4.2.4. Removal, division and installation to the place of the engine and transmission

Removal

The engine can be taken from the car only in the uniform block with transmission; division of the block of the engine and transmission is made for carrying out capital repairs after their extraction from the car. The block of engine/transmission rises from a motive compartment by means of a lifting rigging.


 REMOVAL

1. Install the car on the firm flat platform. Prop up back wheels and cock the emergency brake. A forward part of the car also fix by Poddomkratte it on an axial prop (address Poddomkrachivaniye's Section, towage and change of wheels).

2. For ensuring access to the engine remove both forward wheels, then an otboltita and remove a molding of a wing and a loker of an arch of the right forward wheel.

3. Otboltite also remove the central antispray panel installed under a radiator. The panel fastens by means of clips on its rear edge.

4. Establish the capacity of suitable volume under a radiator, then unscrew a drain stopper and merge a cooler.

Draining of a cooler has to be made on the cold engine (see the Head Routine maintenance).

Also make draining of a cooler from the block of cylinders, having rearranged drain capacity and having unscrewed a drain stopper of the block of cylinders (see the Head Routine maintenance). In case the cooler is still suitable for the use, keep it.
5. After draining of a cooler establish into place and tighten drain traffic jams.
6. Remove a cowl (see the Head Body works). Or disconnect the supporting racks from a cowl and enshrine it in completely open provision. In specialized workshops of SAAB for this purpose extenders of support of a cowl are used.

7. Remove the battery.

Models with system of injection of LH-Jetronic fuel

 PERFORMANCE ORDER

1. Release a fixing strip of the fuel filter and shift the filter on a beam aside.
2. Give bolts of fastening of a persistent bar to a bracket of the block of system of anti-blocking of brakes (ABS).
3. Disconnect all wires from the battery pallet and disunite the plug of the block (ABS).
4. Disconnect a positive cable from the block of plugs on the battery pallet, you otboltit a negative cable of the battery from a grounding point on a forward wing.
5. Shift wires aside, then to an otboltita and take the battery pallet from a motive compartment.
6. In the left part of a motive compartment disconnect wires from the sensor of level of liquid of windscreen washers and the pump.
7. Disconnect from the tank a tube of a washer and for prevention of spilling of liquid to a zakuporta the tank.
8. Give bolts of a support and take the washer tank from a motive compartment.
9. Disconnect the plug of the measuring instrument of an air stream.
10. Release the bifurcate clips fixing the air cleaner to the measuring instrument of an air stream, then disconnect an inlet hose of system of a turbocompressor (if is available) and take the measuring instrument of an air stream from a motive compartment together with the top part of the air cleaner.
11. Where is available, disconnect a connecting wire from the electromagnetic valve of system of a turbocompressor. Weaken clips, disconnect hoses, then give the fixing screws and remove the valve.
12. Carefully disconnect a high-voltage wire of the coil of ignition from a cover of the distributor and shift it aside.
13. Disconnect wires of the sensor of Hall from a distributor sidewall.
14. Release a trosikovy collar of fastening of a wire of the sensor of a detonation, then release clips and disconnect the top hose from a radiator and a casing of the thermostat.
15. On the models equipped with a turbocompressor weaken collars on the giving hoses of system of a turbo-supercharging and disconnect hoses of transmission and the perepuskny valve / valve of pressure, disconnect the giving hoses from transmission.
16. Disconnect an accelerator rope from a bracket and a casing of the throttle valve (see the Head Toplivnaya and exhaust systems).
17. Weaken a collar and disconnect a hose of return of fuel from the fuel pressure regulator. Tie up a hose to a partition.
18. Weaken a clip and disconnect from the highway of fuel a hose of supply of fuel from the fuel filter. Fix a hose behind a false partition.
19. Uncover on the left side of the inlet camera of excessive pressure of a heater in a back part of a motive compartment, at the same time release a plait of wires and a wire of the sensor of a detonation from a trosikovy collar.
20. Remove a rubber molding of the upper edge of the panel of a false partition, then give bolts and take the panel.
21. On the models equipped with system of anti-blocking of brakes (ABS) weaken a fixing strip and take the block of the electronic actuation device (ECU) of the brake system. Put the block aside.
22. Otboltite also remove a bracket of the block of the electronic actuation device of system of anti-blocking of brakes (ABS ECU).
23. Disconnect wires from the block of the electronic actuation device (ECU) of system of injection of Bosch LH fuel and install the block of the electronic actuation device (ECU) on the panel of the left wing.
24. Otboltite also remove a bracket of the block of the electronic actuation device (ECU) of system of injection of Bosch LH fuel.
25. Remember an arrangement of all wires in a motive compartment for the subsequent their installation into place. Disconnect all wires from the engine.

