3.0L V6 Engine: Removal & Installation Saab 9-5 I

REMOVAL & INSTALLATION

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.

Removal

1. Remove engine covers. Remove battery. Unhook front electrical distribution box from battery shelf. Disconnect cruise control cable from throttle lever. Remove positive terminal block from battery shelf. Remove clamp for positive battery cable. Remove vacuum hose from clamps on battery shelf.
2. Remove battery cable conduit clips. Unbolt battery shelf. Raise battery shelf slightly and disconnect cruise control electrical connector. Remove battery shelf with cruise control module and cable.
3. Release throttle cable from bracket. Snap out control rod, release bracket, and fold to one side. Remove hose clamps between inlet pipes and intake manifold, and between resonator and Mass Airflow (MAF) sensor. Slightly lift inlet pipes. Disconnect vacuum hoses and electrical connectors. Remove pipes and resonators.
4. Disconnect secondary air injection hoses from check valves. Cut cable tie at resonator bracket. Remove seal from detachable bulkhead plate. Remove cover and disconnect washer hoses. Disconnect fuel pipe clamps from detachable bulkhead plate. Remove bolts and lift up plate.
5. Disconnect Motronic Electronic Control Module (ECM) electrical connector. Pull wiring through to engine compartment. Remove detachable bulkhead plate. Disconnect wiring from torque arm engine mounting. Lift off power steering servo oil reservoir and remove torque arm. Turn tensioner pulley forward and release tension load. Move belt to one side.
6. Remove power steering pump. Remove clamp from servo pipe. Move pump and reservoir to one side. On A/T equipped vehicles, disconnect gear selector cable. Disconnect transmission cooling lines and drain fluid. Plug hoses. On all vehicles, disconnect rear HO2S sensor connector. Disconnect fuel hoses. See «FUEL PRESSURE RELEASE»(ref-8774-S04978569592000092200000) . Loosen expansion tank cap.
7. Raise and support front of vehicle. Remove both front wheels. Disconnect steering knuckles from MacPherson struts. Remove inner CV joint boot clamps. Pull CV joints apart. Cover CV joint halves. Raise vehicle further. Remove clamp holding HO2S, knock sensor, and crankshaft position sensor wiring to cylinder block. Disconnect HO2S, knock sensor, and crankshaft position sensor electrical connectors.
8. Remove front exhaust pipe. Remove center air shield. Drain coolant. Loosen lower and upper A/C compressor retaining bolts. On A/T equipped vehicles, move oil cooling lines forward. On all vehicles, lower vehicle.
9. Remove upper radiator hose from engine. Drain coolant from hose. Remove lower radiator hose from engine and move hose forward. Remove heat exchanger hoses. Remove expansion tank hose. Lift up power steering servo pump and oil reservoir. Remove brake servo vacuum hose from intake manifold.
10. Disconnect positive battery cable from positive terminal block. Disconnect battery ground cable from gearbox. Remove remaining bolts on A/C compressor. Disconnect rear and right engine mounts. Install Extender (83 94 439) on hood gas springs to hold hood open.
11. Hook Lifting Yoke (83 92 409) onto an engine lift and engine. Remove left engine mount. Lift entire powertrain a short distance and remove resonator bracket. Remove entire powertrain.

Installation

1. Install multi-groove belt, ensuring it runs under right engine mount. Carefully lower powertrain into engine compartment, ensuring engine is aligned with engine mounts.
2. Install resonator bracket. Install engine mount bolts. To install remaining components, reverse removal procedure.

