LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Saab >> 2005 >> 9-5 Linear, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Basic Engine >> Adjustment - Replacement >> Powertrain >> Removing Powertrain
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Removing Powertrain

WARNING: A large number of electrical leads, hoses, etc. are secured by means of cable ties. When these ties have been pulled tight, the excess length is cut off and may leave a sharp end at the fixing points. Beware of injuries like cuts and scratches on your hands caused by these sharp ends.
  1. Lay out wing covers, remove the covers over the battery and intake manifold and remove the battery and battery tray. Open the expansion tank cap.
  2. (auto)  Withdraw the breather hose that sticks up under the main fuse box.
  3. Disconnect the ground cable between the gearbox and LH wheel housing.

    (auto)  Disconnect the cables to the gearbox.

    (man)  Unplug the reversing light connection from the gearbox. Raise the car and remove the lower engine cover.

    Fig 1: Illustration For Steps 3-4
    G03855098Courtesy of SAAB-SCANIA OF AMERICA, INC.
  4. Open the drain plug for the coolant.
    WARNING: To prevent breakage of the airbag contact roller through twisting, the steering wheel should be fixed in place.
    Do this by taping it to the dashboard, for instance.
  5. Turn the front wheels to the straight ahead position and secure the steering wheel in this position. Undo the steering column locking bolt and move the steering column upwards.
    Fig 2: Illustration For Step 5
    G03855099Courtesy of SAAB-SCANIA OF AMERICA, INC.
  6. Disconnect the throttle cable and move it aside.
    Fig 3: Illustration For Steps 6-9
    G03855100Courtesy of SAAB-SCANIA OF AMERICA, INC.
  7. Disconnect the EVAP canister purge valve's vacuum hose from the intake manifold.
  8. Disconnect the brake servo vacuum hose by pressing the red sleeve downwards and pulling the hose upwards.
  9. Separate the fuel connections with ADAPTER, FUEL PRESSURE  83 94 744 and plug them.
    NOTE: If necessary, cut a groove in the rubber seal. Exercise care when doing this so that it can be re-used afterwards.
  10. Disconnect the positive cable at the distribution terminal and the negative cable at the gearbox.
    Fig 4: Illustration For Step 10
    G03855101Courtesy of SAAB-SCANIA OF AMERICA, INC.
  11. (man.) Disconnect the clutch slave cylinder's hose and plug the hose.
    Fig 5: Illustration For Steps 11-12
    G03855102Courtesy of SAAB-SCANIA OF AMERICA, INC.
  12. (man)  Engage 4th gear, remove the selector rod and engage 3rd gear.
  13. (auto)  Disconnect the selector lever cable and bend it aside against the bulkhead.
    Fig 6: Illustration For Step 13
    G03855103Courtesy of SAAB-SCANIA OF AMERICA, INC.
  14. Disconnect the upper radiator hose and remove the bypass valve's vacuum hose.
    Fig 7: Illustration For Steps 14-17
    G03855104Courtesy of SAAB-SCANIA OF AMERICA, INC.
  15. Remove the hose between the pipe to the throttle body and charge air cooler and undo the electrical connector to the pressure/temperature gauge.
  16. Remove the bypass valve with intake manifold and plug same.
  17. Unplug the connector for the radiator fan or fans. Remove the fan cowling retaining bolts, disconnect the upper radiator hose at the top and the pipe connected to the oil cooler (aut.).

    Carefully lift out the fan cowl.

