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Home >> Saab >> 2003 >> 9-5 Linear, 4D Sedan, Standard >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 1 (Basic Engine, V6) >> Adjustment/Replacement >> Power unit, to remove

Power unit, to remove

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  1. Position the car on a lift and drape the wings with protective covers. Raise the car slightly until the wheels are clear of the floor.
    Fig 1: Illustration For Step 3
    G03654175Courtesy of SAAB-SCANIA OF AMERICA, INC.
  2. Reduce the fuel pressure by removing the fuel pump fuse while the engine is running. Switch off the ignition when the engine has stopped and refit the fuse.
  3. Place the wheels in the straight ahead position and unbolt the steering column from the steering gear inside the cabin.
  4. Remove the engine cover and battery cover.
    Fig 2: Illustration For Steps 4-7
    G03654176Courtesy of SAAB-SCANIA OF AMERICA, INC.
  5. Disconnect the battery cables and remove the battery.
  6. Remove the battery tray and detach the wiring harness fasteners from the battery tray.
  7. Unplug the connectors from the automatic transmission's wiring harness.
  8. Remove the front wheels and hub nuts. Unscrew the ground cable, which is connected to the gearbox casing, in the left-hand wheel housing.
    Fig 3: Illustration For Steps 8, 9, 11
    G03654177Courtesy of SAAB-SCANIA OF AMERICA, INC.
  9. Remove the ground cable from the gearbox.
  10. Withdraw the gearbox venting hose.
  11. Detach the selector lever cable from the gear actuator and move the cable aside.
  12. Disconnect the positive cable from the junction terminal and its fasteners on the main fuse board.
    Fig 4: Illustration For Steps 12, 13
    G03654178Courtesy of SAAB-SCANIA OF AMERICA, INC.
  13. Detach the throttle cable from the throttle body and retaining bracket. Bend aside.
  14. Remove the turbo pressure hose from the throttle body.
    Fig 5: Illustration For Steps 14, 15
    G03654179Courtesy of SAAB-SCANIA OF AMERICA, INC.
  15. Unplug the connectors from the turbo pressure sensor and the intake air temperature sensor and disconnect the ground cable from the turbo pressure hose's connecting pipe.
  16. Raise the car additionally. Detach the turbo pressure hose from the charge air cooler. Remove the lower spoiler sections.
    Fig 6: Illustration For Steps 16, 17
    G03654180Courtesy of SAAB-SCANIA OF AMERICA, INC.
  17. Remove the air cleaner's rubber mounts from the subframe.
  18. Insert two 83 95 238 Wedges, between the oil sump and subframe and between the gearbox and sub frame.
    Fig 7: Illustration For Step 18
    G03654181Courtesy of SAAB-SCANIA OF AMERICA, INC.
  19. Detach the rear heated oxygen sensor's wiring from its attachments in the floor (certain models).
  20. Separate the front exhaust system after the catalytic converter.
    Fig 8: Illustration For Step 20
    G03654182Courtesy of SAAB-SCANIA OF AMERICA, INC.
  21. Detach the anti-roll bar link rods at the link arms.
    Fig 9: Illustration For Steps 21-23
    G03654183Courtesy of SAAB-SCANIA OF AMERICA, INC.
  22. Undo the outer tie-rod ends from the suspension struts. Use 89 96 696 PULLER .
  23. Unscrew the lower steering swivel joint bolts from the link arms.
  24. Place a receptacle under the car and open the radiator's drain cock.
    Fig 10: Illustration For Steps 24-26
    G03654184Courtesy of SAAB-SCANIA OF AMERICA, INC.
  25. Lower the car and unscrew the expansion tank filler cap.
  26. Detach the vacuum hose from the charge air bypass valve and remove the turbo pressure hose together with the bypass pipe, valve and connecting pipe.
  27. Remove the heat shield from the front exhaust manifold.
    Fig 11: Illustration For Steps 27-29
    G03654185Courtesy of SAAB-SCANIA OF AMERICA, INC.
  28. Detach the crankcase breather pipe from the turbo intake pipe. Collect the sealing washers.
  29. Unplug the connector and remove the mass air flow sensor and intake hose. Disconnect the venting hose's quick-release coupling and remove the turbo's intake pipe.
  30. Unplug the connectors and remove the radiator fan.
    Fig 12: Illustration For Step 30
    G03654186Courtesy of SAAB-SCANIA OF AMERICA, INC.
  31. Remove the wiper arms, using special tool 85 80 144, and the windscreen cover.
