Saab 2000-06

Engine 1

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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.


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.

Removal & Installation



REMOVAL & INSTALLATION

9-3
2.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain the oil and coolant from the engine and the fluid from the gearbox.
  6.  
  7. Remove the alternator.
  8.  
  9. Remove the right-hand drive shaft with intermediate shaft.
  10.  
  11. Remove the bearing anchorage of the intermediate shaft.
  12.  
  13. Remove the engine mounting from the engine.
  14.  
  15. Remove the drive belt.
  16.  
  17. Remove the power steering pump. Let the servo hoses remain on the pump.
  18.  
  19. Unplug the control module connectors and disconnect the ground cable.
  20.  
  21. Unhook the power steering reservoir and servo hose clips.
  22.  
  23. Remove the A/C bracket and the turbocharger delivery pipe mounting.
  24.  
  25. Remove the power steering pump bracket.
  26.  
  27. Remove the secondary air injection pump complete with connectors, hoses and mountings.
  28.  
  29. Detach the turbocharger delivery hose from the turbocharger.
  30.  
  31. Detach the coolant hoses from the oil cooler. Collect any fluid spill.
  32.  
  33. Detach the coolant pipe with hoses from the thermostat housing.
  34.  
  35. Remove the starter motor.
  36.  
  37. If equipped with automatic transaxle, remove the bolts holding the torque converter in place.
  38.  
  39. Remove the wiring harness between the starter motor and alternator as well as the one from the rear of the intake manifold. Release the two clips from the back of the engine and the cable duct on the gearbox.
  40.  
  41. If equipped with manual transaxle, remove the cable mounting from the gearbox.
  42.  
  43. If equipped with automatic transaxle, remove the clamp and ground cable from the plate bracket and unplug the connector from the gear selector position sensor/control module.
  44.  
  45. Detach the 7-pin connector and the cable duct from the intake manifold.
  46.  
  47. Remove the upper and lower heat shields from the turbocharger.
  48.  
  49. Unplug the connectors of the heated oxygen sensors.
  50.  
  51. Detach the upper oxygen sensor from the catalytic converter.
  52.  
  53. Remove the catalytic converter with mounting.
  54.  
  55. Remove the upper mounting of the catalytic converter from the engine.
  56.  
  57. Remove the coolant pipe between the heat exchanger and thermostat housing.
  58.  
  59. Unplug the connectors and remove the engine control module with mounting.
  60.  
  61. Connect 83 92 409 Lifting yoke to the engine and unload with an engine lift.
  62.  
  63. Remove the bolts holding the torque arms to the subframe.
  64.  
  65. Raise the engine from the subframe.
  66.  
  67. Remove the 4 lower bolts of the transaxle.
  68.  
  69. Place the engine on the floor.
  70.  
  71. Remove the transaxle bolts and lift away the transaxle.
  72.  
  73. If equipped with automatic transaxle, press the torque converter against the gearbox.
  74.  
  75. If equipped with automatic transaxle, fit 87 92 574 Holder to hold the torque converter in place.
  76.  
  77. Transfer the crankcase ventilation hose.
  78.  

To install:


NOTE
Read the engine designation (L or E) and the serial number on the old engine and stamp in the equivalent on the new one.

  1. If equipped with automatic transaxle, turn the torque converter so that the bolt holes align with the holes on the driver plate and turn the engine so that the oval hole in the driver is centered at the starter motor opening. Fit 87 92 574 Holder to hold the torque converter in place during fitting. Lubricate the torque converter guide pin with grease.
  2.  
  3. Make sure the two guide sleeves are fitted on the engine and apply grease to the guide sleeves.
  4.  
  5. Install the transaxle on the engine. If equipped with automatic transaxle, remove 87 92 574 Holder just before the gearbox is in place.
  6.  
  7. Tighten the upper bolts between the engine and transaxle to 14 ft. lbs. (19 Nm). If equipped with automatic transaxle, install the plate bracket for the ground cable.
  8.  
  9. Connect 83 92 409 Lifting yoke, raise the engine with an engine lift and place it on the subframe.
  10.  
  11. Install the bolts that secure the torque arms to the subframe. Tighten the rear torque arm bolts to 59 ft. lbs. (80 Nm), and the front torque arm bolts to 44 ft. lbs. (60 Nm) plus an additional 90°.
  12.  
  13. Fit the lower bolts between the engine and transaxle.
  14.  
  15. If equipped with automatic transaxle, perform the following:


    1. Press the torque converter against the driver plate. Install the plug.
    2.  
    3. Apply a thread locking adhesive to the bolts holding the torque converter to the drive plate. Use the original bolts with corresponding washers. The torque converter will be ruined if the bolts that are used are too long.
    4.  
    5. Turn the crankshaft clockwise with the pulley and tighten the bolts one at a time to 46 ft. lbs. (62 Nm), starting with the oval hole in the drive plate.
    6.  

  16.  
  17. Fit the coolant pipe between the heat exchanger and thermostat housing. Use a new O-ring coated with acid-free vaseline.
  18.  
  19. Position the wiring harness.
  20.  
  21. If equipped with automatic transaxle, plug in the connector of the gear selector position sensor/control module. Install the clamp and ground cable to the plate bracket.
  22.  
  23. If equipped with manual transaxle, install the cable mounting to the transaxle.
  24.  
  25. Connect the two clips on the rear of the engine and fit the cable duct on the transaxle.
  26.  
  27. Fit the engine control module with mounting.
  28.  
  29. Fit the cable duct of the intake manifold and plug in the 7-pin connector.
  30.  
  31. Install the starter.
  32.  
  33. Fit the coolant pipe to the thermostat housing. Use a new O-ring coated with acid-free vaseline.
  34.  
  35. Attach the coolant hoses to the oil cooler.
  36.  
  37. Attach the turbocharger delivery hose to the turbocharger.
  38.  
  39. Install the secondary air injection pump complete with connectors, hoses and mountings.
  40.  
  41. Install the upper mounting of the catalytic converter to the engine and tighten the M10 size bolt to 30 ft. lbs. (42 Nm).
  42.  
  43. Install the catalytic converter with bracket, using 90 513 210 Universal paste on the nut threads. Install the upper heated oxygen sensor. Tighten the flange-to-turbocharger bolts to 18 ft. lbs. (25 Nm), mounting-to-oil sump bolts to 14 ft. lbs. (19 Nm), and the mounting-to-exhaust flange bolts to 30 ft. lbs. (40 Nm).
  44.  
  45. Plug in the connectors of the heated oxygen sensors.
  46.  
  47. Fit the upper and lower heat shields to the turbocharger.
  48.  
  49. Fit the power steering pump bracket.
  50.  
  51. Install the A/C bracket and the turbocharger delivery pipe mounting. Tighten the A/C bracket bolts to 28 ft. lbs. (38 Nm).
  52.  
  53. Hook on the power steering fluid reservoir; secure the hose with the clip.
  54.  
  55. Plug in the engine control module connectors and connect the ground cable.
  56.  
  57. Install the power steering pump and tighten the mounting bolts to 14 ft. lbs. (19 Nm).
  58.  
  59. Fit the drive belt.
  60.  
  61. Install the engine mounting to the engine and tighten the mounting bolts to 69 ft. lbs. (93 Nm).
  62.  
  63. Fit the bearing anchorage of the intermediate shaft and tighten the bolts to 18 ft. lbs. (24 Nm).
  64.  
  65. Install the alternator bracket. Tighten the M8 size bolt to 16 ft. lbs. (22 Nm), and the M10 size bolt to 28 ft. lbs. (38 Nm)
  66.  
  67. Install the alternator.
  68.  
  69. Install the right-hand drive shaft with intermediate shaft.
  70.  
  71. Fill the engine with coolant
  72.  
  73. Fill the engine with clean oil.
  74.  
  75. Fill the transmission to the proper level.
  76.  
  77. Connect the negative battery cable.
  78.  
  79. Start the vehicle, check for leaks and repair if necessary.
  80.  
  81. Bleed the cooling system, if necessary.
  82.  
  83. Bleed the clutch system (manual transmission).
  84.  
  85. Restore all electrical functions.
  86.  