26. The next way remove a nest of the TSI system (diagnostics). Enter the small screw-driver in turn at first into a nest of a gray / red wire (a conclusion 1), and then into a nest of a violet / white wire (a conclusion 2), then wring out the fixing ear and take wires outside. Remember an original arrangement of wires.

27. Remove the remained trosikovy collars of the sensor of a detonation. Then disconnect the plug and fix a wire on a forward wing.
28. Fix the main plait of wires on the top part of the engine.
29. Disconnect from a tee a vacuum hose between the inlet pipeline and the sensor of pressure.
30. Weaken collars and disconnect from the engine heater hoses - in order to avoid a pereputyvaniye at installation into place, mark hoses. Disunite a collar of wires of the measuring instrument of an air stream and shift heater hoses aside.
31. On a partition disconnect a wire of an electronic speedometer, then extend a wire from the rubber plug in day of the panel of a partition and fix it on the top part of the engine.
32. On models with automatic transmission weaken a clip of fastening of a rope of the device of decrease in transfer of transmission (Kickdown) to a rope of the selector of transfers, then weaken a trosikovy collar, the fixing rope to a steering servo-driver pump tube.
33. On models with automatic transmission smooth out areas around unions of cooling liquid of transmission, then give bolts of unions and disconnect liquid hoses from a liquid cooler of transmission. Remove copper washers and put them to the reliable place. Wrap up the ends of hoses an insulating tape, similarly muffle openings in transmission, in order to avoid hit in them of dirt and dust. Tie up hoses to an engine stretcher.
34. Disconnect a transfer choice rod (on models with the manual transmission) or the selector handle (models with automatic transmission) from transmission. The handle of the selector is removed as follows: Give a nut from the operating draft of the selector of transfers and an external rope, then take a rope from a clip, together with the rubber plug, by means of the screw-driver. Fix a rope behind the tank of brake fluid.

35. Weaken collars and disconnect hoses from a broad tank of the cooling system. Give a fastening bolt, release a trosikovy collar, then disconnect wires and remove a broad tank, having taken out it from the right part of a motive compartment.

36. Where is available, take off a driving belt of the air conditioning system, having given for this purpose a lock-nut, having shifted the compressor to the engine and having taken off a driving belt from pulleys.
37. In order to avoid damage cover with a piece of a cardboard the right surface of a radiator and a beam, then disconnect wires from the compressor of the air conditioning system.
38. Give fixing bolts.
39. Weaken a collar and disconnect a pump hose. Then lift the compressor and a hose and put them on a radiator beam. Tie up them to a radiator beam a piece of a string. Do not disconnect from the compressor refrigerator lines (see the prevention in the Head of the Cooling system, heating).
40. Where is available, weaken the clips and trosikovy collars fixing to the engine a wire a lambda sensor, then disconnect the plug on the inlet pipeline and lower a wire on an engine stretcher.
41. Give bolts of a jet bar and the top right support of the engine, remove a support from the engine.
42. Weaken clips and disconnect the lower hose of a radiator.
43. Where is available, weaken a collar and remove the giving hose of system of a turbo-supercharging.
44. Give nuts of fastening of a reception exhaust pipe to a final collector or a turbocompressor, then shift a pipe aside.
45. If is available, give and remove a bolt of fastening of the top support to the engine oil cooler, then weaken bolts of the lower support.
46. Weaken trosikovy collars of a hose of the oil cooler, then remove the oil cooler from bolts of the lower support and put it on the engine. Tie up the oil cooler to the engine a string piece.
47. Suck away liquid from the tank of system of hydrostrengthening of a wheel. Give a fixing bolt of the tank, then lower it and disconnect a hose, having weakened a collar. In order to avoid the passage of liquid, establish suitable capacity under the tank. Take the tank from a motive compartment, and put a hose aside.
48. Give a nipple nut and disconnect the giving hose from the pump of system of hydrostrengthening of a wheel. Seal the end of a hose with an insulating tape or a rubber cap, then tie up a hose to a partition.
49. Where is available, disconnect a vacuum hose of a coal adsorber from the inlet pipeline and shift a hose aside.

