9-3 1999

Engine

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Removal & Installation



Specific to:

Saab 9-3 1999


NOTE
The engine and transaxle are removed together as an assembly.

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. With all 4 wheels on the ground, loosen the axle hub nuts.
  4.  
  5. Relieve the fuel system pressure.
  6.  
  7. Drain the engine coolant.
  8.  
  9. Remove or disconnect the following:

    Battery
     
    Air cleaner assembly and attached hoses
     
    Resonator
     
    Throttle cable and move it to one side
     
    Cruise control wiring harness and cables from the throttle body
     
    Cruise control unit retaining nuts
     
    Cruise control unit
     
    Fuel lines at their connections at the front of the fuel injection manifold and on the fuel pressure regulator
     
    Turbocharger pressure line from the turbocharger compressor, if equipped
     
    Intercooler/throttle housing, if equipped
     
    Vacuum hose from the secondary injection
     
    Brake booster vacuum hose from the intake manifold
     
    Boost pressure control unit, if equipped
     
    Drive belt using a 3 / 8 ratchet extension
     
    Pressure and return pipe from the steering servo pump, and plug the pipes to prevent oil from escaping.
     
    Cooling system hoses at the following connections:
     
    Heater control valve
     
    Expansion tank
     
    Bottom of the radiator
     
    Thermostat housing
     

  10.  
  11. Remove or disconnect the following:

    A/C compressor and its mounting bracket without disconnecting any hoses. Place them on the filter housing for the heater system. Secure the alternator so it will not drop or become damaged.
     
    Positive battery cable from the clips holding it to the body
     
    Ground cable from the transaxle
     
    Ignition cable
     
    Electrical connections from the ignition coil
     
    Wiring connectors from the transaxle
     
    Oxygen (O 2 S) sensor connector
     
    Catalytic converter temperature sensor connector, if equipped
     

  12.  
  13. Inside the vehicle, pull back carpet under glove box to gain access to the central locking system and disconnect the control module. Feed the wires to the engine compartment through the grommet.
    NOTE
    Be sure the halfshafts can slide out of the hubs. If necessary, use a wheel puller to push them out now.



    Hub nuts and both wheels
     
    Front splash shield
     
    Tapered pin from the gearshift rod joint located under the vehicle
     
    Clutch cable and clutch pipe if equipped
     
    Both ball joint nuts and the ball joints from the struts
     



    Front pipe from the exhaust manifold
     
    Catalytic converter
     
    Oil cooler lines
     
    All the lines connected to the transaxle housing

    Click image to see an enlarged view

    Fig. Lowering the entire powertrain assembly-900 and 9-3 models

     

  14.  
  15. Position the lifting table under the vehicle so it is directly under the front engine mount and gearbox. Take off the subframe bolts and the front engine mounts.
  16.  
  17. Lower the lifting table slightly and separate the halfshafts from the hubs.
  18.  
  19. Lower the lifting table fully and remove the subframe.
  20.  
  21. Place the engine on an engine stand.
  22.  

To install:

  1. Place the engine/transaxle on the lifting table.
  2.  
  3. Install the subframe on the rear engine mount and torque the bolts to 35 ft. lbs. (47 Nm).
  4.  
  5. Install the halfshafts into the hubs as the engine is raised into the engine compartment.
  6.  
  7. Install the engine mount and subframe bolts and torque them in sequence as follows:
    1. Front bolts: 85 ft. lbs. (115 Nm).
    2.  
    3. Middle subframe bolts: 141 ft. lbs. (192 Nm).
    4.  
    5. Rear subframe bolts: 90 ft. lbs. (122 Nm).
    6.  
    7. Rear engine mount: 54 ft. lbs. (73 Nm).
    8.  

  8.  
  9. Install or connect the following:

    All oil cooler and hydraulic lines
     
    All charge air cooler lines between the turbocharger and the cooler
     
    Front exhaust pipe to the exhaust manifold
     
    Catalytic converter to the rear exhaust section
     
    Engine shield to the underside of the vehicle
     
    Hub nuts and wheels and torque the wheel nuts to 89 ft. lbs. (121 Nm) but do not tighten the hub nuts yet
     

  10.  
  11. Feed the wiring through the grommet and reconnect the central locking system control module.

    Clutch cable or bleed the clutch hydraulic cylinder, if equipped
     
    Tapered pin to the gearshift selector
     
    O 2 S sensor and catalytic converter temperature sensor
     
    All transaxle wiring
     
    A/C compressor, servo pump and drive belt
     
    Power brake booster vacuum hose and pressure sensor connections
     
    Cruise control including cables and the electrical harness connections
     
    Battery and cables
     

  12.  
  13. With all 4 wheels on the ground torque the hub nuts to 215 ft. lbs. (290 Nm).
  14.  
  15. Fill the coolant system.
  16.  
  17. Fill the engine with clean oil.
  18.  
  19. Start the vehicle, check for leaks and repair if necessary.
  20.  

Specific to:

Saab 900 1998

Saab 9000 1998

Saab 9-3 1999

Saab 9-5 1999


NOTE
Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer systems and may require the computer to undergo a relearning process, once the negative battery cable is reconnected.

 
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