Removal & Installation - A/t: Other Saab 9-3 I

9-3

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Also place mating marks on engine hood and other major assemblies before removal.

Fuel Pressure Release

To release fuel pressure, disconnect fuel lines at fuel pressure regulator and fuel injection manifold.

1. Ensure fuel pressure is released. See «FUEL PRESSURE RELEASE»(ref-8639-S21059329402001091800000) . Disconnect negative, and then positive battery cables. Remove battery. Remove cable retaining clamp on dipstick. Remove dipstick, and plug hole. Remove vent hose.
2. Remove transmission selector lever arm. Disconnect and remove shift cable or shaft. Disconnect Gray and Black electrical connectors. Cut all plastic straps which hold wiring to transmission.
3. Remove air filter housing. Disconnect connector for Heated Oxygen Sensor (HO2S). Remove rubber bushings from lift brackets. Install Lifting Beam (83 948 50).
4. Raise and support vehicle. Remove front wheels. Remove center and right spoiler sections. Remove front section of exhaust pipe. Disconnect lower control arm ball joints. Remove clip for HO2S wire harness on front of engine.
5. Remove 2 subframe-to-engine bolts. Position Mobile Jack (83 94 793) with Fixture (83 94 801) under subframe. Remove remaining 6 subframe bolts/nuts and washers. Lower mobile jack about 4". Release frame from pivots, and remove subframe.
6. Place container under vehicle, and remove transmission cooling lines. Plug all openings. Release left drive shaft from its splines and pull it straight out. Plug drive shaft inlet hole. Separate right drive shaft from intermediate shaft. Secure drive shafts to vehicle body, and secure aside. Remove intermediate shaft attachment on engine.
7. Remove lower generator bolt. Remove 3 intermediate shaft attachment bolts. Turn generator upward. Force out shaft attachment to free guide pins. Pull out intermediate shaft with attachment.
8. Plug axle shaft ports. Remove actuator cover between engine and transmission. Remove 6 torque converter-to-flexplate bolts. Lock torque converter in position to avoid having converter fall during transmission removal. Remove lower engine-to-transmission bolts. Remove front engine mount bolts.
9. Remove rear bolt of remaining 3 upper engine-to-transmission bolts. Lower vehicle. Using lifting beam, lower engine and transmission so about a 4" gap is present between vehicle body and transmission front mount. Gap can be seen from left front wheel housing.
10. Secure Lifting Cable (87 92 251) to transmission rear bolt holes. Connect lifting cable to engine hoist. Remove slack from cable. Remove 2 remaining transmission-to-engine bolts. Remove transmission from engine and lower to floor. Disconnect lifting cable from engine hoist. Raise vehicle, and pull out transmission.
11. To install transmission, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8639-S00274035362000091200000) . Check and fill fluids to appropriate levels.

To release fuel pressure, disconnect fuel lines at fuel pressure regulator and fuel injection manifold.

1. Ensure fuel pressure is released. See «FUEL PRESSURE RELEASE»(ref-8639-S04087940702000091200000) . Disconnect negative, and then positive battery cables. Remove battery and windshield washer fluid reservoir. Disconnect electrical cable from battery tray. Remove clamps for positive cable from under battery tray. Remove fuel filter. Remove battery tray.
2. Disconnect wiring from mass airflow sensor. Remove sensor. Disconnect by-pass hose from turbocharger output duct and turbocharger outlet duct (if equipped). Disconnect throttle cable from throttle body. Remove gear selector cable from transaxle lever. DO NOT separate ball joint. Disconnect oil cooler hose from top of transaxle.
3. Disconnect gear selector cable from transaxle. Disconnect oil cooler hose from front of transaxle. Remove turbocharger oil supply hose clamp from transaxle (if equipped).
4. Remove negative battery cable from transaxle. Disconnect speed sensor wiring from transaxle. Remove transaxle-to-engine bolts that are accessible from above. Remove upper starter retaining bolt. Disconnect starter brace.
5. Install Holder (83 94 835) in engine lift hooks, and place Yoke (83 93 850) on inner fenders to support engine from above. Raise and support vehicle. Remove left front wheel. Remove fender liner. Remove starter motor without disconnecting cables. Secure starter motor aside.
6. Remove torque converter-to-flexplate bolts. Remove 2 ball joint-to-lower suspension arm bolts. Disconnect anti-roll bar from lower suspension arm. Remove front engine mount bolt. Remove bolts that retain subframe to front of vehicle. Loosen bolts that retain rear of subframe to vehicle. Carefully lower front of subframe.
7. Remove clamps around axle shaft universal joint boots. Withdraw axle shafts from transaxle. Support weight of transaxle with appropriate jack. Remove remaining transaxle-to-engine bolts. Separate transaxle from engine. Visually inspect that transaxle is free and clear for removal. Lower transaxle from vehicle.

To install transaxle, reverse removal procedure. Coat torque converter-to-flexplate bolts with thread sealant. Refill transaxle fluid to appropriate level. Tighten bolts/nuts to specification. See TORQUE SPECIFICATIONS . Adjust throttle and gear selector cables.