Models with a control system of the Trionic engine

 PERFORMANCE ORDER

1. Give nuts of fastening of a reception exhaust pipe to a final collector or to a turbocompressor.

2. Then shift a pipe aside. Remove laying.

3. Remove a safety box from a forward part of the pallet of the battery.

4. Give the holder of a positive cable of the battery on the battery pallet (the fixing screw is specified by an arrow).

5. Take a plastic cover from the block of plugs.

6. Disconnect the top cable (it is specified by an arrow), having turned off a nut.

7. Give screws and remove the block of plugs.
8. Give support screws.
9. Then remove the block of the electronic actuation device of system of anti-blocking of brakes (ABS ECU). Otboltite a negative wire of the battery from a grounding point on a forward wing.
10. Otboltite.
11. Remove the battery pallet.
12. Disconnect air admission sleeves from assembly of the air cleaner / block of a turbo-supercharging (if is available) and a throttle casing.
13. Disconnect a wire of the sensor of temperature of the let-in air. Remove an air admission sleeve.
14. Disconnect an accelerator rope from a bracket and a casing of the valve of a throttle (see the Head Toplivnaya and exhaust systems).
15. Take off an auxiliary driving belt (see the Head Routine maintenance).
16. Otboltite the pump of system of hydrostrengthening of a wheel (see the Head Podvesk and steering), but do not disconnect hydraulic hoses.
17. For providing additional working space remove back section of a loker of an arch of a wheel. Give a bolt.
18. Otboltite covered a hairpin between a stretcher and the internal panel. Shift the pump aside.
19. Otboltite a grounding cable from the top right support of the engine.
20. Then unscrew bolts.
21. Remove a jet bar / support from the engine.
22. Otboltite a bracket of the pump of system of hydrostrengthening of a wheel, then remove the generator (see the Head Sistemy of start and a charge).
23. Otboltite the holder of a tube of the pump of system of hydrostrengthening of a wheel from a bracket of the bearing of the right power shaft.
24. Where is available, disconnect a wire a lambda sensor (see the Head Toplivnaya and exhaust systems). Access to the socket under the inlet pipeline is extremely complicated, for its simplification unscrew the sensor from the lower exhaust pipe; be careful - do not damage a wire. Tie up the sensor to the engine.
25. Now can be disconnected from an engine wire partition. For this purpose unscrew a cover of the main socket and disconnect the plug.
26. Disconnect a slip.
27. Uncover (covers) a partition. Pick up the phone of a washer and a drain hose.
28. Weaken clips and remove the lengthening plait of wires going to the sensor of absolute pressure in the pipeline (MAP) in the right part of a partition. Remove the MAP sensor. Pay attention to laying of a plait under assembly of a heater and behind a bracket of the engine of screen wipers of a windshield.
29. Otboltite also remove the panel of a false partition.
30. Remove a box of safety locks of system of anti-blocking of brakes (ABS) from the support and establish it aside.
31. Weaken a wire loop of a support of a box of safety locks of the ABS system.
32. Remove from the support the tank of brake fluid / hydraulic liquid of coupling, then weaken a wire loop on the holder in a false partition. Disunite the socket of wires in the left part of a partition.
33. Remove the block of the electronic actuation device (ECU) of the Trionic system (see the Head Toplivnaya and exhaust systems).
34. Otboltite a grounding cable in the left part of transmission.
35. Weaken collars and disconnect the top hose of a radiator from a radiator and a casing of the thermostat.
36. Disconnect wires from the switch of fires of a backing and the sensor of an electronic speedometer.
37. Fix the main plait of wires on the top part of the engine.
38. Disconnect vacuum hoses of a coal adsorber and system of ventilation of a case from the inlet pipeline.
39. Disconnect a hose of the vacuum amplifier of brakes from the inlet pipeline.
40. Where it is required, disconnect a small hose of a broad tank from a radiator.
41. Weaken collars and disconnect the lower hose of a radiator and the lower hose of a broad tank from the water pump.
42. Similarly weaken collars and disconnect heater hoses from a head of cylinders and the tube of a cooler located in a back part of the block of cylinders. Tie up hoses aside. If necessary mark each hose for their correct subsequent connection.
43. Connect a heater hose to a cooler tube.
44. Connect a heater hose to a head of cylinders.
.45. On models with the manual transmission establish a hose clip on a hose of the hydraulic liquid of coupling going to transmission. Give the union and disconnect a hose from the tube of the executive cylinder conducting to a coupling case.
46. In order to avoid damages cover with a piece of a cardboard the right part of a radiator and a beam, then disconnect wires from the air conditioning system and give fixing bolts. Lift the compressor and install it on a radiator beam. Do not disconnect from the compressor refrigerator lines (see the preventions provided in the Head of the Cooling system, heating).
47. Disconnect the union of an admission of fuel and a hose of return of fuel from the fuel highway and the regulator of pressure of fuel.
48. Weaken a collar of a hose of return of fuel to the fuel pressure regulator. Remove hoses aside.
49. On models with the manual transmission disconnect a rod of the choice of transfer from transmission, having given a 10-millimeter bolt.
50. If it is required, then at this stage draining of oil from the manual transmission can be made, however it is not an indispensable condition as power shafts remain in transmission.
51. On the models equipped with system of a turbo-supercharging weaken collars of the giving hose of system of a turbo-supercharging, then disconnect hoses of the bypass valve / valve of pressure and transmission, and remove the giving hose, having disconnected it from transmission.
52. On models with automatic transmission weaken a clip of fastening of a rope of the device of decrease in transfer of transmission (Kickdown) to a rope of the selector of transfers, then weaken a trosikovy collar, the fixing rope to a wheel servo-driver pump tube, also disconnect the selector handle from transmission.
53. On models with automatic transmission clear areas around unions of the cooling system of gearbox oil, then give nipple bolts and disconnect liquid hoses from a cooler of transmission liquid. Remove copper washers and put them to the reliable place. Muffle an insulating tape the ends of hoses and an opening in transmission in order to avoid hit of dirt and dust there. Tie up hoses to an engine stretcher.
54. On models with automatic transmission disconnect the selector handle from transmission, working as follows. Give a nut of the operating draft of the selector of transfers (see §41) and an external rope, then release a rope from a clip together with the rubber plug by means of the screw-driver. Fix a rope behind the tank with brake fluid.

