Removing the cylinder block

/ 9-3 (9440) / 2004 / 2. Engine / 4-cylinder petrol / Basic engine / Adjustment/replacement / Removing the cylinder block

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) 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).

4.	Remove the engine assembly, see Power unit, to remove .

5.	Leave the power train on the trolley lift.

6.	Remove the cover to the spark plugs.

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 Connectors, handling and inspection .

7.A.

Unplug the connector from the charge air control valve.

7.B.

Unplug the connector from the coolant temperature sensor.

7.C.

Unplug the engine control module connector.

7.D.

Unplug the engine control module connector.

7.E.

Unplug the connector from grounding point G7.

7.F.

Unplug the bypass valve connector.

7.G.

Unplug the throttle body connector.

7.H.

Unplug the 4 ignition coil connectors.

7.I.

Unplug the connector from the ionization detection module.

7.J.

M03 : Unplug the connector from the exhaust temperature sensor.

7.K.

Unplug the connector from the front oxygen sensor.

7.L.

Unplug the connector from the rear oxygen sensor.

7.M.

Unplug the connector from the atmospheric pressure sensor.

7.N.

Unplug the connector from the intake manifold pressure sensor.

7.O.

Remove the power steering fluid pressure switch.

7.P.

Remove the starter motor contacts.

7.Q.

Cars with secondary air injection pump: Unplug the secondary air injection pump connector.

7.R.

Remove the oil pressure switch.

7.S.

Unplug the connector from the crankshaft position sensor.

7.T.

Unplug the EVAP canister purge valve connector.

7.U.

Unplug the oil level sensor connector.

7.V.

Unplug the generator connector.

7.W.

Unplug connector H8-9.

7.X.

Remove the reversing light switch.

7.Y.

Remove the wiring harness retaining bolts. Pull out the wiring harness and lift it aside.

8.	Remove the lower charge air pipe.

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.

14.	Detach the hoses form the water-cooled oil cooler.

15.	Remove the cylinder head breather hose.

16.	Remove the turbocharger coolant pipe.

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.

19.	Remove the intermediate shaft from the engine and gearbox.

20.	LH side : Pull out the drive shaft from the gearbox. Prise with 87 92 616 Removal tool, drive shafts . Lift out the drive shaft.

21.	Remove the LH drive shaft seal with 87 92 350 Puller, drive shaft seal and 87 91 683 Puller .

22.	Remove the RH drive shaft seal with 87 92 350 Puller, drive shaft seal and 87 91 683 Puller .

23.	Cars with secondary air injection pump : Remove the pipe between the pump and the valve.

24.	Remove the starter motor.

25.	Remove the water-cooled oil cooler.

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 centre bolt. Turn clockwise.

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

30.	Secure the engine with an engine lift.

31.	Remove the torque arms from the oil sump and gearbox.

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.

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.

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.

42.	Cars with secondary air injection pump : Remove the pump with bracket

43.	Remove the lower intake manifold attachment bracket.

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.

48.	Cars with manual gearbox: Remove the flywheel. Cars with automatic transmission : Remove the driver plate.

49.	Remove 83 94 868 Flywheel locking attachment .

50.	Remove the ignition coils.

51.	Remove the bracket.

52.	Remove the ground cable from the camshaft cover.

53.	Remove the camshaft cover.

54.	Remove the engine mounting bracket.

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.

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.

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.

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.

70.	Remove the oil filter cover.

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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