SAAB WIS ONLINE

Power train

Power train

To remove


The method described applies to removal of the power train with A/C and automatic transmission or manual gearbox.

Important

A large number of electrical cables, hoses, leads etc. are secured with plastic cable ties. When these cable ties are pulled tight the excess length is cut off. This may leave a sharp edge.

Bear this in mind when securing ties to avoid leaving sharp edges, which could be the cause of cuts and scratches on your hands.



1. Drape protective covers over the wings to protect the paintwork and remove the battery.

2. Open the coolant drain plug. Remove the filler cap from the expansion tank to speed up the draining.

3. Remove the two engine covers. Remove the air cleaner. To do this loosen the hose clip, unplug the two connectors and remove the retaining bolts.


4. Disconnect the throttle cable and bend it aside.

5. Remove the Cruise Control unit complete with cables. First expose the ball in the throttle an release the cable from the clip in the bulk-head partition. Disconnect the electrical connections on the Cruise Control system and remove the retaining screws.

6. Separate and plug the fuel connectors.


7. Disconnect the tank breather hose and bend it to one side.

8. Remove the secondary air injection vacuum hoses (if fitted) and detach the brake servo vacuum hose.

9. Remove the top radiator hose. Note that it is secured to the fan cowl by a clip.


10. Unplug the radiator fan connector, disconnect the power steering pump pipe from the radiator bridge and battery tray. Remove the fan cowl retaining screws and carefully lift out the fan cowl.

11. Remove the secondary air injection hose (where fitted).

12. Disconnect the bottom radiator hose from the radiator.


13. Slacken the power steering pump belt pulley bolts slightly. Relieve the drive belt of tension and move it aside.


14. Remove the power steering pump pulley. Remove the two power steering pump retaining bolts and lift out the pump.


15. Unplug the A/C compressor connector and undo the clip. Remove the A/C compressor's upper retaining bolts.

16. Disconnect the radiator hose connected to the throttle body at the expansion tank.


17. Disconnect the hoses connected to the heater core at the engine and bend them aside. Also disconnect the radiator hose from the expansion tank at the engine.

18. Unplug the two electrical connectors for the automatic transmission behind the battery and place the cables on the power train. (Manual gearbox: remove the reversing light switch.)


19. Disconnect the positive cable from the positive terminal.

20. Disconnect the grounding connection on the gearbox and tuck the cable out of the way.

21. Remove the breather hose from the automatic transmission and plug the hole in the transmission casing.

22. Remove the gear-selector cable by undoing the nut. (Manual gearbox: engage 4th gear, separate the selector rod and engage 3rd gear by means of the gear lever. Disconnect the clutch cable.)

23. Remove the engine wiring harness.


• Remove the glove box and air ducts and fold up the carpet.

• In cars with a passenger airbag, remove the knee shield.

• Remove the engine wiring harness.

From the engine bay:

• Pull the wiring harness through the lead-through into the engine bay and place the wiring on the engine.

24. Slacken the hub centre nuts on both sides and raise the car.


25. Remove both front wheels and remove the hub centre nuts. Detach the brake calipers and hang them from the MacPherson struts. Undo the nut securing the steering swivel joint on both sides. User puller 89 96 696.

26. Remove the cover in the right-hand wheel housing and the spoiler sections.

27. Raise the car higher and unplug the oxygen sensor connectors. Remove the front exhaust pipe. (If the front exhaust pipe need not be removed for repair, separate the joint between the front and centre exhaust pipe sections.)


28. Undo the bolt in the A/C compressor bracket. The bolt cannot be removed in this position.

29. Place a receptacle under the automatic transmission, remove the oil lines from the transmission casing and plug the holes.


30. Run lifting trolley 83 94 739 under the car and arrange it so that the holders on the trolley are directly below the front engine mountings and the gearbox and abut against them. Remove the subframe retaining bolts. Remove the front engine mountings from the body.

31. Lower the lifting trolley about 25 cm and with it the subframe and power train. Make sure that the steering swivel joints come away and lift out the drive shafts.

32. Remove the A/C compressor and suspend it from the tow rope attachment eye by means of cable ties.

33. Lower the lifting trolley all the way down and remove the nut in the rear engine mounting. Pull the subframe away to the rear.



To fit




Important

A large number of electrical cables, hoses, leads etc. are secured with plastic cable ties.

After pulling these cable ties tight, cut the excess length off to leave the ends as short as possible at the attachment points. Bear this in mind and help to reduce the risk of sharp edges scratching bare hands or causing damage by chafing.



1. Fit the subframe and tighten the rear engine mounting. Insert the rear bolts fitted with washers. Run the lifting trolley with power train under the raised car.

