors.
    9. 7.I. Unplug the connector from the ionization detection module.
      Fig 5: Illustration For Step 7I-7L
      G03708010Courtesy of SAAB-SCANIA OF AMERICA, INC.
    10. 7.J. M03:  Unplug the connector from the exhaust temperature sensor.
    11. 7.K. Unplug the connector from the front oxygen sensor.
    12. 7.L. Unplug the connector from the rear oxygen sensor.
    13. 7.M. Unplug the connector from the atmospheric pressure sensor.
      Fig 6: Illustration For Steps 7M-7O
      G03708011Courtesy of SAAB-SCANIA OF AMERICA, INC.
    14. 7.N. Unplug the connector from the intake manifold pressure sensor.
    15. 7.O. Remove the power steering fluid pressure switch.
    16. 7.P. Remove the starter motor contacts.
    17. 7.Q. Cars with secondary air injection pump:  Unplug the secondary air injection pump connector.
      Fig 7: Illustration For Steps 7P-7W
      G03708012Courtesy of SAAB-SCANIA OF AMERICA, INC.
    18. 7.R. Remove the oil pressure switch.
    19. 7.S. Unplug the connector from the crankshaft position sensor.
    20. 7.T. Unplug the EVAP canister purge valve connector.
    21. 7.U. Unplug the oil level sensor connector.
    22. 7.V. Unplug the generator connector.
    23. 7.W. Unplug connector H8-9.
    24. 7.X. Remove the reversing light switch.
    25. 7.Y. Remove the wiring harness retaining bolts. Pull out the wiring harness and lift it aside.
  8. Remove the lower charge air pipe.
    Fig 8: Illustration For Steps 9, 10
    G03708013Courtesy of SAAB-SCANIA OF AMERICA, INC.
  9. Remove the turbocharger heat shield.
  10. Remove the catalytic converter heat shield.
  11. Unplug the heated oxygen sensor connectors and lower the cables carefully.
  12. Unplug the temperature sensor connector and lower it carefully.
  13. Remove the catalytic converter from the engine block and the turbocharger. Lubricate the turbocharger studs with rust solvent oil. Lift out the catalytic converter.
    Fig 9: Illustration For Steps 13
    G03708014Courtesy of SAAB-SCANIA OF AMERICA, INC.
  14. Detach the hoses form the water-cooled oil cooler.
    Fig 10: Illustration For Steps 14, 15
    G03708015Courtesy of SAAB-SCANIA OF AMERICA, INC.
  15. Remove the cylinder head breather hose.
  16. Remove the turbocharger coolant pipe.
    Fig 11: Illustration For Step 16, 17
    G03708016Courtesy of SAAB-SCANIA OF AMERICA, INC.
  17. Remove the thermostat housing and pipe. Leave the hoses on the thermostat housing.
  18. RH side:  Tap out the drive shaft from the intermediate shaft with a brass drift and mallet. Lift out the drive shaft.
    Fig 12: Illustration For Step 18
    G03708017Courtesy of SAAB-SCANIA OF AMERICA, INC.
  19. Remove the intermediate shaft from the engine and gearbox.
    Fig 13: Illustration For Step 19
    G03708018Courtesy of SAAB-SCANIA OF AMERICA, INC.
  20. LH side:  Pull out the drive shaft from the gearbox. Pry with 87 92 616 REMOVAL TOOL, DRIVE SHAFTS  . Lift out the drive shaft.
    Fig 14: Illustration For Step 20
    G03708019Courtesy of SAAB-SCANIA OF AMERICA, INC.
  21. Remove the LH drive shaft seal with 87 92 350 PULLER, DRIVE SHAFT SEAL  and 87 91 683 PULLER  .
    Fig 15: Illustration For Steps 21
    G03708020Courtesy of SAAB-SCANIA OF AMERICA, INC.
  22. Remove the RH drive shaft seal with 87 92 350 PULLER, DRIVE SHAFT SEAL  and 87 91 683 PULLER  .
    Fig 16: Illustration For Steps 22
    G03708021Courtesy of SAAB-SCANIA OF AMERICA, INC.
  23. Cars with secondary air injection pump:  Remove the pipe between the pump and the valve.
    Fig 17: Illustration For Steps 23, 24
    G03708022Courtesy of SAAB-SCANIA OF AMERICA, INC.
  24. Remove the starter motor.
  25. Remove the water-cooled oil cooler.
    Fig 18: Illustration For Steps 25, 26
    G03708023Courtesy of SAAB-SCANIA OF AMERICA, INC.
  26. Remove the power steering pump from the cylinder head and move it aside.
  27. Cars with automatic transmission:  Undo the 6 bolts holding the torque converter to the driver plate. Turn the plate with an open spanner on the pulley center bolt. Turn clockwise.
    Fig 19: Illustration For Steps 27, 28
    G03708024Courtesy of SAAB-SCANIA OF AMERICA, INC.
  28. Cars with automatic transmission:  Detach the plug, press the torque converter toward the transmission and fit 87 92 574 HOLDER  to hold the torque converter in place when removing the transmission.