1. Disconnect negative battery cable. Raise and support vehicle. Remove 2 bolts securing rear exhaust pipe to exhaust manifold. Remove center air shield. Drain coolant. Lower vehicle. Remove engine covers. Disconnect all components attached to intake manifold. Remove intake manifold bolts. Remove throttle body preheater hoses, crankcase ventilation hose, and vacuum hoses from intake manifold.
2. Disconnect IAC valve connector. Remove fuel pressure regulator hose. Remove wiring harness conduit under throttle body. Disconnect throttle position indicator connector and ignition coil. Disconnect throttle body connector. Lift off intake manifold. Plug holes with paper.
3. Unplug injector connector. Disconnect camshaft position sensor. Disconnect fuel lines and plug connectors. Remove bolts securing center intake manifold complete with fuel rail and place it to one side. Mark lower section of intake manifold for reassembly reference. Remove lower intake manifold. Plug holes with paper. Remove coolant manifold and bend aside. Disconnect spark plug wires.
4. Remove HO2S sensor from its holder. Remove crankcase ventilation housing. Plug holes with paper. Remove steering servo oil reservoir. Disconnect wiring from torque arm engine mount. Remove torque arm. Remove power steering servo line clamp from torque arm engine mount. Remove engine mount. Remove upper hose from expansion tank. Remove upper part of generator air intake.
5. Slightly loosen crankshaft pulley bolts. Remove multi-groove belt, belt tensioner, power steering servo pump, water pump pulley, and timing cover. Remove crankshaft pulley (do not remove center bolt). Put cylinder No. 1 at TDC of compression stroke. Align matching marks on camshaft sprockets and timing cover, and crankshaft. Lock camshaft sprockets in place.
6. Mark direction of rotation, and camshaft/crankshaft alignment marks on timing belt. Release belt tension and remove belt. Turn crankshaft back 60 degrees BTDC. Remove bracket holding upper adjusting roller and tensioning roller.
7. Remove timing cover, using care not to damage "O" rings. Remove cylinder head camshaft sprockets and unscrew timing cover bolts from cylinder head. Camshaft sprockets are marked 1 and 2. WARNING: Ensure wrench used to remove camshaft sprockets does not have jaws that are too long. There is a risk of damaging casting, causing tappet to jam.
8. Loosen exhaust camshaft bearing cap bolts in stages, one to one-half turn at a time. Remove camshaft seal and lift out exhaust camshaft. NOTE: Intake camshaft removal is not necessary.
9. Loosen cylinder head bolts one-quarter, then one-half turn. Remove cylinder head bolts in order. (Scheme 30) Remove cylinder head. Use care when placing cylinder head aside as intake camshaft is still in place and valve stems could be bent. Remove intake camshaft, exhaust manifold and tappets.

Scheme 30

Scheme 31

Scheme 32

1. Position crankshaft at 60 degrees BTDC. Clean all contact surfaces and install head gasket. Ensure gasket is installed with mark OBEN/TOP facing upward. Install exhaust manifold and tappets. Place cylinder head in position. Torque NEW bolts in order, to specification. See «TORQUE SPECIFICATIONS»(ref-8774-S03607170062000092200000). (Scheme 30)
2. Install camshafts and lubricate with oil. Note markings on bearing caps and cylinder head. Install bearing caps and tighten bolts in sequence, working outward. Lubricate seal lips and install gasket, camshaft bolt and washer. Install timing cover retaining screws in cylinder head. Ensure locating pins are correctly positioned. Install camshaft sprockets in relation to locating pins. (Scheme 31)
3. Install tensioning roller and upper adjusting roller. Install Locking Tool (KM-800-1) on No. 1 and No. 2 camshaft sprockets, and Locking Tool (KM-800-2) on No. 3 and No. 4 camshaft sprockets. Turn crankshaft to just before zero degrees and install Locking Tool (KM-800-10) on crankshaft. Carefully turn crankshaft in direction of engine rotation until arm is against water pump flange. Tighten arm.
4. Install timing belt. Install Belt Holder (KM-800-30) to hold timing belt in place. (Scheme 32) Adjust tensioning roller by hand to prevent belt from slipping out of cogs. Install crankcase ventilation housing and oxygen sensor connector in its holder. Ensure "O" rings are in valve cover and wipe clean. To install remaining components, reverse removal procedure.