2000-2002 Model

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

  1. Before servicing the vehicle, refer to the Precautions 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 to prevent oil escaping from the pipe.
     

  10.  
  11. Disconnect the cooling system hoses at the following connections:


    1. Heater control valve
    2.  
    3. Expansion tank
    4.  
    5. Bottom of the radiator
    6.  
    7. Thermostat housing

      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 transmission
       
      Ignition cable
       
      Electrical connections from the ignition coil
       
      Wiring connectors from the transmission
       
      O 2 S connector
       
      Catalytic converter temperature sensor connector, if equipped
       

    8.  

  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.
  14.  
  15. Remove or disconnect the following:
    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 transmission housing

    Click image to see an enlarged view

    Fig. Lowering the entire powertrain assembly-9-3 models with 2.0L and 2.3L engines

     

  16.  
  17. 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.
  18.  
  19. Lower the lifting table slightly and separate the halfshafts from the hubs.
  20.  
  21. Lower the lifting table fully and remove the subframe.
  22.  
  23. Place the engine on an engine stand.
  24.  

To install:

  1. Place the engine/transmission 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.
  12.  
  13. Install or connect the following:

    Clutch cable or bleed the clutch hydraulic cylinder, if equipped
     
    Tapered pin to the gearshift selector
     
    Oxygen (O 2 S) sensor and catalytic converter temperature sensor
     
    All transmission 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
     

  14.  
  15. With all 4 wheels on the ground torque the hub nuts to 215 ft. lbs. (290 Nm).
  16.  
  17. Fill the coolant system.
  18.  
  19. Fill the engine with clean oil.
  20.  
  21. Start the vehicle, check for leaks and repair if necessary.
  22.  

2003-06 Model (Except 2.8L Engine)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Open cap on expansion tank.
  4.  
  5. On lift, raise car slightly and remove front wheels.
  6.  
  7. Remove lower spoiler shield. Detach hose to headlamp washers, unplug connector and remove it.
  8.  
  9. Drain cooling system.
  10.  
  11. Remove wheel well liners.
  12.  
  13. Remove cover by the gearbox.
  14.  
  15. Detach the hose for the headlamp washers and drain washer fluid reservoir.
  16.  
  17. Lower the car slightly and remove the front bumper.
  18.  
  19. Remove the cover on the left side and the hose between the charge air pipe and cooler.
  20.  
  21. Remove the lower charge air pipe bracket from the fan cowling.
  22.  
  23. Remove cover on right side and hose between charge air cooler and pipe.
  24.  
  25. Remove receiver-drier bolts from the radiator.
  26.  
  27. Remove the lower seal between the charge air cooler and the radiator.
  28.  
  29. Lower the car and remove the upper engine cover.
  30.  
  31. Remove the battery cover and battery cooler pipe.
  32.  
  33. Remove the hood release cable coupling by first undoing the clip in the body and then separating the quick-release couple using a screwdriver.
  34.  
  35. Remove the upper radiator support.
  36.  
  37. Unplug the pressure-temperature sensor connector.
  38.  
  39. Disconnect the bypass valve hose.
  40.  
  41. Detach the charge air hose from the throttle body and release the upper charge air pipe bracket from the fan cowling. Remove the pipe and hose.
  42.  
  43. Remove the battery.
  44.  
  45. Detach the ventilation hose from the radiator.
  46.  
  47. Detach the vacuum hose quick-release coupling from the vacuum pump.
  48.  
  49. With automatic transmission, unplug the connector from the TCM. Remove the control module.
  50.  
  51. Unplug the connector under the control module.
  52.  
  53. Release the main fuse box in front of the battery tray and move it aside.
  54.  
  55. Unplug the hood switch connector, release the cable clip and remove the battery tray.
  56.  
  57. Detach the connector and release the clip holding the cables on the fan cowling.
  58.  
  59. Unplug the reverse light switch connector.
  60.  
  61. Remove the seal over the radiator core.
  62.  
  63. Remove the upper radiator brackets from the body.
  64.  
  65. Unplug both connectors from the left side structural member.
  66.  
  67. With automatic transmission, detach the pipes from the fluid cooler.
  68.  
  69. Remove the fan cowling bolts and loosen cowling slightly.
  70.  
  71. Secure the condenser and charge air cooler to the body with cable ties.
  72.  
  73. Remove the fan cowling. Carefully detach A/C pipes from retaining clip on right side structural member.
  74.  
  75. With receptacle under radiator, remove lower radiator hose.
  76.  
  77. Remove upper radiator hose.
  78.  
  79. Remove the radiator.
  80.  
  81. Unplug the A/C pressure sensor connector.
  82.  
  83. Detach the hoses from the turbocharger inlet pipe and remove the pipe.
  84.  
  85. Unplug the mass air flow (MAF) sensor connector. Cap the turbocharger inlet.
  86.  
  87. Remove the air cleaner cover and the air cleaner.
  88.  
  89. Detach the intake hose and remove the air cleaner casing.
  90.  
  91. Remove the windshield washer filler pipe.
  92.  
  93. Remove 2 mounting screws from inside the main fuse box.
  94.  
  95. Disconnect the positive battery cable connection.
  96.  
  97. Undo the engine harness connector retaining screw in the main fuse box.
  98.  
  99. Remove the engine harness clamp from the body and the ground cables.
  100.  
  101. Bend up the engine harness and secure it to the engine with a suitable strap.
  102.  
  103. Unplug the coolant level connector.
  104.  
  105. Detach the expansion tank from the body and secure it to the engine.
  106.  
  107. Undo coolant hose quick-release couplings while trapping any coolant spill. Bend hose aside and secure it to the engine.
  108.  
  109. Detach cables from gearbox. Carefully bend then aside and secure to expansion tank bracket with cable ties.
  110.  
  111. With pliers, pinch off clutch hose and disconnect quick-release coupling from clutch slave cylinder.
  112.  
  113. Release any pressure in the fuel system by carefully pressing the service valve needle. Collect any fuel spillage.
  114.  
  115. Detach both fuel lines from fuel rail while gripping the lower nut. Plug the fuel line openings.
  116.  
  117. Disconnect quick-release coupling for ventilation line and detach fuel lines and vent lines from clips on camshaft cover. Bend up vent hose from intake manifold and place it on camshaft cover.
  118.  
  119. Be sure steering wheel and front wheels are in the straight-ahead position.
    WARNING
    To prevent contact roller for airbag from breaking due to twisting, steering wheel should be fixed in position, such as taping it to the instrument panel.

  120.  
  121. Detach the steering shaft from the steering gear.
  122.  
  123. Raise the car. Mark the rotation direction of the auxiliary drive belt, then remove it.
  124.  
  125. Unplug the A/C compressor connector and remove the compressor retaining bolts.
  126.  
  127. Remove the power steering pipe clamp bolts from the subframe.
  128.  
  129. Slightly loosen rear torsion arm bolts.
  130.  
  131. Fit an engine centering tool kit, 83 96 152, to subframe, as illustrated. Adjust the centering tool bolts so adjuster screw slots are completely visible.
    NOTE
    Because of narrow tolerances on the driveshafts, centering tool must be used to carefully fit the powertrain to the subframe and body during installation.