All models

 PERFORMANCE ORDER

1. By means of a face key give 2 nuts of the right support of the engine. At the same time use the extender, working from the right top side of a motive compartment.

2. Weaken and remove collars of fastening of rubber cuffs of power shafts to internal hinges for the purpose of a possibility of a rassoyedineniye of hinges when moving outside of forward support of a suspension bracket. If the twisted clips were applied cut them by means of scissors on metal.
3. Working in turn from each party of the car, weaken (but do not remove) the lower bolts of fastening of support to rotary fists, and completely remove the top bolts. It will allow to shift fists aside enough to disunite internal hinges of power shafts. Also, it will be useful at a detachment of tips of steering drafts for ensuring more free movement of support of a suspension bracket.
4. Working in turn from each party of the car, take rotary fists; at the same time disconnect rubber cuffs for a possibility of separation of internal hinges from the internal ends of power shafts. Wrap up the naked ends of hinges of power shafts polyethylene or an insulating tape in order to avoid hit in them of dirt and dust.
5. Give and remove the lower fixing bolt of assembly of the electric fan of the cooling system.
6. Give the top fixing bolt of assembly of the electric fan of the cooling system. Disconnect the plug and take the fan block from a motive compartment. Be careful, do not damage a radiator matrix.
7. If necessary lower and install the car at height convenient for work with the winch. Connect a lifting rigging to lifting earrings, pribolchenny to a head of cylinders.

8. You twist the winch until it does not assume engine weight. Give a nut of the left support of the engine - there is no need to completely remove a bolt as in a support there is a cut.

9. Before starting extraction of the engine from the car, make final check that all components which have to be removed and disconnected are removed and disconnected. Make sure that such components as a rod of the selector of the choice of transfers, are fixed in such a way that they cannot be damaged at extraction from the car of the block of engine / transmission.
10. Carefully begin to lift assembly engine / transmission from a motive compartment, checking that assembly did not cling to components on surrounding panels of a motive compartment. In particular you watch that the block of the engine was not hooked for the block of system of anti-blocking of brakes (ABS), a rope of decrease in transfer of automatic transmission (Kickdown) (for models with automatic transmission) and a radiator. After rise of assembly over a forward beam finally take assembly engine / transmission from a motive compartment and lower it on the earth. At the same time, for accurate installation on the earth, the help of the assistant can be necessary.

Transmission detachment from the engine

 PERFORMANCE ORDER

1. It is preferable to make draining of gearbox oil / liquid (see Chapters the Manual transmission or Automatic transmission). Establish into place drain and jellied traffic jams, tighten them with the required effort. Draining of gearbox oil is not an indispensable condition as flanges of power shafts still remain fixed on each party of transmission.
2. In case the engine understands according to the procedures described in the Head Routine maintenance merge motive oil and if it is required, remove an oil filter. Clear and establish into place a drain stopper, strong tighten it.
3. Install assembly engine / transmission on a workbench, on suitable wooden blocks (or in case of lack of a workbench, on the cleared platform on a workshop floor).
4. Remove a starter (see the Head Sistemy of start and a charge).