1. Disconnect negative battery cable. Raise and support vehicle. Remove 2 front exhaust pipe-to-exhaust manifold bolts. Remove air shield. Drain coolant. Lower vehicle. Remove engine covers. Disconnect cruise control cable. Disconnect throttle cable from bracket. Unclip control rod, detach bracket and move it aside.
2. Disconnect hose clamps between inlet pipes and intake manifold, and between resonator and Mass Airflow (MAF) sensor. Raise inlet pipes slightly. Disconnect all vacuum hoses and electrical connectors. Mark hoses for reassembly reference. Remove pipes with resonator. Disconnect fuel lines and plug connectors.
3. Remove intake manifold bolts. Remove throttle body preheater hoses, crankcase ventilation hose, and vacuum hoses from intake manifold. Mark hoses for reassembly reference. Disconnect IAC valve connector. Disconnect fuel pressure regulator hose. Remove wiring harness conduit under throttle body.
4. Disconnect Throttle Position Sensor (TPS) connector and ignition coil. Disconnect throttle body connector and lift off intake manifold. Plug holes with paper.
5. Disconnect coolant manifold and move aside. Disconnect spark plug wires and ignition coil. Move coil aside and disconnect ignition coil bracket.
6. Remove lifting eye and heat shield covering exhaust manifold. Disconnect resonator bracket and remove secondary air injection pipe from exhaust manifold. Lift power steering servo oil reservoir. Disconnect wire from torque arm engine mount. Remove torque arm. Remove servo line clamp from torque arm engine mount. Remove engine mount. Disconnect upper hose from expansion tank and upper part of generator air intake.
7. Slightly loosen crankshaft pulley bolts. Remove drive belt, belt tensioner, power steering pump pulley, water pump pulley and cover. Remove crankshaft pulley, but do not remove center bolt. Put cylinder No. 1 at TDC of compression stroke. Camshaft sprocket, timing cover and crankshaft marks should be aligned. Lock camshaft sprockets in place.
8. Mark timing belt direction of rotation. Remove timing belt. Turn crankshaft back 60 degrees BTDC. Remove bracket securing upper adjusting pulley and tensioning pulley. Remove timing cover. Ensure "O" rings are in place and do not fall into engine.
9. Remove cylinder head camshaft sprockets No. 3 and 4. Remove 2 timing cover bolts from cylinder head. WARNING: Ensure wrench used to remove camshaft sprockets does not have jaws that are too long. There is a risk of damaging casting, causing tappet to jam.
10. Loosen bolts one-half to one turn at a time and remove bearing caps on exhaust camshaft. Remove camshaft seal and lift out camshaft. Loosen cylinder head bolts, one-half, then one-quarter turn, in order. Lift off cylinder head. Use care not to bend valve stems. Remove intake manifold, valve depressors, oxygen sensor holder, exhaust manifold and heat shield.

Scheme 33

1. Position crankshaft at 60 degrees BTDC. Clean all contact surfaces and install head gasket. Ensure gasket is installed with OBEN/TOP facing upward. Install exhaust manifold, tappets, heat shield and oxygen sensor holder. Place cylinder head in position. Torque NEW bolts in order, to specification. (Scheme 30) See «TORQUE SPECIFICATIONS»(ref-8774-S03607170062000092200000) table.
2. Install camshafts and lubricate with oil. Ensure locating pins are correctly positioned. (Scheme 31) Note markings on bearing caps and cylinder head. Install bearing caps and tighten bolts in order. Lubricate seal lips and install gasket, camshaft bolt and washer. Install timing cover retaining screws in cylinder head.
3. Install Locking Tool (KM-800-1) on No. 1 and No. 2 camshaft sprockets, and Locking Tool (KM-800-2) on No. 3 and No. 4 camshaft sprockets. Turn crankshaft to just before zero degrees and install locking tool on crankshaft. Carefully turn crankshaft in direction of engine rotation until arm is against water pump flange. Tighten arm.
4. Install timing belt. Install Belt Holder (KM-800-30) to hold timing belt in place. (Scheme 32) Adjust tensioning roller by hand to prevent belt from slipping out of cogs. Adjust belt counterclockwise. Install a section of belt. Install Belt Tension Meter (83 94 985) to measure belt tension.
5. Slightly tighten adjusting roller center bolts. Adjust lower adjusting roller counterclockwise to a belt tension of 205-221 ft. lbs. (275-300 N.m). Belt turning torque should be 30 ft. lbs. (40 N.m). NOTE: Belt tension adjustment at this time is not final. Do not use this adjustment as a check for final adjustment.
6. Adjust tensioning pulley with an Allen wrench until 2 marks are aligned. Remove locking tool for camshaft sprockets No. 1 and 2. Adjust upper adjusting roller until camshaft sprocket No. 2 moves.03-.07" (1-2 mm) clockwise. Remove upper locking tool.
7. Rotate crankshaft over 2 revolutions until just before zero mark. Place locking tool on crankshaft. Carefully turn crankshaft in direction of engine rotation until arm is against water pump flange. Tighten arm. Install Camshaft Alignment Tool (KM-800-20) and ensure markings on camshaft sprockets are aligned with markings on tool. (Scheme 33) Check tensioning roller to ensure marks are in alignment.
8. Install timing cover. Ensure "O" rings are in place in valve cover and wipe clean. Install valve cover. Install engine lifting hook and upper radiator hose. To complete installation, reverse removal procedure.