  29. Fit 83 96 178 Lifting eyes, B207
    Fig 20: Illustration For Steps 29
    G03708025Courtesy of SAAB-SCANIA OF AMERICA, INC.
    Fig 21: Illustration For Steps 29
    G03708026Courtesy of SAAB-SCANIA OF AMERICA, INC.
  30. Secure the engine with an engine lift.
  31. Remove the torque arms from the oil sump and gearbox.
    Fig 22: Illustration For Steps 31, 32
    G03708027Courtesy of SAAB-SCANIA OF AMERICA, INC.
  32. Raise the engine and remove the lower gearbox retaining bolts.
  33. Carefully lower the engine onto a pallet.
  34. Remove the upper gearbox retaining bolts.
    Fig 23: Illustration For Step 34
    G03708028Courtesy of SAAB-SCANIA OF AMERICA, INC.
  35. Fit 87 92 442 Lifting cable to the gearbox and raise the gearbox slightly. Remove the gearbox from the engine.
  36. Lift up the engine and fit 83 94 751 HOLDER, ENGINE  . Fit the engine to the floor stand 78 74 878 FLOOR STAND  .
  37. Remove the turbocharger oil delivery pipe.
    Fig 24: Illustration For Step 37-40
    G03708029Courtesy of SAAB-SCANIA OF AMERICA, INC.
  38. Remove the turbocharger oil return pipe.
  39. Remove the lower turbocharger attachment bracket.
  40. Remove the crankcase ventilation hose from the camshaft cover.
  41. Remove the generator.
    Fig 25: Illustration For Steps 41, 42
    G03708030Courtesy of SAAB-SCANIA OF AMERICA, INC.
  42. Cars with secondary air injection pump:  Remove the pump with bracket
  43. Remove the lower intake manifold attachment bracket.
    Fig 26: Illustration For Steps 43-45
    G03708031Courtesy of SAAB-SCANIA OF AMERICA, INC.
  44. Remove the crankshaft position sensor.
  45. Remove the bolt from the dipstick tube.
  46. Fit 83 94 868 Flywheel locking attachment to secure the flywheel.
  47. Cars with manual gearbox:  Remove the bolts holding the pressure plate and remove the clutch and driven plate hub.
    Fig 27: Illustration For Step 47
    G03708032Courtesy of SAAB-SCANIA OF AMERICA, INC.
  48. Cars with manual gearbox:  Remove the flywheel.

    Cars with automatic transmission  : Remove the driver plate.

    Fig 28: Illustration For Step 48
    G03708033Courtesy of SAAB-SCANIA OF AMERICA, INC.
  49. Remove 83 94 868 Flywheel locking attachment.
  50. Remove the ignition coils.
    Fig 29: Illustration For Step 50-53
    G03708034Courtesy of SAAB-SCANIA OF AMERICA, INC.
  51. Remove the bracket.
  52. Remove the ground cable from the camshaft cover.
  53. Remove the camshaft cover.
  54. Remove the engine mounting bracket.
    Fig 30: Illustration For Step 54-56
    G03708035Courtesy of SAAB-SCANIA OF AMERICA, INC.
  55. Remove the belt tensioner.
  56. Zero the crankshaft. Remove the crankshaft pulley with 83 95 360 HOLDING TOOL, CRANKSHAFT PULLEY  (shaft only) and 83 96 210 HOLDING TOOL, CRANKSHAFT PULLEY, B207  .
  57. Remove the timing cover and gasket.
    Fig 31: Illustration For Step 57, 59, 60
    G03708036Courtesy of SAAB-SCANIA OF AMERICA, INC.
  58. Remove the crankshaft seal.
  59. Remove the timing chain tensioner.
  60. Remove the plug from the cylinder head.
  61. Remove the upper bolt from the chain guide on the inlet side.
    Fig 32: Illustration For Step 61-65
    G03708037Courtesy of SAAB-SCANIA OF AMERICA, INC.
  62. Remove the upper timing chain guide rail.
  63. Remove the lower chain guide bolt. Pull down the chain guide. Detach the lower section of the chain.
  64. Remove the camshaft sprockets. Use a spanner to grip the camshaft flats when the bolts are loosened. Lift up the chain.
  65. Remove the tensioner guide by lifting it up. Inspect the condition of the guide. Replace if necessary.
  66. Remove the balancer shaft chain tensioner.
    Fig 33: Illustration For Step 66-68
    G03708038Courtesy of SAAB-SCANIA OF AMERICA, INC.
  67. Remove the balancer shaft chain guide bars.
  68. Remove the balancer shaft chain, sprocket and wedge.
  69. Remove the cylinder head in the order shown in the illustration.
    Fig 34: Illustration For Step 1-11
    G03708039Courtesy of SAAB-SCANIA OF AMERICA, INC.
  70. Remove the oil filter cover.
    Fig 35: Illustration For Steps 70, 71
    G03708040Courtesy of SAAB-SCANIA OF AMERICA, INC.
  71. Remove the dipstick tube.
  72. Lift down the cylinder block from 78 74 878 FLOOR STAND  and remove 83 94 751 HOLDER, ENGINE  .
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