  132.  
  133. Lower the car and re-install the radiator support member.
  134.  
  135. Attach a strap, 83 95 212, to radiator support, lower the strap and wind it an extra turn around the A/C compressor to relieve any strain.
  136.  
  137. Remove left and right side engine mounts.
  138.  
  139. Raise the car and disconnect the driveshaft from the hub by removing the center nuts. It may be necessary to use a driveshaft puller, 89 96 951, or a brass drift and mallet.
  140.  
  141. Remove outboard steering link nuts and separate links from steering swivel member.
  142.  
  143. Grip anti-roll bar link flats with a wrench, then disconnect the anti-roll bar links.
  144.  
  145. Undo the lower swivel joints from the steering swivel members and lower the suspension arms.
  146.  
  147. Disconnect the driveshafts and move them away.
  148.  
  149. Measure a distance of about 8 inches (87 mm) from front end of muffler and cut the exhaust pipe between the muffler and flexpipe.
  150.  
  151. Detach front pipe from the catalytic converter.
  152.  
  153. Disconnect the ground cable from the gearbox and the connector for the angle sensor (if equipped).
  154.  
  155. Position a subframe-to-engine centering tool, 83 96 145, on engine lift (70).
    NOTE
    Ensure adjuster screws on height adjusters, 83 95 170, are in their lowest position.

  156.  
  157. Position the engine lift, the raise and insert the guide pins in the subframe reference holes. Adjust the lifting pillars with the height adjusters so they rest evenly on the subframe.
  158.  
  159. Check with the body guide pins that the subframe is positioned correctly in relation to the body.
  160.  
  161. Raise engine lift slightly to ensure stable contact, then remove the subframe bolts in the body (72).
  162.  
  163. Carefully lower the engine and transmission assembly on the engine lift, checking that no components a caught or damaged during removal.

    Click image to see an enlarged view

    Fig. Showing location of coolant quick-release connections, gearbox cables and clutch hose-9-3 2003-06



    Click image to see an enlarged view

    Fig. Showing engine centering tool installed-9-3 2003-06



    Click image to see an enlarged view

    Fig. Showing engine lift equipment installed-9-3 2003-06

  164.  

To install:

  1. Position the engine lift under the vehicle, moving the engine and transmission in position.
  2.  
  3. Lift the powertrain until the inboard driveshaft U-joints are level with the wheel hubs, then insert the driveshafts into the hubs.
  4.  
  5. Lift the powertrain a little higher and position the lower swivel joints to steering swivel members. If necessary, adjust the engine lift screws to provide even contact with the body. Ensure guide pins are correctly positioned.
  6.  
  7. Install the subframe-to-body bolts. Raise the engine lift fully and tighten the subframe bolts to 55 ft. lbs. (75 Nm), plus and additional 90 degrees.
  8.  
  9. Install or connect the following:

    Lower swivel joint bolts to 37 ft. lbs. (50 Nm); ensure steering knuckle stub is visible on top of steering knuckle housing before bolt is installed.
     
    Anti-roll bar link bolts to 47 ft. lbs. (64 Nm)
     
    Outboard steering links and bolts to 26 ft. lbs. (35 Nm)
     
    Ground cable to gearbox and connector for angle sensor (if equipped).
     
    Position joint clamp on front exhaust pipe
     
    Catalytic converter to front exhaust pipe, tightening nuts to 18 ft. lbs. (25 Nm)
     
    Adjust joint clamp so pipe ends are in the middle, then tighten clamp nuts to 30 ft. lbs. (40 Nm)
     
    Right engine mount, after lowering car: right mount to 52 ft. lbs. (70 Nm), plus an additional 60 degrees
     
    Left engine mount to 52 ft. lbs. (70 Nm), plus an additional 45 degrees
     
    Right engine pad-to-body to 30 ft. lbs. (40 Nm), plus an additional 60 degrees
     
    Release strap from radiator member and A/C compressor
     
    Raise car and remove engine centering kit
     
    Rear torsion arm bolts to 52 ft. lbs. (70 Nm), plus an additional 90 degrees
     
    Bolts to power steering pipe clamps on subframe
     
    A/C compressor and connector
     
    Auxiliary drive belt (in proper direction of rotation)
     
    Steering shaft to steering gear. Use new clamp bolt and tighten to 20 ft. lbs. (27 Nm)
     

  10.  
  11. Lower the car and remove the restraint from steering wheel
  12.  
  13. Connect the quick-release coupling on the vent line and press fuel lines and vent lines into clips on camshaft cover.
  14.  
  15. Unplug fuel lines and connect to fuel rail while gripping lower nut. Use new seals.
  16.  
  17. Connect the quick-release coupling to the clutch slave cylinder and release the pliers.
  18.  
  19. Connection at clutch slave cylinder must be mounted at the correct angle, as illustrated.
  20.  
  21. Install or connect the following:
    CAUTION
    To reduce risk of hoses coming loose from delivery side of turbocharger, hoses and connecting pieces must be cleaned thoroughly with a cleaning agent, 30 15 815. Use new hose clamps.



    Cables to gearbox
     
    Coolant hoses at quick-release couplings
     
    Expansion tank to body
     
    Coolant level sensor connector
     
    Ground cables and clamp for engine harness to body
     
    Retaining screw for engine harness connector in main fuse box
     
    Positive cable to battery
     
    2 retaining screws for main fuse box and box cover
     
    Windshield washer filler pipe
     
    Air cleaner housing, intake hose and air cleaner cover
     



    Mass airflow sensor connector
     
    Turbocharger inlet pipe and hoses to inlet pipe
     
    Connector for A/C pressure sensor
     

  22.  
  23. Install the radiator. Cut off the cable ties.
  24.  
  25. Be sure the condenser and charge air cooler hooks are positioned correctly and fit the radiator retaining bolts.
  26.  
  27. Install the upper and lower radiator hoses.
  28.  
  29. Position the fan cowling and press the A/C pipes into the retaining clips. For automatic transmission vehicles, connect the oil pipes from the transmission to the radiator.
  30.  
  31. Install or connect the following:

    Both connectors on left side structural member
     
    Upper radiator brackets to body
     
    Seal over radiator core
     
    Reverse light switch connector
     
    Connector and clip securing cables on fan cowling
     
    Battery tray and cable clip
     
    Hood switch connector
     
    Main fuse box in front of battery tray
     
    Connector to control module
     
    Cover and connector to transmission control module (with automatic transmission)
     
    Vacuum hose coupling to vacuum pump
     
    Ventilation hose to radiator
     
    Battery
     
    Charge air hose to throttle body and upper charge air pipe bracket on fan cowling
     
    Hose to bypass valve and connector to pressure/temperature sensor
     
    Upper radiator support
     
    Hood cable quick-release coupling; secure it to body with new clips
     
    Battery cover and battery cooler pipes
     

  32.  
  33. Raise the car and install the lower seal between the charge air cooler and the radiator.
  34.  
  35. Install the receiver-drier bolts to the radiator.
  36.  
  37. Install the hose between the charge air cooler and charge air pip and fit cover on right side.
  38.  
  39. Install the charge air pipe lower bracket on the fan cowling (left side).
  40.  
  41. Install the charge air hose between the charge air pip and charge air cooler and install cover (left side).
  42.  
  43. Lower the car slightly and install the front bumper.
  44.  
  45. Install or connect the following:

    Hose to headlamp washers
     
    Cover on gearbox
     
    Inner wheel well liners and both front wheel housings
     
    Lower spoiler shield and hose to headlamp washers
     
    Headlamp washer connector
     
    Driveshafts and tighten center hub nuts to 170 ft. lbs. (230 Nm)
     
    Front wheels and tighten lug nuts to 81 ft. lbs. (110 Nm)
     

  46.  
  47. Refill the engine oil, cooling system and washer fluids.
  48.  
  49. Bleed the cooling system, if necessary.
  50.  
  51. Bleed the clutch system (manual transmission).
  52.  
  53. Restore all electrical functions.
  54.  
  55. Install upper engine cover.
  56.  

9-3 2001-02

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

  1. Before servicing the vehicle, refer to the precautions at 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: BatteryAir cleaner assembly and attached hosesResonatorThrottle cable and move it to one sideCruise control wiring harness and cables from the throttle bodyCruise control unit retaining nutsCruise control unitFuel lines at their connections at the front of the fuel injection manifold and on the fuel pressure regulatorTurbocharger pressure line from the turbocharger compressor, if equippedIntercooler/throttle housing, if equippedVacuum hose from the secondary injectionBrake booster vacuum hose from the intake manifold.Boost pressure control unit, if equippedDrive belt using a 3/8 ratchet extensionPressure and return pipe from the steering servo pump and plug to prevent oil escaping from the pipe.

