SAAB WIS ONLINE

Engine with gearbox, removing and fitting

Engine with gearbox, removing and fitting

To remove


1. Secure the steering wheel with the column lock with the wheels pointing straight ahead. Fabric tape can also be used.

2. Disconnect the battery.

Remove the ground cable.

3. Hang two 83 95 212 Strap over the radiator member.


4. Raise the car

5. Remove the front wheels.

6. Remove the spoiler shield.

Detach the front part of the wing liner and bend away.

Suspend the radiator assembly with the straps.

7. Drain the coolant

Place a receptacle underneath

Open the drain screw (arrow)

Lower the car.


8. Remove the upper engine cover.

Unscrew the lid on the oil filler connection

2x Unscrew

Screw on the lid on the oil filler connection

9. Remove the battery.

Disconnect the positive cable (1)

Remove the battery holder (2) - Undo the screw (3)


10. Remove the battery holder

Undo the ground distributor - Undo the screw

Undo the positive distributor - Undo the screw

3x Unscrew

Detach the coolant hose

11. Dismantle the engine management system cable set

Undo the engine bay fuse holder - 2x unscrew

Undo the cable set contacts - 2x unscrew

Remove the ground cable.

Undo the cable set


12. Detach the coolant hoses from the engine

13. Remove the air cleaner casing (1)

Pull off the cable set connector (2) - mass air flow sensor

Undo the cable set (arrows)

Detach the engine ventilation hose (3)

Detach the intake hose (4)

Pull off the pressure switch cable set connector


14. Remove the multi-belt.


15. Remove the electric connection. Undo the A/C compressor and suspend it with 83 95 212 Strap


16. Lower the fuel pressure

Warning

The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:

• Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.

• Absolutely No Smoking!

• Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.

• Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.

• Wear protective goggles.


Use 83 94 744 Adapter, fuel pressure gauge

Unscrew the test connector protective collar

on the fuel rail

17. Remove the fuel line

Use 83 95 261 Fuel line tool

Undo the fuel line holder - Unscrew the nut

Close the fuel line - Use KM-807


18. Detach the fuel evaporation hose

Use 83 95 261 Fuel line tool .

19. Remove the coolant equalising container

3x Remove the coolant hose

Pull off the cable set connector

20. 2x Remove the water hose (1)

21. Detach the brake servo vacuum line (2)

From intake manifold


22. Detach the selector mechanism wires


Press loose the ball joints from the control levers

Take out the supports

Detach the electrical connection on the reversing light switch

Clamp the clutch hose using 30 07 739 Hose pinch-off pliers

Remove the union from the slave cylinder


23. Raise the car

24. Close the coolant drain screw

25. 2x Undo the drive shaft

2x Unscrew nut (3)


26. 2x Remove the track rod ball joint

from steering swivel member

2x Unscrew nut

2x Remove track rod ball joint (1) use 87 91 287 Puller, 150 mm


27. 2x Remove pitman arm

from spring strut support pipe

2x Unscrew nut (3)

Instruction: Hold with an open spanner.

28. 2x Remove track rod (5)

from steering swivel member

2x Unscrew nut (4) - 2x Remove bolt

29. 2x Press out the drive shaft

Use 89 96 951 Puller, drive shaft or KM-6282 (1)

Instruction: Fit KM-6282 onto the front wheel hub with 3 wheel bolts


30. Raise the car

31. Detach the cable set connector for the catalytic converter control lambda sensor

Important: When removing the middle silencer, a catalytic converter, an exhaust manifold or an exhaust manifold with catalytic converter, the components of the exhaust system remaining on the car must be supported to stop them hanging. The exhaust system component with the flexible pipe can be fastened to the underbody using a suitable object, e.g. steel wire. If the flexible pipe bends 5 - 10 degrees from its intended mounting position there may be damage caused and complete failure of the flexible pipe.

32. Remove the exhaust system

Remove the front exhaust pipe - 3x Unscrew nut


33. Remove the exhaust system

Instruction: 2. A technician is needed

Undo the exhaust system - 5x Thrust ring

34. Remove the steering intermediate spindle

Important: Do not change the position of the steering wheel. Leave the steering column lock engaged or fix the steering wheel to the dashboard with adhesive tape.

Undo the clamp screw (1)


35. Remove the wing liner front nuts on both sides

36. Fit KM-6313 (83 96 145 Centring fixture, subframe - engine) with 83 96 368 Additional kit for centring fixture (1)

Place KM-6313 ( 83 96 145 Centring fixture, subframe - engine ) on the left of the front axle member (arrows, picture I)

Instruction: The guide bolt must be in the hole in the subframe

2x Place the right holder on the subframe (arrows, picture II)

Instruction: The guide bolt must be in the hole in the subframe (arrow, picture III)

2x Tighten bolt


37. Fit support

Adjust support mounting

Screw on the nut

38. 3x Adjust the support

Gearbox side

Instruction: Turn the spindle until the brackets (1) are firmly against the guide pins

Engine control side Instruction: Place the support pin firmly into the hole in the engine block (arrow), tighten the nut, bolts and support


39. Lower the car

40. Undo the right engine pad adapter

3x Unscrew (1)


