LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Saab >> 2004 >> 9-3 Linear, Standard >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Basic Engine >> Adjustment-Replacement >> Power train removal >> To remove
April 5, 2026: LEMON Manuals is launched! Read the announcement.

To remove

WARNING: There is a large number of cables, hoses, wires, etc., that are secured with hard plastic cable ties. After tightening, the loose ends of these cable ties are cut off and may leave more or less sharp edges at fixing points.

Pay attention to the risk of cuts caused by these sharp ends!

  1. Place the car on a lift and apply wing covers.
  2. Open the cap on the expansion tank.
  3. Raise the car slightly and remove the front wheels.
  4. Remove the lower spoiler shield. Detach the hose to the headlamp washers, unplug the connector and remove it.
    Fig 1: Illustration For Step 4
    G03707723Courtesy of SAAB-SCANIA OF AMERICA, INC.
  5. Place a receptacle under the car, connect a hose to the radiator and drain the coolant.
    Fig 2: Illustration For Step 5
    G03707724Courtesy of SAAB-SCANIA OF AMERICA, INC.
  6. Remove the wing liners from both front wheel housings and the cover by the gearbox.
    Fig 3: Illustration For Step 6
    G03707725Courtesy of SAAB-SCANIA OF AMERICA, INC.
  7. Detach the hose for the headlamp washers and drain the washer fluid reservoir.
    Fig 4: Illustration For Step 7
    G03707726Courtesy of SAAB-SCANIA OF AMERICA, INC.
  8. Lower the car slightly and remove the bumper.
    Fig 5: Illustration For Step 8
    G03707727Courtesy of SAAB-SCANIA OF AMERICA, INC.
  9. Remove the cover on the left-hand side and the charge air hose between the charge air pipe and the charge air cooler.
    Fig 6: Illustration For Steps 9-10
    G03707728Courtesy of SAAB-SCANIA OF AMERICA, INC.
  10. Remove the lower charge air pipe bracket from the fan cowling.
  11. Remove the cover on the right-hand side and the hose between the charge air cooler and the charge air pipe.
    Fig 7: Illustration For Steps 11-13
    G03707729Courtesy of SAAB-SCANIA OF AMERICA, INC.
  12. Remove the dryer filter bolts from the radiator.
  13. Remove the lower seal between the charge air cooler and the radiator.
  14. Lower the car and remove the upper engine cover.
    Fig 8: Illustration For Steps 14-15
    G03707730Courtesy of SAAB-SCANIA OF AMERICA, INC.
  15. Remove the battery cover and the battery cooler pipe.
  16. Undo the bonnet cable quick-release coupling by first undoing the clip in the body and then separating the quick-release coupling. Use a screwdriver.
    Fig 9: Illustration For Steps 16-17
    G03707731Courtesy of SAAB-SCANIA OF AMERICA, INC.
  17. Remove the upper radiator member.
  18. Unplug the connector to the pressure/temperature sensor and disconnect the bypass valve hose.
    Fig 10: Illustration For Steps 18-21
    G03707732Courtesy of SAAB-SCANIA OF AMERICA, INC.
  19. Detach the charge air hose from the throttle body and undo the upper charge air pipe bracket from the fan cowling. Remove the pipe with hose.
  20. Remove the battery.
  21. Detach the ventilation hose from the radiator.
  22. Detach the vacuum hose quick-release coupling form the vacuum pump.
    Fig 11: Illustration For Step 22
    G03707733Courtesy of SAAB-SCANIA OF AMERICA, INC.
  23. Aut  : Unplug the connector to the TCM. Remove the cover with the control module. Unplug the connector under the control module.
    Fig 12: Illustration For Steps 23-25
    G03707734Courtesy of SAAB-SCANIA OF AMERICA, INC.
  24. Undo the main fuse box in front of the battery tray and move it aside.
  25. Unplug the bonnet switch connector, undo the cable clip and remove the battery tray.
  26. Unplug the connector and undo the clip securing the cables on the fan cowling.
    Fig 13: Illustration For Steps 26-27
    G03707735Courtesy of SAAB-SCANIA OF AMERICA, INC.