  18. Remove the grille.
  19. Disconnect the hose between the turbocharger and charge air cooler and plug same.
    Fig 8: Illustration For Steps 19-20
    G03855105Courtesy of SAAB-SCANIA OF AMERICA, INC.
  20. Remove the mass air flow sensor with rubber gaiter and unplug its connector.
  21. Disconnect the lower radiator hose from the coolant pump, the hose by the expansion tank, and the hoses for the heat exchanger. For cars with ACC: Disconnect the vacuum hose from the bypass valve on the hose to the heat exchanger. Remove the radiator.
    Fig 9: Illustration For Step 21
    G03855106Courtesy of SAAB-SCANIA OF AMERICA, INC.
  22. Remove the bracket with the connector for the engine wiring harness and the wiring harness mountings from the bulkhead. Unhook it and lay it on the engine.
    Fig 10: Illustration For Steps 22-24
    G03855107Courtesy of SAAB-SCANIA OF AMERICA, INC.
  23. Remove the wiper arms and cover over the wiper assembly. Use PULLER 85 80 144 
    NOTE: The plastic hooks go under the windscreen. The cover panel must first be pulled forwards.
  24. Undo the nuts securing the control module connector. Unplug the connector and place it on the engine.
  25. Remove the hub nuts on both sides and raise the car.
    Fig 11: Illustration For Step 27
    G03855108Courtesy of SAAB-SCANIA OF AMERICA, INC.
  26. Remove the front wheels.
  27. Drive in WEDGES  83 95 238 between the gearbox and subframe and between the oil sump and subframe.
  28. Raise the car.
    Fig 12: Illustration For Steps 28-29
    G03855109Courtesy of SAAB-SCANIA OF AMERICA, INC.

    Remove the A/C compressor's retaining bolts.

  29. Remove the retaining nuts and air hose from the air filter housing.
  30. Lower the car to the floor.
  31. Suspend the condenser cooler, charge air cooler and A/C compressor to the radiator member with STRAPS  83 95 212. The engine oil cooler is dismantled with the engine and fastened to the subframe with, for instance, cable ties.
  32. Unplug the A/C compressor connector and undo the quick-release coupling on the vacuum hose connected to the wastegate.
    Fig 13: Illustration For Step 32
    G03855110Courtesy of SAAB-SCANIA OF AMERICA, INC.
  33. Remove the right-hand engine mounting complete with yoke.
    Fig 14: Illustration For Steps 33-34
    G03855111Courtesy of SAAB-SCANIA OF AMERICA, INC.
  34. Relieve the pressure on the belt tensioner using a ratchet handle and lift off the multigroove belt.
  35. Remove the left-hand engine mounting's retaining nuts.
    Fig 15: Illustration For Step 35
    G03855112Courtesy of SAAB-SCANIA OF AMERICA, INC.
  36. Remove the power steering fluid reservoir with hoses and place it on the engine.
    Fig 16: Illustration For Steps 36, 37 & 39
    G03855113Courtesy of SAAB-SCANIA OF AMERICA, INC.
  37. Pinch off the hose between the steering servo and reservoir.
  38. Remove the sheet metal mounting on the pipe to the steering servo. Slightly loosen the steering servo hose so that it becomes moveable.
  39. (auto) Unplug the quick-release couplings to gearbox oil cooler and plug. Use 83 95 261 Tools, fuel line. Mark the hoses to tell them apart.
  40. Raise the car higher.
  41. Remove the three steering swivel joint retaining nuts on both sides.
    Fig 17: Illustration For Steps 41-43
    G03855114Courtesy of SAAB-SCANIA OF AMERICA, INC.
  42. Undo the nuts securing the anti-roll bar supports to the suspension strut.
  43. Undo the two outer track-rod ends. Use 87 91 287 Puller, 150mm
  44. Carefully tap the drive shafts out of the hubs.
  45. Remove the oil cooler and suspend it from the front of the engine frame.
    Fig 18: Illustration For Step 48
    G03855115Courtesy of SAAB-SCANIA OF AMERICA, INC.
  46. Separate the exhaust pipe behind the catalytic converter and remove the temperature sensor.
  47. Run Lifting trolley 83 94 739 with assembly fixture 83 95 196  under the car. Align the fixture with adjusting feet 83 95 170  under the subframe with the locating studs at front left and rear right.
  48. Remove the 10 subframe and supporting plate retaining bolts.

    From chassis number W3050999, the inner sleeve in the subframe bushings has been made 38 mm long instead of previously 35 mm. If the bushing is 35 mm, a 3 mm spacer must be fitted between the bushing and washer.

    WARNING: The spacer washer must not be fitted together with a bushing with 38 mm inner sleeve.
  49. Lower the lifting trolley approx. 25 cm and thus also the subframe and power train. Make sure that the swivel joints release and lift out the drive shafts. Unhook the hose for the engine oil cooler from its bracket on the subframe.
  50. Pull the trolley as far back as possible to provide room for the A/C compressor and lower carefully.
  51. Then lower the power train complete with subframe, steering gear and front exhaust pipe.
scientia non olet · About LEMON Manuals