41. Undo the left engine holder adapter

3x Unscrew (1)


42. Raise the car

43. Position a 83 95 311 Trolley lift with 83 94 801 Parent fixture underneath.

44. Fit KM-6312 or 83 96 137 Centring tool, subframe - body

Place KM-6312 (2) 83 96 137 Centring tool, subframe - body - Onto KM-904 (1) or 83 95 188 Basic fixture

Instruction: Lower the body location pins (3)

Put in place KM-6312

Instruction: Firmly under the front axle member, observing the centring points in the front axle member (arrow)


45. Undo the subframe

Important: Do not use an impulse or impact nut runner to undo the subframe

7x Undo the bolt (arrows)

Important: Lower the subframe with the engine and gearbox carefully out of the engine bay. Do not damage any components

46. Lower the power unit

Instruction: 2 Technicians are needed

47. Run out the drive unit

48. Check the threads

8x Check the clamp nut

49. Clean the threads

From the clamping piece

To fit



50. Run in the drive unit

Instruction: Fix the body locating pins in the upper position

51. Lift up the drive unit

Instruction: 2. Technicians are needed

Important: Run in the front axle member with engine and gearbox carefully into the engine bay. Do not damage any components

Run the body locating pins into the body locating holes

52. Fit the subframe. Tightening torque: 75 Nm + 135° (55 lbf ft +135°)



53. Run out the trolley lift

54. Remove the straps

55. Lower the car

56. Fit the left engine holder adapter

3x Tighten bolt - Tightening torque 55 Nm

57. Fit the right engine pad adapter

3x Tighten bolt - Tightening torque 55 Nm

58. Raise the car

59. Remove the support

Engine control side

60. Remove KM-6313 or 83 96 145 Centring fixture, subframe - engine

61. Fit the steering intermediate spindle

Instruction: Before fitting the clamp bolt, check that the groove in the steering gear spindle is aligned with the intermediate spindle hole.

Clean the threads and apply 74 96 268 Thread locking adhesive to the threads.

Tightening torque 30 Nm (22 lbf ft)

62. Put in place the exhaust system

Instruction: 2 Technicians are needed

63. Fit the exhaust system

Instruction: Change the seal

3x Change nut

3x Tighten nut - Tightening torque 20 Nm

64. Fasten the cable set connector for the catalytic converter control lambda sensor

65. Lower the car

66. 2x Pull in the drive shaft

Instruction: Change nuts

2x Screw on nuts

67. 2x Fit track rod

Instruction: Change nuts and bolts

2x Tighten nut - Tightening torque 50 Nm


68. 2x Fit the pitman arm

Instruction: Change nuts

2x Tighten the nut

Instruction: Hold with an open spanner - Tightening torque 65 Nm

69. 2x Fit track rod ball joint

Instruction: Change nuts

2x Tighten nut - Tightening torque 35 Nm

70. Lower the car

71. 2x Fasten drive shaft

2x Tighten the nut

Instruction: Torque tighten nuts to 150 Nm, undo 45° and tighten to 250 Nm

72. Attach the selector mechanism wires

Press the ball joint onto the control lever

Fasten the selector mechanism wire in the support

73. Fit the quick coupling for the clutch slave cylinder. Remove the hose pinch-off pliers. Make sure the connection is fixed in the right position.

Fit the reversing light switch connection

Bleed the clutch. See Bleeding the clutch hydraulic system in situ

74. Fit the brake servo vacuum line

Instruction: The connection should make an audible click

75. 2x Fit hot water hose

76. Fit the coolant equalising container

3x Fit the coolant hose

Connect cable set connector

77. Fit EVAP canister purge valve hose

78. Fit the fuel line

Fasten the fuel line holder - Tighten nut

79. Fit the A/C compressor

- Tightening torque 20 Nm

Plug in the connector

80. Fit the multi-belt.


81. Fit the air filter housing

Fit the intake hose

Fit the engine vent hose

Connect cable set connector

Fasten the cable set

Fasten the pressure switch cable set connector

82. Fit the coolant hoses to the engine

83. Fit the engine management system cable set

Fit cable set connector II

Fit cable set connector I

2x Tighten bolt - Tightening torque 2.5 Nm

Fit the ground cable.

Fasten the engine bay fuse holder - 2x Tighten the bolt

Fasten the cable set

84. Fit the battery holder

3x Tighten bolt

Fit the ground distributor - Tighten the bolt

Fit the positive distributor - Tighten the bolt

Fasten the cable set

85. Fit the battery.

Fit the battery holder - Tighten the bolt

Fit the positive cables

Fit the guard

86. Raise the car

87. Fit the spoiler shield

88. Lower the car

89. 2x Fit the front wheel

90. Fit the upper engine cover.

Unscrew the lid on the oil filler connection

2x Tighten bolt - Tightening torque 8 Nm

Screw on the lid on the oil filler connection

91. Connect the battery.

92. Fill with coolant

Instruction: Fill and bleed the cooling system - See Cooling system, filling and bleeding

Observe the prescribed amount of coolant

93. Program erased memories

94. Test drive and check steering wheel position. Adjust as necessary.