  27. Unplug the reversing light switch connector.
  28. Remove the seal over the radiator core.
    Fig 14: Illustration For Steps 28-29
    G03707736Courtesy of SAAB-SCANIA OF AMERICA, INC.
  29. Remove the upper radiator brackets from the body.
  30. Unplug both connectors from the left-hand structural member. Auto:  Detach the oil pipes from the fluid cooler. Use 87 92 806 Removal tool, automatic transmission oil pipes.
    Fig 15: Illustration For Step 30
    G03707737Courtesy of SAAB-SCANIA OF AMERICA, INC.
    Fig 16: Illustration For Steps 30-31
    G03707738Courtesy of SAAB-SCANIA OF AMERICA, INC.
  31. Remove the fan cowling retaining bolts and loosen the cowling slightly.
  32. Secure the condenser and the charge air cooler to the body with cable ties.
  33. Remove the fan cowling. Carefully detach the A/C pipes from their retaining clips on the right structural member.
    Fig 17: Illustration For Step 33
    G03707739Courtesy of SAAB-SCANIA OF AMERICA, INC.
  34. Place a receptacle under the radiator and remove the lower radiator hose.
    Fig 18: Illustration For Steps 34-37
    G03707740Courtesy of SAAB-SCANIA OF AMERICA, INC.
  35. Remove the upper radiator hose.
  36. Remove the radiator.
  37. Unplug the connector for the A/C pressure sensor.
  38. Detach the hoses from the turbo inlet pipe and remove the turbo inlet pipe. Unplug the mass air flow sensor connector. Plug the turbo inlet.
    Fig 19: Illustration For Steps 38-39
    G03707741Courtesy of SAAB-SCANIA OF AMERICA, INC.
  39. Remove the air cleaner cover and the air cleaner. Detach the inlet hose and remove the air cleaner casing.
    Fig 20: Illustration For Step 39
    G03707742Courtesy of SAAB-SCANIA OF AMERICA, INC.
  40. Remove the windscreen washer filler pipe.
    Fig 21: Illustration For Steps 40-44
    G03707743Courtesy of SAAB-SCANIA OF AMERICA, INC.
  41. Remove the cover on the main fuse box and undo the two retaining screws.
  42. Disconnect the positive cable from the battery.
  43. Undo the retaining screw on the engine harness connector in the main fuse box.
  44. Remove the engine harness clamp from the body and the ground cables.
  45. Bend up the engine harness and secure it to the engine with e.g. 83 95 212 STRAP  .
  46. Unplug the coolant level connector. Detach the expansion tank from the body and secure it to the engine. Use 83 95 212 STRAP  .
    Fig 22: Illustration For Step 46
    G03707744Courtesy of SAAB-SCANIA OF AMERICA, INC.
  47. Undo the coolant hose quick-release couplings while trapping any coolant spill, bend aside and secure the hoses to the engine.
    Fig 23: Illustration For Steps 47-49
    G03707745Courtesy of SAAB-SCANIA OF AMERICA, INC.
  48. Detach the gear cables from the gearbox, carefully bend them aside and secure them to the expansion tank bracket on the body with cable ties.
  49. Fit 30 07 739 Hose pinch-off pliers to the clutch hose and disconnect the quick release coupling from the clutch slave cylinder.
    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.
  50. Release any pressure in the fuel system by carefully pressing the service valve needle. Collect any fuel spill. Detach both fuel lines from the fuel rail while gripping the lower nut. Plug the fuel lines. Use 82 92 948 Plugs, A/C system, kit.
    Fig 24: Illustration For Steps 50-51
    G03707746Courtesy of SAAB-SCANIA OF AMERICA, INC.
  51. Disconnect the quick-release coupling for the ventilation line and detach the fuel lines and ventilation lines from the clips on the camshaft cover. Bend up the ventilation hose from the intake manifold and place it on the camshaft cover.
  52. Check and adjust the steering wheel and the steering assembly so that they are pointing straight ahead.
    WARNING: In order to avoid the contact roller for the airbag twisting and breaking the steering wheel must be secured via the steering column lock or by taping it to the panel.