    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 extension38
     
    Pressure and return pipe from the steering servo pump and plug to prevent oil escaping from the pipe.
     

  10.  
  11. Disconnect the cooling system hoses at the following connections: Heater control valveExpansion tankBottom of the radiatorThermostat housing 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 bodyGround cable from the transmissionIgnition cableElectrical connections from the ignition coil Wiring connectors from the transmissionO2S connectorCatalytic converter temperature sensor connector, if equipped
    1. Heater control valve
    2.  
    3. Expansion tank
    4.  
    5. Bottom of the radiator
    6.  
    7. Thermostat housing
    8.  
    9. 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.
    10.  
    11. Positive battery cable from the clips holding it to the body
    12.  
    13. Ground cable from the transmission
    14.  
    15. Ignition cable
    16.  
    17. Electrical connections from the ignition coil
    18.  
    19. Wiring connectors from the transmission
    20.  
    21. O2S connector
    22.  
    23. Catalytic converter temperature sensor connector, if equipped
    24.  

  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.
  14.  
  15. Remove or disconnect the following: Hub nuts and both wheelsFront splash shieldTapered pin from the gearshift rod joint located under the vehicleClutch cable and clutch pipe if equippedBoth ball joint nuts and the ball joints from the struts

    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
     

  16.  


NOTE
Be sure the halfshafts can slide out of the hubs. If necessary, use a wheel puller to push them out now.



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



Click image to see an enlarged view

Fig. Lowering the entire powertrain assembly-9-3 models with 2.0L and 2.3L engines (2001-02)



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.
 
Lower the lifting table slightly and separate the halfshafts from the hubs.
 
Lower the lifting table fully and remove the subframe.
 
Place the engine on an engine stand.
 

To install:

  1. Place the engine/transmission 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: Front bolts: 85 ft. lbs. (115 Nm).Middle subframe bolts: 141 ft. lbs. (192 Nm).Rear subframe bolts: 90 ft. lbs. (122 Nm).Rear engine mount: 54 ft. lbs. (73 Nm).
    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 linesAll charge air cooler lines between the turbocharger and the coolerFront exhaust pipe to the exhaust manifoldCatalytic converter to the rear exhaust sectionEngine shield to the underside of the vehicleHub nuts and wheels and torque the wheel nuts to 89 ft. lbs. (121 Nm) but do not tighten the hub nuts yet
    1. All oil cooler and hydraulic lines
    2.  
    3. All charge air cooler lines between the turbocharger and the cooler
    4.  
    5. Front exhaust pipe to the exhaust manifold
    6.  
    7. Catalytic converter to the rear exhaust section
    8.  
    9. Engine shield to the underside of the vehicle
    10.  
    11. Hub nuts and wheels and torque the wheel nuts to 89 ft. lbs. (121 Nm) but do not tighten the hub nuts yet
    12.  

  10.  
  11. Feed the wiring through the grommet and reconnect the central locking system control module.
  12.  
  13. Install or connect the following: Clutch cable or bleed the clutch hydraulic cylinder, if equippedTapered pin to the gearshift selectorOxygen (O2S) sensor and catalytic converter temperature sensorAll transmission wiringA/C compressor, servo pump and drive beltPower brake booster vacuum hose and pressure sensor connectionsCruise control including cables and the electrical harness connectionsBattery and cables

    Clutch cable or bleed the clutch hydraulic cylinder, if equipped
     
    Tapered pin to the gearshift selector
     
    Oxygen (O2S) sensor and catalytic converter temperature sensor
     
    All transmission 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
     

  14.  
  15. With all 4 wheels on the ground torque the hub nuts to 215 ft. lbs. (290 Nm).
  16.  
  17. Fill the coolant system.
  18.  
  19. Fill the engine with clean oil.
  20.  
  21. Start the vehicle, check for leaks and repair if necessary.
  22.  


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

  1. Before servicing the vehicle, refer to the precautions at 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: BatteryAir cleaner assembly and attached hosesResonatorThrottle cable and move it to one sideCruise control wiring harness and cables from the throttle bodyCruise control unit retaining nutsCruise control unitFuel lines at their connections at the front of the fuel injection manifold and on the fuel pressure regulatorTurbocharger pressure line from the turbocharger compressor, if equippedIntercooler/throttle housing, if equippedVacuum hose from the secondary injectionBrake booster vacuum hose from the intake manifold.Boost pressure control unit, if equippedDrive belt using a 3/8 ratchet extensionPressure and return pipe from the steering servo pump and plug to prevent oil escaping from the pipe.

    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 extension38
     
    Pressure and return pipe from the steering servo pump and plug to prevent oil escaping from the pipe.
     

  10.  
  11. Disconnect the cooling system hoses at the following connections: Heater control valveExpansion tankBottom of the radiatorThermostat housing 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 bodyGround cable from the transmissionIgnition cableElectrical connections from the ignition coil Wiring connectors from the transmissionO2S connectorCatalytic converter temperature sensor connector, if equipped
    1. Heater control valve
    2.  
    3. Expansion tank
    4.  
    5. Bottom of the radiator
    6.  
    7. Thermostat housing
    8.  
    9. 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.
    10.  
    11. Positive battery cable from the clips holding it to the body
    12.  
    13. Ground cable from the transmission
    14.  
    15. Ignition cable
    16.  
    17. Electrical connections from the ignition coil
    18.  
    19. Wiring connectors from the transmission
    20.  
    21. O2S connector
    22.  
    23. Catalytic converter temperature sensor connector, if equipped
    24.  

  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.
  14.  
  15. Remove or disconnect the following: Hub nuts and both wheelsFront splash shieldTapered pin from the gearshift rod joint located under the vehicleClutch cable and clutch pipe if equippedBoth ball joint nuts and the ball joints from the struts

    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
     

  16.  


NOTE
Be sure the halfshafts can slide out of the hubs. If necessary, use a wheel puller to push them out now.



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



Click image to see an enlarged view

Fig. Lowering the entire powertrain assembly-9-3 models with 2.0L and 2.3L engines 2001-02



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.
 
Lower the lifting table slightly and separate the halfshafts from the hubs.
 
Lower the lifting table fully and remove the subframe.
 
Place the engine on an engine stand.
 

To install:

  1. Place the engine/transmission 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: Front bolts: 85 ft. lbs. (115 Nm).Middle subframe bolts: 141 ft. lbs. (192 Nm).Rear subframe bolts: 90 ft. lbs. (122 Nm).Rear engine mount: 54 ft. lbs. (73 Nm).
    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 linesAll charge air cooler lines between the turbocharger and the coolerFront exhaust pipe to the exhaust manifoldCatalytic converter to the rear exhaust sectionEngine shield to the underside of the vehicleHub nuts and wheels and torque the wheel nuts to 89 ft. lbs. (121 Nm) but do not tighten the hub nuts yet
    1. All oil cooler and hydraulic lines
    2.  
    3. All charge air cooler lines between the turbocharger and the cooler
    4.  
    5. Front exhaust pipe to the exhaust manifold
    6.  
    7. Catalytic converter to the rear exhaust section
    8.  
    9. Engine shield to the underside of the vehicle
    10.  
    11. Hub nuts and wheels and torque the wheel nuts to 89 ft. lbs. (121 Nm) but do not tighten the hub nuts yet
    12.  