Tightening torque 47 Nm (35 lbf ft).

2. Fit the drive belt, lower the car carefully and raise the lifting table. Align the drive shafts and steering swivel joints.


3. Hang the A/C compressor in position and fit the bolts but do not tighten them. Then tighten the lower bolt.

4. Raise the engine by means of the lifting trolley and fit the front engine mountings.

Tightening torque 73 Nm (54 lbf ft).

5. Tighten the sub-frame retaining bolts.


Tightening torques

front: 115 Nm (85 lbf ft)

middle: 190 Nm (140.6 lbf ft)

- rear: 110 Nm (81.4 lbf ft) + 75°.

6. Check that the seals for the automatic transmission oil pipe connections are intact. Fit the nipples.


Tightening torque: 25 Nm (18.5 lbf ft).

7. Fit the front exhaust pipe. Connect the oxygen sensors.

Important

Fit new gaskets. It is very important that all joints are sealed.


8. Align the steering swivel joints and fit the nuts.


Tightening torque: 75 Nm (55.5 lbf ft).

9. Fit the spoiler sections and the cover in the right-hand wheel housing.

10. Refit the brake calipers.

Tightening torque 105 Nm (77.7 lbf ft).

11. Fit the hub nuts loosely and put the wheels back on the car.

Tightening torques

110 Nm (81 lbf ft)

12. Lower the car and tighten the hub centre nuts. Always use new nuts.

Tightening torque 290 Nm (214.6 lbf ft).

Warning

Do not forget to tighten the hub centrer nuts.


13. Lower the car and refit the engine wiring harness. Insert the wiring through the lead-through in the bulkhead. Connect the wiring. Refit the air ducts and the glove box. Fit the knee shield (in cars with passenger air bag).


Check that the seal in the lead-through is correctly fitted.

14. Automatic transmission:


Fit gear-selector cable.

Manual gearbox:

Lock 4th gear with locking pin 87 92 335 (with the ring upwards) in the gearbox. Engage 4th gear and insert locking pin 87 92 335 (with the ring downwards) in the gear lever housing. Fit the selector rod. Remove the locking pins from the gearbox and gearbox housing and insert a new plastic plug in the gearbox. Try changing gear.

Refit the clutch cable.

15. Refit the automatic transmission breather hose.

16. Connect the grounding connection to the gearbox.

Warning

Remembering to ground the gearbox is extremely important. Danger of fire.


17. Connect the positive cable to the positive terminal.

18. Connect the automatic transmission electrical connectors.

Manual gearbox: Connect the reversing light switch.

19. Fit the bottom radiator hose to the radiator.



A Hose from expansion tank

B Hose from heater core

C Hose from heater core

20. Connect the radiator hose from the expansion tank to the water intake and the hoses from the heater core to the water intake and coolant bridge.


21. Connect the radiator hose connected to the throttle body at the expansion tank.

22. Tighten the two top A/C compressor retaining bolts. Plug in the connector.


23. Fit the power steering pump and the pump pulley. Fit the drive belt.

24. Fit the secondary air injection hose (where fitted). Check that the coolant drain plug has been properly tightened.


25. Carefully fit the fan cowl in place. Fit the retaining screws and the power steering pump pipe and plug in the two connectors.

26. Fit the top radiator hose.

27. Fit the brake servo vacuum hose. Fit the secondary air injection vacuum hose (where fitted).


28. Fit the tank breather hose.

29. Fit the two fuel connections.

30. Fit the Cruise Control unit complete with cables. Refit the electrical connections and hook the Cruise Control cable onto the throttle body. Hook the throttle cable in place.


31. Fit the air cleaner and mass air flow sensor. Plug in the two connectors.

32. Fit the battery and the engine covers. Remove the protective covers from the wings.

33. Top up with coolant and check the system for leaks.

34. Top up the gearbox oil in the gearbox dip stick pipe (aut.).

35. Top up engine oil, check other oil and fluid levels and top up as necessary. Make sure that engine, engine bay and cabin are clean.

Warning

Coolant is very hot and under high pressure. Risk of burn injury when the pressure cap is opened. Be extremely careful.


36. Bleed the cooling system as follows: Fill the system up to the MAX level, fit the pressure cap, start the engine and warm it up, preferably at different rpm, until the radiator fan starts. Remove the pressure cap and top up to MAX. Fit the pressure cap and run the engine at varying rpm until the radiator fan starts three more times. Switch off the engine and refill to the MAX level if necessary.

37. Test drive the car and check all functions. Also check oil levels in the engine and gearbox.