  53. Detach the steering shaft from the steering gear.
    Fig 25: Illustration For Step 53
    G03707747Courtesy of SAAB-SCANIA OF AMERICA, INC.
  54. Raise the car. CV: Remove Chassis reinforcement, front subframe. All:  Release tension and remove poly-V-belt. Mark direction of rotation of belt. Use 83 96 095 TENSION RELEASE TOOL, BELT CIRCUIT B207  .
    Fig 26: Illustration For Step 54
    G03707748Courtesy of SAAB-SCANIA OF AMERICA, INC.
  55. Unplug the A/C compressor connector and remove the A/C compressor retaining bolts.
    Fig 27: Illustration For Step 55
    G03707749Courtesy of SAAB-SCANIA OF AMERICA, INC.
  56. Undo the bolts on the power steering pipe clamps on the subframe.
    Fig 28: Illustration For Step 56
    G03707750Courtesy of SAAB-SCANIA OF AMERICA, INC.
  57. Undo the rear torque arm bolts slightly.
    Fig 29: Illustration For Step 57
    G03707751Courtesy of SAAB-SCANIA OF AMERICA, INC.
  58. Fit 83 96 152 ENGINE CENTERING TOOL KIT  to the subframe. Due to narrow tolerances on the drive shafts, the centering tool must be used to carefully fit the powertrain to the subframe and body during refitting. Adjust the centering tool bolts so that the adjuster screw slots are completely visible. See CENTERING TOOL, ENGINE AND SUBFRAME .
    Fig 30: Illustration For Step 58
    G03707752Courtesy of SAAB-SCANIA OF AMERICA, INC.
  59. Lower the car and refit the radiator member.
  60. Attach 83 95 212 STRAP  to the radiator member, lower the strap and wind it an extra turn round the A/C compressor to relieve it.
  61. Remove the right and left engine mountings.
    Fig 31: Illustration For Step 61
    G03707753Courtesy of SAAB-SCANIA OF AMERICA, INC.
  62. Raise the car and undo the drive shaft center nuts. Detach the drive shafts from the hub. Use 89 96 951 DRIVE SHAFT HUB PULLER  or a brass drift and mallet.
    WARNING: Use protective goggles to protect against flying splinters of metal.
  63. Undo the nuts and the outboard steering links from the steering swivel member with 87 91 287 Puller, 150 mm.
    Fig 32: Illustration For Steps 63-65
    G03707754Courtesy of SAAB-SCANIA OF AMERICA, INC.
  64. Undo the lower anti-roll bar links while gripping the flats with a thin spanner.
  65. Undo the lower swivel joints from the steering swivel members and lower the suspension arms.
  66. Undo the drive shafts and move them away.
  67. Measure a distance of 87 mm from the front end of the silencer and cut the exhaust pipe between the silencer and the flexipipe with a 83 95 667 Pipe cutter/exhaust system.
  68. Detach the front pipe from the catalytic converter.
    Fig 33: Illustration For Steps 67-68
    G03707755Courtesy of SAAB-SCANIA OF AMERICA, INC.
  69. Disconnect the ground cable from the gearbox and the connector for the angle sensor (option).
    Fig 34: Illustration For Step 69
    G03707756Courtesy of SAAB-SCANIA OF AMERICA, INC.
  70. Place 83 96 145 Centering tool, subframe - engine on the trolley lift. Make sure adjuster screws on the height adjusters, part no. 83 95 170, are in their lowest position. See CENTERING TOOL, ENGINE AND SUBFRAME .
    Fig 35: Illustration For Steps 70, 72
    G03707757Courtesy of SAAB-SCANIA OF AMERICA, INC.
  71. Position the trolley lift; raise and insert the guide pins in the subframe reference holes. Adjust the lifting pillars with the height adjusters, part no. 83 95 170, so that they rest evenly on the subframe. Check with the body guide pins that the subframe is positioned correctly in relation to the body. See CENTERING TOOL, ENGINE AND SUBFRAME .
  72. Raise the trolley lift slightly for stable contact and undo the subframe bolts in the body.
  73. Carefully lower the power train on the trolley lift, making sure nothing gets caught or damaged.
scientia non olet · About LEMON Manuals