  10.  
  11. Feed the wiring through the grommet and reconnect the central locking system control module.
  12.  
  13. Install or connect the following: Clutch cable or bleed the clutch hydraulic cylinder, if equippedTapered pin to the gearshift selectorOxygen (O2S) sensor and catalytic converter temperature sensorAll transmission wiringA/C compressor, servo pump and drive beltPower brake booster vacuum hose and pressure sensor connectionsCruise control including cables and the electrical harness connectionsBattery and cables

    Clutch cable or bleed the clutch hydraulic cylinder, if equipped
     
    Tapered pin to the gearshift selector
     
    Oxygen (O2S) sensor and catalytic converter temperature sensor
     
    All transmission 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
     

  14.  
  15. With all 4 wheels on the ground torque the hub nuts to 215 ft. lbs. (290 Nm).
  16.  
  17. Fill the coolant system.
  18.  
  19. Fill the engine with clean oil.
  20.  
  21. Start the vehicle, check for leaks and repair if necessary.
  22.  

9-3 2003-04


Before servicing the vehicle, refer to the precautions at the beginning of this section.
 
Open cap on expansion tank.
 
On lift, raise car slightly and remove front wheels.
 
Remove lower spoiler shield. Detach hose to headlamp washers, unplug connector and remove it.
 
Drain cooling system.
 
Remove wheel well liners.
 
Remove cover by the gearbox.
 
Detach the hose for the headlamp washers and drain washer fluid reservoir.
 
Lower the car slightly and remove the front bumper.
 
Remove the cover on the left side and the hose between the charge air pipe and cooler.
 
Remove the lower charge air pipe bracket from the fan cowling.
 
Remove cover on right side and hose between charge air cooler and pipe.
 
Remove receiver-drier bolts from the radiator.
 
Remove the lower seal between the charge air cooler and the radiator.
 
Lower the car and remove the upper engine cover.
 
Remove the battery cover and battery cooler pipe.
 
Remove the hood release cable coupling by first undoing the clip in the body and then separating the quick-release couple using a screwdriver.
 
Remove the upper radiator support.
 
Unplug the pressure-temperature sensor connector.
 
Disconnect the bypass valve hose.
 
Detach the charge air hose from the throttle body and release the upper charge air pipe bracket from the fan cowling. Remove the pipe and hose.
 
Remove the battery.
 
Detach the ventilation hose from the radiator.
 
Detach the vacuum hose quick-release coupling from the vacuum pump.
 
With automatic transmission, unplug the connector from the TCM. Remove the control module.
 
Unplug the connector under the control module.
 
Release the main fuse box in front of the battery tray and move it aside.
 
Unplug the hood switch connector, release the cable clip and remove the battery tray.
 
Detach the connector and release the clip holding the cables on the fan cowling.
 
Unplug the reverse light switch connector.
 
Remove the seal over the radiator core.
 
Remove the upper radiator brackets from the body.
 
Unplug both connectors from the left side structural member.
 
With automatic transmission, detach the pipes from the fluid cooler.
 
Remove the fan cowling bolts and loosen cowling slightly.
 
Secure the condenser and charge air cooler to the body with cable ties.
 
Remove the fan cowling. Carefully detach A/C pipes from retaining clip on right side structural member.
 
With receptacle under radiator, remove lower radiator hose.
 
Remove upper radiator hose.
 
Remove the radiator.
 
Unplug the A/C pressure sensor connector.
 
Detach the hoses from the turbocharger inlet pipe and remove the pipe.
 
Unplug the mass air flow (MAF) sensor connector. Cap the turbocharger inlet.
 
Remove the air cleaner cover and the air cleaner.
 
Detach the intake hose and remove the air cleaner casing.
 
Remove the windshield washer filler pipe.
 
Remove 2 mounting screws from inside the main fuse box.
 
Disconnect the positive battery cable connection.
 
Undo the engine harness connector retaining screw in the main fuse box.
 
Remove the engine harness clamp from the body and the ground cables.
 
Bend up the engine harness and secure it to the engine with a suitable strap.
 
Unplug the coolant level connector.
 
Detach the expansion tank from the body and secure it to the engine.
 
Undo coolant hose quick-release couplings while trapping any coolant spill. Bend hose aside and secure it to the engine.
 
Detach cables from gearbox. Carefully bend then aside and secure to expansion tank bracket with cable ties.
 
With pliers, pinch off clutch hose and disconnect quick-release coupling from clutch slave cylinder.
 
Release any pressure in the fuel system by carefully pressing the service valve needle. Collect any fuel spillage.
 
Detach both fuel lines from fuel rail while gripping the lower nut. Plug the fuel line openings.
 
Disconnect quick-release coupling for ventilation line and detach fuel lines and vent lines from clips on camshaft cover. Bend up vent hose from intake manifold and place it on camshaft cover.
 
Be sure steering wheel and front wheels are in the straight-ahead position.
 


WARNING
To prevent contact roller for airbag from breaking due to twisting, steering wheel should be fixed in position, such as taping it to the instrument panel.

  1. Detach the steering shaft from the steering gear.
  2.  
  3. Raise the car. Mark the rotation direction of the auxiliary drive belt, then remove it.
  4.  
  5. Unplug the A/C compressor connector and remove the compressor retaining bolts.
  6.  
  7. Remove the power steering pipe clamp bolts from the subframe.
  8.  
  9. Slightly loosen rear torsion arm bolts.
  10.  
  11. Fit an engine centering tool kit, 83 96 152, to subframe, as illustrated. Adjust the centering tool bolts so adjuster screw slots are completely visible.
  12.  


NOTE
Because of narrow tolerances on the driveshafts, centering tool must be used to carefully fit the powertrain to the subframe and body during installation.

  1. Lower the car and re-install the radiator support member.
  2.  
  3. Attach a strap, 83 9-5 212, to radiator support, lower the strap and wind it an extra turn around the A/C compressor to relieve any strain.
  4.  
  5. Remove left and right side engine mounts.
  6.  
  7. Raise the car and disconnect the driveshaft from the hub by removing the center nuts. It may be necessary to use a driveshaft puller, 89 96 9-51, or a brass drift and mallet.
  8.  
  9. Remove outboard steering link nuts and separate links from steering swivel member.
  10.  
  11. Grip anti-roll bar link flats with a wrench, then disconnect the anti-roll bar links.
  12.  
  13. Undo the lower swivel joints from the steering swivel members and lower the suspension arms.
  14.  
  15. Disconnect the driveshafts and move them away.
  16.  
  17. Measure a distance of about 8 inches (87 mm) from front end of muffler and cut the exhaust pipe between the muffler and flexpipe.
  18.  
  19. Detach front pipe from the catalytic converter.
  20.  
  21. Disconnect the ground cable from the gearbox and the connector for the angle sensor (if equipped).
  22.  
  23. Position a subframe-to-engine centering tool, 83 96 145, on engine lift (70).
  24.  


NOTE
Ensure adjuster screws on height adjusters, 83 9-5 170, are in their lowest position.

  1. Position the engine lift, the raise and insert the guide pins in the subframe reference holes. Adjust the lifting pillars with the height adjusters so they rest evenly on the subframe.
  2.  
  3. Check with the body guide pins that the subframe is positioned correctly in relation to the body.
  4.  
  5. Raise engine lift slightly to ensure stable contact, then remove the subframe bolts in the body (72).
  6.  
  7. Carefully lower the engine and transmission assembly on the engine lift, checking that no components a caught or damaged during removal.
  8.  