    Fig 13: Illustration For Steps 31-33
    G03654187Courtesy of SAAB-SCANIA OF AMERICA, INC.
  32. Remove the engine control module's rubber seal and its connector.
  33. Remove the cover over the engine wiring harness connector on the bulkhead. Separate the connector and remove the wiring with holder and place it on the engine.
  34. Detach the vacuum hose from the heater system's shut-off valve.
    Fig 14: Illustration For Steps 34-36
    G03654188Courtesy of SAAB-SCANIA OF AMERICA, INC.
  35. Detach the brake servo's vacuum hose from the intake pipe connection by moving the red part of the hose in towards the intake pipe and pulling it outwards.
  36. Detach the venting hose from the throttle body.
  37. Undo the fuel rail connections. Have an absorbent cloth or paper handy to catch any fuel spillage. Carefully bend the hoses aside.
    Fig 15: Illustration For Steps 37, 38
    G03654189Courtesy of SAAB-SCANIA OF AMERICA, INC.
  38. Detach the power steering oil reservoir from its bracket and undo the cable tie securing the hydraulic hoses. Fix the reservoir with hoses to the engine. Make sure that no oil leaks out of the reservoir's ventilation hole.
  39. Detach the upper and lower radiator hoses and the hoses connected to the expansion tank and radiator.
    Fig 16: Illustration For Steps 39, 40
    G03654190Courtesy of SAAB-SCANIA OF AMERICA, INC.
  40. Detach the automatic transmission's hydraulic hoses. Place a receptacle underneath. Fit a plastic bag or the like over the hose connections. Plug the oil cooler connections.
  41. Remove the radiator.
    Fig 17: Illustration For Step 41
    G03654191Courtesy of SAAB-SCANIA OF AMERICA, INC.
  42. Undo the hose connections for the cabin heat exchanger. Note the location of the hoses for subsequent assembly.
    Fig 18: Illustration For Step 42
    G03654192Courtesy of SAAB-SCANIA OF AMERICA, INC.
  43. Remove the hose between the turbo's outlet and the charge air cooler.
    Fig 19: Illustration For Steps 43, 45
    G03654193Courtesy of SAAB-SCANIA OF AMERICA, INC.
  44. Remove the front grille.
  45. Secure the charge air cooler and the condenser with a 83 95 212 Cable tie
  46. Unplug the A/C compressor's connector.
    Fig 20: Illustration For Steps 46, 48
    G03654194Courtesy of SAAB-SCANIA OF AMERICA, INC.
  47. Attach and pull down a 83 95 212 Cable tie, which is to be used later to secure the AC compressor.
  48. Detach the A/C pipes from the attachment points on the subframe.
  49. Release the multigroove belt from tension and remove the right-hand engine mount with attachment and bracket.
    Fig 21: Illustration For Step 49
    G03654195Courtesy of SAAB-SCANIA OF AMERICA, INC.
  50. Undo and remove the left-hand engine mount.
    Fig 22: Illustration For Step 50
    G03654196Courtesy of SAAB-SCANIA OF AMERICA, INC.
  51. Check to make sure that everything has been detached and moved aside so that no damage will occur when the engine is removed.
  52. Raise the car and place the 83 95 311 Lifting trolley with lifting table under the power train. The height adjustments on the fixture should be in the lowest position.
    Fig 23: Illustration For Steps 52-53
    G03654197Courtesy of SAAB-SCANIA OF AMERICA, INC.
  53. Raise the lifting table and adjust it according to the locating points on the car body and fixture.

    Continue raising the lifting table until it touches the subframe. Raise it a little more and then adjust its height until it abuts evenly against the subframe.

  54. Undo the subframe retaining bolts and the triangular stiffeners.
    Fig 24: Illustration For Step 54
    G03654198Courtesy of SAAB-SCANIA OF AMERICA, INC.
  55. Carefully lower the power unit slightly, remove the drive shafts from the hubs and make sure that the generator's cooling duct has come away from its connection.
  56. Remove the A/C compressor retaining bolts. Lift out the compressor and secure it with the previously mounted cable tie.
    Fig 25: Illustration For Step 56
    G03654199Courtesy of SAAB-SCANIA OF AMERICA, INC.
  57. Lower the power unit additionally. Take care to ensure that nothing catches on it and that nothing has been left in place which could be damaged when the engine is removed.
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