To dismantle the engine

Fig 1: Illustration For Steps 1-4

Courtesy of SAAB-SCANIA OF AMERICA, INC.

Place the dismantled engine on a lifting trolley.

1. Remove the starter motor.
2. Remove the belt tensioner and generator. Remove the support bearing bracket with intermediate shaft and inboard drive-shaft joint. Plug the gearbox with protective plugs 87 92 244.
3. Remove the generator bracket and crankcase breather's oil trap complete with hoses.
4. Remove the intake manifold's steady bar and remove the rear engine mounting.
5. Remove the gearbox retaining bolts. Disconnect the exhaust pipe from the turbocharger and unplug the oxygen sensor connectors.
   Fig 2: Illustration For Steps 5-6

   Courtesy of SAAB-SCANIA OF AMERICA, INC.
6. Remove the gearbox stay. Remove the servo pump and put it on the subframe.
7. Lift the power train and roll away the table with the subframe. Remove the bracket, engine mounting and bolts lower, rear on the engine to the gearbox.
8. Fit ENGINE HOLDER  83 95 220 to the engine and lift over the power train to 78 74 878 FLOOR STAND. 
   Fig 3: Illustration For Steps 8, 9, 10, 12, 13, 14 & 16

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9. Drain off the oil.
10. Remove the protective plate and undo the torque converter retaining bolts (aut.). Gradually withdraw the torque converter while rotating the crankshaft pulley.
11. Prevent the torque converter from moving by means of CONVERTER HOLDER  87 92 574.
12. Lift away the gearbox. Use LIFTING CABLE  87 92 442.
13. Remove the oil filler pipe from its bracket and disconnect the preheating hoses from the throttle body.
14. Remove the bracket for the electric leads from the cylinder head.
15. Unplug all electric connectors between the intake manifold and engine.
16. Remove the crankcase breather nipple.
17. Remove the delivery pipe between the charge air cooler and throttle body.
    Fig 4: Illustration For Steps 17-22

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18. Disconnect the crankcase breather pipe from the turbocharger's inlet pipe.
19. Remove the heat shield from above the turbocharger.
20. Remove the power steering pump and power steering bracket by means of the lifting eyebolt.
21. Remove the A/C compressor bracket.
22. Remove the turbocharger steady bar, disconnect the coolant and oil hoses, and remove the turbocharger complete with exhaust manifold. Heat it carefully if it sticks.
23. Remove the throttle body preheating hose.
    Fig 5: Illustration For Steps 23-27

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24. Remove the bolts retaining the intake manifold.

    Lift it away from the power train.

25. Disconnect the filler hose from the expansion tank.
26. Remove the pipe from the heat exchanger and the hose from the cylinder head.
27. Remove the thermostat housing's cover complete with thermostat.
28. Remove the coolant pump with filler pipe, and the sleeve with the O-rings.
    Fig 6: Illustration For Steps 28-30

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
29. Remove the oil filter and the adapter housing.
30. Remove the crankshaft position sensor.
31. Align the 0 mark on the crankshaft pulley with the mark on the transmission casing.
    Fig 7: Illustration For Steps 31-33

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
32. Fit FLYWHEEL LOCKING ATTACHMENT  83 94 868 and remove the crankshaft pulley.
33. Remove the flywheel, pressure plate and linings or driven plate and remove the flywheel locking segment.
34. Remove the ignition discharge module.
    Fig 8: Illustration For Steps 34-35

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35. Remove the spark plugs and remove the camshaft cover.
36. Remove the chain tensioner. First remove the plug, then use a 27 mm socket.
    Fig 9: Illustration For Steps 36-38

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
37. Remove the camshaft sprockets, holding each camshaft steady with a spanner applied to the end of it.
38. Fit a rubber band round the chain guides and remove the cylinder head. Start with the bolts in the timing cover and then continue in reverse order to assembly. Collect the bolts with a magnet.
39. Turn the engine into a suitable working position and remove the oil sump and the pipe running to the oil filter. Leave the guide sleeve in the cylinder block.
    Fig 10: Illustration For Steps 39-40

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
40. Remove the oil pump and timing cover.
41. Remove the top chain guide and chain tensioner for the balancer-shaft chain.
    Fig 11: Illustration For Steps 41-46

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
42. Remove the idler sprocket and balancer-shaft chain.
43. Remove the oil pump driver and sprocket from the crankshaft.
44. Remove the balancer-shaft and camshaft chain guides.
45. Remove the timing chain guard and remove the chain complete with sprocket.
    IMPORTANT: Turn the balancer shafts 180 so that the weights point up and remove them with great care so that the inner bearing bushings are not damaged.
46. Remove the balancer shafts complete with sprockets and bearing housings.
47. Remove the end plate.
    Fig 12: Illustration For Steps 47-53

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
    IMPORTANT: When dismantling bearing caps and shells, store them carefully and in the right order so that they can be reassembled in their original positions.
48. Remove any carbon deposits from the edges, turn the engine into a convenient position and remove all big-end bearing caps.
    NOTE: Use a 12 point 14 mm socket.
49. Fit PROTECTIVE SLEEVE  75 19 531 on the studs and press or carefully tap the pistons out of the cylinders.
50. Remove all main bearing caps and lift out the crankshaft.
    IMPORTANT: Observe the utmost care when handling the slotted ring.
51. Remove the slotted ring.
52. Remove all the bearing shells for both the main bearings and big-end bearings. Also remove the two thrust washers from main bearing no. 3.
53. Remove the piston cooling nozzles.