    Click image to see an enlarged view

    Fig. Showing location of coolant quick-release connections, gearbox cables and clutch hose-9-3 (2003-04)



    Click image to see an enlarged view

    Fig. Showing engine centering tool installed-9-3 (2003-04)



    Click image to see an enlarged view

    Fig. Showing engine lift equipment installed-9-3 (2003-04)


To install:

  1. Position the engine lift under the vehicle, moving the engine and transmission in position.
  2.  
  3. Lift the powertrain until the inboard driveshaft U-joints are level with the wheel hubs, then insert the driveshafts into the hubs.
  4.  
  5. Lift the powertrain a little higher and position the lower swivel joints to steering swivel members. If necessary, adjust the engine lift screws to provide even contact with the body. Ensure guide pins are correctly positioned.
  6.  
  7. Install the subframe-to-body bolts. Raise the engine lift fully and tighten the subframe bolts to 55 ft. lbs. (75 Nm), plus and additional 90 degrees.
  8.  
  9. Install or connect the following: Lower swivel joint bolts to 37 ft. lbs. (50 Nm); ensure steering knuckle stub is visible on top of steering knuckle housing before bolt is installed.Anti-roll bar link bolts to 47 ft. lbs. (64 Nm)Outboard steering links and bolts to 26 ft. lbs. (35 Nm)Ground cable to gearbox and connector for angle sensor (if equipped).Position joint clamp on front exhaust pipeCatalytic converter to front exhaust pipe, tightening nuts to 18 ft. lbs. (25 Nm)Adjust joint clamp so pipe ends are in the middle, then tighten clamp nuts to 30 ft. lbs. (40 Nm)Right engine mount, after lowering car: right mount to 52 ft. lbs. (70 Nm), plus an additional 60 degreesLeft engine mount to 52 ft. lbs. (70 Nm), plus an additional 45 degreesRight engine pad-to-body to 30 ft. lbs. (40 Nm), plus an additional 60 degreesRelease strap from radiator member and A/C compressorRaise car and remove engine centering kitRear torsion arm bolts to 52 ft. lbs. (70 Nm), plus an additional 90 degreesBolts to power steering pipe clamps on subframeA/C compressor and connectorAuxiliary drive belt (in proper direction of rotation)Steering shaft to steering gear. Use new clamp bolt and tighten to 20 ft. lbs. (27 Nm)
    1. Lower swivel joint bolts to 37 ft. lbs. (50 Nm); ensure steering knuckle stub is visible on top of steering knuckle housing before bolt is installed.
    2.  
    3. Anti-roll bar link bolts to 47 ft. lbs. (64 Nm)
    4.  
    5. Outboard steering links and bolts to 26 ft. lbs. (35 Nm)
    6.  
    7. Ground cable to gearbox and connector for angle sensor (if equipped).
    8.  
    9. Position joint clamp on front exhaust pipe
    10.  
    11. Catalytic converter to front exhaust pipe, tightening nuts to 18 ft. lbs. (25 Nm)
    12.  
    13. Adjust joint clamp so pipe ends are in the middle, then tighten clamp nuts to 30 ft. lbs. (40 Nm)
    14.  
    15. Right engine mount, after lowering car: right mount to 52 ft. lbs. (70 Nm), plus an additional 60 degrees
    16.  
    17. Left engine mount to 52 ft. lbs. (70 Nm), plus an additional 45 degrees
    18.  
    19. Right engine pad-to-body to 30 ft. lbs. (40 Nm), plus an additional 60 degrees
    20.  
    21. Release strap from radiator member and A/C compressor
    22.  
    23. Raise car and remove engine centering kit
    24.  
    25. Rear torsion arm bolts to 52 ft. lbs. (70 Nm), plus an additional 90 degrees
    26.  
    27. Bolts to power steering pipe clamps on subframe
    28.  
    29. A/C compressor and connector
    30.  
    31. Auxiliary drive belt (in proper direction of rotation)
    32.  
    33. Steering shaft to steering gear. Use new clamp bolt and tighten to 20 ft. lbs. (27 Nm)
    34.  

  10.  
  11. Lower the car and remove the restraint from steering wheel
  12.  
  13. Connect the quick-release coupling on the vent line and press fuel lines and vent lines into clips on camshaft cover.
  14.  
  15. Unplug fuel lines and connect to fuel rail while gripping lower nut. Use new seals.
  16.  
  17. Connect the quick-release coupling to the clutch slave cylinder and release the pliers.
  18.  
  19. Connection at clutch slave cylinder must be mounted at the correct angle, as illustrated.
  20.  
  21. Install or connect the following: Cables to gearboxCoolant hoses at quick-release couplingsExpansion tank to bodyCoolant level sensor connectorGround cables and clamp for engine harness to bodyRetaining screw for engine harness connector in main fuse boxPositive cable to battery2 retaining screws for main fuse box and box coverWindshield washer filler pipeAir cleaner housing, intake hose and air cleaner cover

    Cables to gearbox
     
    Coolant hoses at quick-release couplings
     
    Expansion tank to body
     
    Coolant level sensor connector
     
    Ground cables and clamp for engine harness to body
     
    Retaining screw for engine harness connector in main fuse box
     
    Positive cable to battery
     
    2 retaining screws for main fuse box and box cover
     
    Windshield washer filler pipe
     
    Air cleaner housing, intake hose and air cleaner cover
     

  22.  


CAUTION
To reduce risk of hoses coming loose from delivery side of turbocharger, hoses and connecting pieces must be cleaned thoroughly with a cleaning agent, 30 15 815. Use new hose clamps.



Mass airflow sensor connector
 
Turbocharger inlet pipe and hoses to inlet pipe
 
Connector for A/C pressure sensor
 



Install the radiator. Cut off the cable ties.
 
Be sure the condenser and charge air cooler hooks are positioned correctly and fit the radiator retaining bolts.
 
Install the upper and lower radiator hoses.
 
Position the fan cowling and press the A/C pipes into the retaining clips. For automatic transmission vehicles, connect the oil pipes from the transmission to the radiator.
 
Install or connect the following: Both connectors on left side structural memberUpper radiator brackets to bodySeal over radiator coreReverse light switch connectorConnector and clip securing cables on fan cowlingBattery tray and cable clipHood switch connectorMain fuse box in front of battery trayConnector to control moduleCover and connector to transmission control module (with automatic transmission)Vacuum hose coupling to vacuum pumpVentilation hose to radiatorBatteryCharge air hose to throttle body and upper charge air pipe bracket on fan cowlingHose to bypass valve and connector to pressure/temperature sensorUpper radiator supportHood cable quick-release coupling; secure it to body with new clipsBattery cover and battery cooler pipes
  1. Both connectors on left side structural member
  2.  
  3. Upper radiator brackets to body
  4.  
  5. Seal over radiator core
  6.  
  7. Reverse light switch connector
  8.  
  9. Connector and clip securing cables on fan cowling
  10.  
  11. Battery tray and cable clip
  12.  
  13. Hood switch connector
  14.  
  15. Main fuse box in front of battery tray
  16.  
  17. Connector to control module
  18.  
  19. Cover and connector to transmission control module (with automatic transmission)
  20.  
  21. Vacuum hose coupling to vacuum pump
  22.  
  23. Ventilation hose to radiator
  24.  
  25. Battery
  26.  
  27. Charge air hose to throttle body and upper charge air pipe bracket on fan cowling
  28.  
  29. Hose to bypass valve and connector to pressure/temperature sensor
  30.  
  31. Upper radiator support
  32.  
  33. Hood cable quick-release coupling; secure it to body with new clips
  34.  
  35. Battery cover and battery cooler pipes
  36.  

 
Raise the car and install the lower seal between the charge air cooler and the radiator.
 
Install the receiver-drier bolts to the radiator.
 
Install the hose between the charge air cooler and charge air pip and fit cover on right side.
 
Install the charge air pipe lower bracket on the fan cowling (left side).
 
Install the charge air hose between the charge air pip and charge air cooler and install cover (left side).
 
Lower the car slightly and install the front bumper.
 
Install or connect the following: Hose to headlamp washersCover on gearboxInner wheel well liners and both front wheel housingsLower spoiler shield and hose to headlamp washersHeadlamp washer connectorDriveshafts and tighten center hub nuts to 170 ft. lbs. (230 Nm)Front wheels and tighten lug nuts to 81 ft. lbs. (110 Nm)

Hose to headlamp washers
 
Cover on gearbox
 
Inner wheel well liners and both front wheel housings
 
Lower spoiler shield and hose to headlamp washers
 
Headlamp washer connector
 
Driveshafts and tighten center hub nuts to 170 ft. lbs. (230 Nm)
 
Front wheels and tighten lug nuts to 81 ft. lbs. (110 Nm)
 

 
Refill the engine oil, cooling system and washer fluids.
 