1. Remove timing belt. See appropriate cylinder head removal and installation procedure. Install Holder (83 95 063) and remove crankshaft toothed belt sprocket and spacer ring. Remove seal, using care not to damage crankshaft sealing surface.
2. To install seal , install inner section of Crankshaft Seal Assembly Tool (83 94 942) on crankshaft with cone facing outward. Lubricate seal and install on shaft. Tap seal in place. Install spacer ring. Install crankshaft sprocket. Tighten bolt to specification. See «TORQUE SPECIFICATIONS»(ref-8774-S03607170062000092200000) .

1. Disconnect negative battery cable. Raise and support vehicle. Remove splash shields for access to oil pan. Drain engine oil. Remove oil pan mounting bolts and remove oil pan. (Scheme 34)
2. To install, reverse removal procedures. Use NEW oil pan gasket. Tighten oil pan bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8774-S03607170062000092200000). Fill crankcase with engine oil.

1. Remove oil pan. See «OIL PAN»(ref-8774-S33740222942000092200000). Remove motor mount lower bolts/nuts from frame bracket. Remove oil intake pipe. Remove A/C compressor hose support strap (if equipped). Remove oil pan housing bolts, leaving corner bolts in place to hold oil pan housing in place.
2. Place matching marks on drive shaft for reassembly. Remove drive shaft bolts. Slide drive shaft rearward, away from transmission, and secure aside. Remove catalytic converter hanger bolts. Lower vehicle.
3. Using an engine support from above engine, raise and support engine enough to remove oil pan housing. Raise vehicle. Remove remaining oil pan housing bolts, and remove oil pan housing and gasket. (Scheme 34) To install, reverse removal procedures. See «TORQUE SPECIFICATIONS»(ref-8774-S03607170062000092200000).

Scheme 34

1. Remove transmission. For M/T vehicles, see appropriate article in CLUTCHES. For A/T vehicles, see TRANSMISSION REMOVAL & INSTALLATION in TRANSMISSION SERVICING. Remove flywheel or drive plate. Remove seal, using care not to damage sealing surface.
2. To install, lubricate seal lips. Tap seal into place, ensuring seal lips are correctly fitted on crankshaft. Install flywheel or drive plate. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-8774-S03607170062000092200000) .

1. Remove timing belt. See appropriate cylinder head removal procedure under «REMOVAL & INSTALLATION»(ref-8774-S33941222152000092200000). Raise and support vehicle. Disconnect front exhaust pipe from both exhaust manifolds. Remove protective plate. Install Holder (83 95 063) and remove crankshaft pulley.
2. Remove generator. Remove A/C compressor and lay aside. Drain engine oil. Remove oil pan, oil strainer and anti-slosh baffles. Disconnect oil pressure switch electrical connector. Lower vehicle and place a stand under front of engine block. Remove bracket along with engine mounting. Remove oil pump housing. (Scheme 35) To install oil pump, reverse removal procedure. Use NEW gasket. Replace front oil seal. (Scheme 36) Ensure gears are coated with oil.

Scheme 35

Scheme 36