Removing the power train, B235R (Viggen)
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Removing the power train, B235R (Viggen)
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Warning
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A large number of hoses, electrical leads etc. are secured with cable ties. When these ties have been pulled tight, the excess is cut off and may leave sharp edges at the fixing points.
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Beware of injuries like cuts and scratches caused by these sharp ends!
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1.
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Cover the wings and remove the battery. Make a note of the radio code if necessary.
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2.
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Remove the cap from the expansion tank to speed up draining.
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4.
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Remove the air shields.
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5.
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Take a receptacle and open the drain plug to drain the coolant.
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6.
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Remove the air cleaner complete with hoses. See the removal instructions for the cylinder head, B235R (Viggen)
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7.
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Remove the engine cover.
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8.
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Detach the protective cap on the accelerator wire. Detach the accelerator wire and place it to one side.
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9.
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Detach the hoses to the crankcase ventilation and separate them.
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10.
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Undo the cable channel at the fuel rail.
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11.
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Separate the fuel lines with tool 83 95 261
and a pair of flat nose pliers for dismantling the rubber seal in the quick-release coupling. Wipe up any fuel spill with a cloth.
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12.
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Detach the tank ventilation hose and bend it to one side.
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13.
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Undo the hose clips on the charge air pipe.
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14.
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Unplug the connector for the temperature sensor.
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15.
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Detach the hoses to the pressure sensor and bypass pipe and undo the screw to the bypass pipe. Remove as one unit. Plug the hoses and connecting pieces.
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16.
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Remove the heat shield over the exhaust manifold.
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17.
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Detach the vacuum hose to the brake servo from the intake manifold.
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18.
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Unplug the connector and dismantle the boost pressure control valve from the bracket.
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19.
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Dismantle the pipe to the crankcase ventilation.
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20.
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Dismantle the inlet pipe to the turbo with hoses.
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21.
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Cut the cable ties on the cables by the MacPherson strut.
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22.
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Relieve the tension on the belt tensioner with an ratchet handle extension piece and insert a 3.5 mm drill in the hole. Lift off the belt.
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Important
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Exercise the utmost care to ensure that the belt tensioner does not break at its end position!
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23.
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Remove the power steering pump from its bracket and place it out of the way.
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24.
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Detach the coolant hoses at the radiator, heater unit - water pump, expansion tank - cylinder head, and the hoses to the bypass valve.
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25.
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Undo the hoses to the turbo and remove the hose to the charge air cooler.
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26.
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Disconnect the A/C compressor signal cable and undo the top retaining bolt on the A/C compressor.
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27.
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Take off the lid on the maxi fuse board, disconnect the positive cable from the plus terminal (follows with the engine) and undo the ground cable on the gearbox (behind the maxi fuse board).
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28.
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Disconnect the reverse gear sensor on the gearbox.
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29.
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Engage 4th gear. Remove the plastic plug from the gearbox and insert a locking pin. Separate the selector lever. Engage 3rd gear and secure the gear lever with a locking pin.
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30.
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Depress the clutch pedal approx. 50 mm with a brake cramp. This will prevent brake fluid from running out of the reservoir. Remove the locking clip at the slave cylinder and disconnect the pressure pipe. Replace the locking clip.
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Note
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There is risk of hydraulic fluid leaking out. Keep a cloth handy.
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31.
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Remove the glove box (LHD) or, alternatively, the lower section of the dashboard on the right-hand side (RHD), fold back the floor mat. Detach the wiring harness to the engine.
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32.
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Unplug the connector above the grommet in the engine bay. Pull out the wiring harness through the grommet and lay it on the engine.
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33.
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Undo the hub centre-nuts on both sides and raise the car to a comfortable working height.
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34.
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Remove both the front wheels and remove the hub centre-nuts. Undo the brake callipers and hang them from the MacPherson struts. Undo the suspension arm nuts on both sides and lower the suspension arms. Use
89 96 696 Puller
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35.
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Remove the covers in the wheel housings. Remove the grounding point between the gearbox and the body.
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36.
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Loosen the joint between the front exhaust pipe and the intermediate pipe.
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37.
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Detach the oil hoses to the oil cooler and plug the hoses.
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38.
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Undo the remaining A/C compressor bolts.
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39.
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Place the lifting trolley under the car so that the supports are centred under the front engine mountings and the gearbox. Remove the bolts on the subframe and the front engine mountings.
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40.
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Lower the lifting trolley slightly and with it the drive train and subframe. Remove the drive shaft from the hub on both sides.
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41.
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Detach the A/C compressor and hang it from the towing eye. Lower the lifting trolley completely.
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