Bleed the cooling system, if necessary.
 
Bleed the clutch system (manual transmission).
 
Restore all electrical functions.
 
Install upper engine cover.
 



Before servicing the vehicle, refer to the precautions at the beginning of this section.
 
Open cap on expansion tank.
 
On lift, raise car slightly and remove front wheels.
 
Remove lower spoiler shield. Detach hose to headlamp washers, unplug connector and remove it.
 
Drain cooling system.
 
Remove wheel well liners.
 
Remove cover by the gearbox.
 
Detach the hose for the headlamp washers and drain washer fluid reservoir.
 
Lower the car slightly and remove the front bumper.
 
Remove the cover on the left side and the hose between the charge air pipe and cooler.
 
Remove the lower charge air pipe bracket from the fan cowling.
 
Remove cover on right side and hose between charge air cooler and pipe.
 
Remove receiver-drier bolts from the radiator.
 
Remove the lower seal between the charge air cooler and the radiator.
 
Lower the car and remove the upper engine cover.
 
Remove the battery cover and battery cooler pipe.
 
Remove the hood release cable coupling by first undoing the clip in the body and then separating the quick-release couple using a screwdriver.
 
Remove the upper radiator support.
 
Unplug the pressure-temperature sensor connector.
 
Disconnect the bypass valve hose.
 
Detach the charge air hose from the throttle body and release the upper charge air pipe bracket from the fan cowling. Remove the pipe and hose.
 
Remove the battery.
 
Detach the ventilation hose from the radiator.
 
Detach the vacuum hose quick-release coupling from the vacuum pump.
 
With automatic transmission, unplug the connector from the TCM. Remove the control module.
 
Unplug the connector under the control module.
 
Release the main fuse box in front of the battery tray and move it aside.
 
Unplug the hood switch connector, release the cable clip and remove the battery tray.
 
Detach the connector and release the clip holding the cables on the fan cowling.
 
Unplug the reverse light switch connector.
 
Remove the seal over the radiator core.
 
Remove the upper radiator brackets from the body.
 
Unplug both connectors from the left side structural member.
 
With automatic transmission, detach the pipes from the fluid cooler.
 
Remove the fan cowling bolts and loosen cowling slightly.
 
Secure the condenser and charge air cooler to the body with cable ties.
 
Remove the fan cowling. Carefully detach A/C pipes from retaining clip on right side structural member.
 
With receptacle under radiator, remove lower radiator hose.
 
Remove upper radiator hose.
 
Remove the radiator.
 
Unplug the A/C pressure sensor connector.
 
Detach the hoses from the turbocharger inlet pipe and remove the pipe.
 
Unplug the mass air flow (MAF) sensor connector. Cap the turbocharger inlet.
 
Remove the air cleaner cover and the air cleaner.
 
Detach the intake hose and remove the air cleaner casing.
 
Remove the windshield washer filler pipe.
 
Remove 2 mounting screws from inside the main fuse box.
 
Disconnect the positive battery cable connection.
 
Undo the engine harness connector retaining screw in the main fuse box.
 
Remove the engine harness clamp from the body and the ground cables.
 
Bend up the engine harness and secure it to the engine with a suitable strap.
 
Unplug the coolant level connector.
 
Detach the expansion tank from the body and secure it to the engine.
 
Undo coolant hose quick-release couplings while trapping any coolant spill. Bend hose aside and secure it to the engine.
 
Detach cables from gearbox. Carefully bend then aside and secure to expansion tank bracket with cable ties.
 
With pliers, pinch off clutch hose and disconnect quick-release coupling from clutch slave cylinder.
 
Release any pressure in the fuel system by carefully pressing the service valve needle. Collect any fuel spillage.
 
Detach both fuel lines from fuel rail while gripping the lower nut. Plug the fuel line openings.
 
Disconnect quick-release coupling for ventilation line and detach fuel lines and vent lines from clips on camshaft cover. Bend up vent hose from intake manifold and place it on camshaft cover.
 
Be sure steering wheel and front wheels are in the straight-ahead position.
 


WARNING
To prevent contact roller for airbag from breaking due to twisting, steering wheel should be fixed in position, such as taping it to the instrument panel.

  1. Detach the steering shaft from the steering gear.
  2.  
  3. Raise the car. Mark the rotation direction of the auxiliary drive belt, then remove it.
  4.  
  5. Unplug the A/C compressor connector and remove the compressor retaining bolts.
  6.  
  7. Remove the power steering pipe clamp bolts from the subframe.
  8.  
  9. Slightly loosen rear torsion arm bolts.
  10.  
  11. Fit an engine centering tool kit, 83 96 152, to subframe, as illustrated. Adjust the centering tool bolts so adjuster screw slots are completely visible.
  12.  


NOTE
Because of narrow tolerances on the driveshafts, centering tool must be used to carefully fit the powertrain to the subframe and body during installation.

  1. Lower the car and re-install the radiator support member.
  2.  
  3. Attach a strap, 83 9-5 212, to radiator support, lower the strap and wind it an extra turn around the A/C compressor to relieve any strain.
  4.  
  5. Remove left and right side engine mounts.
  6.  
  7. Raise the car and disconnect the driveshaft from the hub by removing the center nuts. It may be necessary to use a driveshaft puller, 89 96 9-51, or a brass drift and mallet.
  8.  
  9. Remove outboard steering link nuts and separate links from steering swivel member.
  10.  
  11. Grip anti-roll bar link flats with a wrench, then disconnect the anti-roll bar links.
  12.  
  13. Undo the lower swivel joints from the steering swivel members and lower the suspension arms.
  14.  
  15. Disconnect the driveshafts and move them away.
  16.  
  17. Measure a distance of about 8 inches (87 mm) from front end of muffler and cut the exhaust pipe between the muffler and flexpipe.
  18.  
  19. Detach front pipe from the catalytic converter.
  20.  
  21. Disconnect the ground cable from the gearbox and the connector for the angle sensor (if equipped).
  22.  
  23. Position a subframe-to-engine centering tool, 83 96 145, on engine lift (70).
  24.  


NOTE
Ensure adjuster screws on height adjusters, 83 9-5 170, are in their lowest position.

  1. Position the engine lift, the raise and insert the guide pins in the subframe reference holes. Adjust the lifting pillars with the height adjusters so they rest evenly on the subframe.
  2.  
  3. Check with the body guide pins that the subframe is positioned correctly in relation to the body.
  4.  
  5. Raise engine lift slightly to ensure stable contact, then remove the subframe bolts in the body (72).
  6.  
  7. Carefully lower the engine and transmission assembly on the engine lift, checking that no components a caught or damaged during removal.
  8.  


    Click image to see an enlarged view

    Fig. Showing location of coolant quick-release connections, gearbox cables and clutch hose-9-3 2003-04



    Click image to see an enlarged view

    Fig. Showing engine centering tool installed-9-3 2003-04



    Click image to see an enlarged view

    Fig. Showing engine lift equipment installed-9-3 2003-04


To install:

  1. Position the engine lift under the vehicle, moving the engine and transmission in position.
  2.  
  3. Lift the powertrain until the inboard driveshaft U-joints are level with the wheel hubs, then insert the driveshafts into the hubs.
  4.  
  5. Lift the powertrain a little higher and position the lower swivel joints to steering swivel members. If necessary, adjust the engine lift screws to provide even contact with the body. Ensure guide pins are correctly positioned.
  6.  
  7. Install the subframe-to-body bolts. Raise the engine lift fully and tighten the subframe bolts to 55 ft. lbs. (75 Nm), plus and additional 90 degrees.
  8.  
  9. Install or connect the following: Lower swivel joint bolts to 37 ft. lbs. (50 Nm); ensure steering knuckle stub is visible on top of steering knuckle housing before bolt is installed.Anti-roll bar link bolts to 47 ft. lbs. (64 Nm)Outboard steering links and bolts to 26 ft. lbs. (35 Nm)Ground cable to gearbox and connector for angle sensor (if equipped).Position joint clamp on front exhaust pipeCatalytic converter to front exhaust pipe, tightening nuts to 18 ft. lbs. (25 Nm)Adjust joint clamp so pipe ends are in the middle, then tighten clamp nuts to 30 ft. lbs. (40 Nm)Right engine mount, after lowering car: right mount to 52 ft. lbs. (70 Nm), plus an additional 60 degreesLeft engine mount to 52 ft. lbs. (70 Nm), plus an additional 45 degreesRight engine pad-to-body to 30 ft. lbs. (40 Nm), plus an additional 60 degreesRelease strap from radiator member and A/C compressorRaise car and remove engine centering kitRear torsion arm bolts to 52 ft. lbs. (70 Nm), plus an additional 90 degreesBolts to power steering pipe clamps on subframeA/C compressor and connectorAuxiliary drive belt (in proper direction of rotation)Steering shaft to steering gear. Use new clamp bolt and tighten to 20 ft. lbs. (27 Nm)
    1. Lower swivel joint bolts to 37 ft. lbs. (50 Nm); ensure steering knuckle stub is visible on top of steering knuckle housing before bolt is installed.
    2.  
    3. Anti-roll bar link bolts to 47 ft. lbs. (64 Nm)
    4.  
    5. Outboard steering links and bolts to 26 ft. lbs. (35 Nm)
    6.  
    7. Ground cable to gearbox and connector for angle sensor (if equipped).
    8.  
    9. Position joint clamp on front exhaust pipe
    10.  
    11. Catalytic converter to front exhaust pipe, tightening nuts to 18 ft. lbs. (25 Nm)
    12.  
    13. Adjust joint clamp so pipe ends are in the middle, then tighten clamp nuts to 30 ft. lbs. (40 Nm)
    14.  
    15. Right engine mount, after lowering car: right mount to 52 ft. lbs. (70 Nm), plus an additional 60 degrees
    16.  
    17. Left engine mount to 52 ft. lbs. (70 Nm), plus an additional 45 degrees
    18.  
    19. Right engine pad-to-body to 30 ft. lbs. (40 Nm), plus an additional 60 degrees
    20.  
    21. Release strap from radiator member and A/C compressor
    22.  
    23. Raise car and remove engine centering kit
    24.  
    25. Rear torsion arm bolts to 52 ft. lbs. (70 Nm), plus an additional 90 degrees
    26.  
    27. Bolts to power steering pipe clamps on subframe
    28.  
    29. A/C compressor and connector
    30.  
    31. Auxiliary drive belt (in proper direction of rotation)
    32.  
    33. Steering shaft to steering gear. Use new clamp bolt and tighten to 20 ft. lbs. (27 Nm)
    34.  

  10.  
  11. Lower the car and remove the restraint from steering wheel
  12.  
  13. Connect the quick-release coupling on the vent line and press fuel lines and vent lines into clips on camshaft cover.
  14.  
  15. Unplug fuel lines and connect to fuel rail while gripping lower nut. Use new seals.
  16.  
  17. Connect the quick-release coupling to the clutch slave cylinder and release the pliers.
  18.  
  19. Connection at clutch slave cylinder must be mounted at the correct angle, as illustrated.
  20.  
  21. Install or connect the following: Cables to gearboxCoolant hoses at quick-release couplingsExpansion tank to bodyCoolant level sensor connectorGround cables and clamp for engine harness to bodyRetaining screw for engine harness connector in main fuse boxPositive cable to battery2 retaining screws for main fuse box and box coverWindshield washer filler pipeAir cleaner housing, intake hose and air cleaner cover

    Cables to gearbox
     
    Coolant hoses at quick-release couplings
     
    Expansion tank to body
     
    Coolant level sensor connector
     
    Ground cables and clamp for engine harness to body
     
    Retaining screw for engine harness connector in main fuse box
     
    Positive cable to battery
     
    2 retaining screws for main fuse box and box cover
     
    Windshield washer filler pipe
     
    Air cleaner housing, intake hose and air cleaner cover
     

  22.  


CAUTION
To reduce risk of hoses coming loose from delivery side of turbocharger, hoses and connecting pieces must be cleaned thoroughly with a cleaning agent, 30 15 815. Use new hose clamps.



Mass airflow sensor connector
 
Turbocharger inlet pipe and hoses to inlet pipe
 
Connector for A/C pressure sensor
 



Install the radiator. Cut off the cable ties.
 
Be sure the condenser and charge air cooler hooks are positioned correctly and fit the radiator retaining bolts.
 
Install the upper and lower radiator hoses.
 
Position the fan cowling and press the A/C pipes into the retaining clips. For automatic transmission vehicles, connect the oil pipes from the transmission to the radiator.
 
Install or connect the following: Both connectors on left side structural memberUpper radiator brackets to bodySeal over radiator coreReverse light switch connectorConnector and clip securing cables on fan cowlingBattery tray and cable clipHood switch connectorMain fuse box in front of battery trayConnector to control moduleCover and connector to transmission control module (with automatic transmission)Vacuum hose coupling to vacuum pumpVentilation hose to radiatorBatteryCharge air hose to throttle body and upper charge air pipe bracket on fan cowlingHose to bypass valve and connector to pressure/temperature sensorUpper radiator supportHood cable quick-release coupling; secure it to body with new clipsBattery cover and battery cooler pipes
  1. Both connectors on left side structural member
  2.  
  3. Upper radiator brackets to body
  4.  
  5. Seal over radiator core
  6.  
  7. Reverse light switch connector
  8.  
  9. Connector and clip securing cables on fan cowling
  10.  
  11. Battery tray and cable clip
  12.  
  13. Hood switch connector
  14.  
  15. Main fuse box in front of battery tray
  16.  
  17. Connector to control module
  18.  
  19. Cover and connector to transmission control module (with automatic transmission)
  20.  
  21. Vacuum hose coupling to vacuum pump
  22.  
  23. Ventilation hose to radiator
  24.  
  25. Battery
  26.  
  27. Charge air hose to throttle body and upper charge air pipe bracket on fan cowling
  28.  
  29. Hose to bypass valve and connector to pressure/temperature sensor
  30.  
  31. Upper radiator support
  32.  
  33. Hood cable quick-release coupling; secure it to body with new clips
  34.  
  35. Battery cover and battery cooler pipes
  36.  

 
Raise the car and install the lower seal between the charge air cooler and the radiator.
 
Install the receiver-drier bolts to the radiator.
 
Install the hose between the charge air cooler and charge air pip and fit cover on right side.
 
Install the charge air pipe lower bracket on the fan cowling (left side).
 
Install the charge air hose between the charge air pip and charge air cooler and install cover (left side).
 
Lower the car slightly and install the front bumper.
 
Install or connect the following: Hose to headlamp washersCover on gearboxInner wheel well liners and both front wheel housingsLower spoiler shield and hose to headlamp washersHeadlamp washer connectorDriveshafts and tighten center hub nuts to 170 ft. lbs. (230 Nm)Front wheels and tighten lug nuts to 81 ft. lbs. (110 Nm)

Hose to headlamp washers
 
Cover on gearbox
 
Inner wheel well liners and both front wheel housings
 
Lower spoiler shield and hose to headlamp washers
 
Headlamp washer connector
 
Driveshafts and tighten center hub nuts to 170 ft. lbs. (230 Nm)
 
Front wheels and tighten lug nuts to 81 ft. lbs. (110 Nm)
 

 
Refill the engine oil, cooling system and washer fluids.
 
Bleed the cooling system, if necessary.
 
Bleed the clutch system (manual transmission).
 
Restore all electrical functions.
 
Install upper engine cover.
 

 
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