5. Disconnect from the socket of a wire of an electronic speedometer, having inserted the screw-driver.

6. Extend a clamp.

7. Disconnect the plug in a back part of the engine.

8. If necessary at this stage the plait of wires of the engine can be completely disconnected - it is located on a tube of a mouth of the gulf of oil.
9. Where the generator was not removed yet (on early models), give a nut and disconnect a wire from a back part of the generator. Also disconnect a wire of an alarm lamp of battery charging (green / white) from the generator. Give bolts of fastening of the generator from a basic bracket of the bearing of a power shaft and a bracket of the pump of system of hydrostrengthening of a wheel and remove the generator from the engine.
10. Otboltite a basic bracket of the bearing of a power shaft from a back part of the block of cylinders, at the same time taking shlitsevy a shaft from lengthening of a power shaft.
11. Otboltite also remove a bracket of a back support of the engine.
12. Establish the capacity of suitable volume under an oil filter, then unscrew and remove from a bracket an oil filter in a forward or back part of the block of cylinders (how it is established).

Models with the manual transmission

 PERFORMANCE ORDER

1. On the models equipped with system of a turbo-supercharging give a bolt of fastening of an oil tube of system of a turbo-supercharging to transmission.

2. Otboltite from a transmission casing the lower cover also remove it.

3. Make sure that both the engine, and transmission are appropriately fixed, give bolts of fastening of a casing of transmission to the engine. Remember an installation site of each bolt - at installation they have to be screwed in on the former places. Disconnect transmission from the engine. Be careful - do not allow the weight of transmission to lean on a main shaft and coupling.

Models with automatic transmission

 PERFORMANCE ORDER

1. Unscrew approximately on 10 cm the top hairpin of fastening of transmission to the block of cylinders of the engine. For this purpose previously turn off a nut on several turns, then wind the second nut on a hairpin and, having pulled together them, unscrew a hairpin for the lower nut.
2. Disconnect a rope of the device of decrease in transfer of automatic transmission (Kickdown) from a bracket of the inlet pipeline. Take a spring clamp and disconnect an accelerator rope from the lever on a throttle casing.
3. Remove the ventilating valve from the top part of transmission.
4. On the models equipped with system of a turbo-supercharging give a bolt of fastening of a bracket of an oil tube of system of a turbo-supercharging to transmission.

5. Working through a starter opening, give 3 bolts of fastening of a flywheel to the rotation converter. For ensuring access to each bolt turn the engine by means of the face key which is put on a crankshaft pulley bolt.

6. In the workshops SAAB, for deduction of the converter of rotation in transmission at separation of transmission from the engine, the special tool is used. The tool is extremely simple and consists of a plate which is connected to the rotation converter through a distributive opening in the top part of transmission. The plate keeps in the situation with the help of a clip.

7. For deduction of weight of transmission it is preferable to use the winch.
8. Make sure that both the engine, and transmission equally of an operta, then give bolts of fastening of a casing of transmission to the engine. Keep in mind that at assembly each bolt has to be established on the former place. Disconnect transmission from the engine. Make sure that the converter of rotation remained in a transmission casing, otherwise it can drop out and be damaged.

Connection of transmission to the engine

Models with automatic transmission

 PERFORMANCE ORDER

1. Carefully apply transmission to the engine. You watch that the converter of rotation remained completely linked to transmission what it is necessary to use the special tool described in §122 to.
2. Insert the top fixing hairpin into transmission and tighten it, then give and remove the top lock-nut, then tighten a fixing nut.
3. Establish and tighten with the required effort the remained bolts of fastening of transmission to the engine.
4. Remove the special tool, then insert and tighten with the required effort 3 bolts of fastening of a flywheel to the rotation converter. At the same time turn the engine by means of a face key.
5. On the models equipped with system of a turbo-supercharging insert and tighten bolts of fastening of a bracket of an oil tube of system of a turbo-supercharging to transmission.
6. Install into place in the top part of transmission the ventilating valve.
7. Connect a rope of the device of decrease in transfer of automatic transmission (Kickdown) to draft on a throttle casing, then establish into place and fix an external rope on a bracket of the inlet pipeline, make adjustment of its tightness (see the Head Automatic transmission).
8. Tighten a lock-nut of the adjusting device.

Models with the manual transmission

 PERFORMANCE ORDER

1. Apply high-temperature lubricant on vents of a main shaft of transmission. Be not overzealous when greasing as it can lead to pollution by lubricant of a frictional clutch plate.
2. Carefully bring transmission to the engine. You watch that the weight of transmission did not fall on a main shaft as it is connected to a frictional clutch plate. Insert and tighten with the required effort bolts of fastening of transmission to the engine.
3. Establish into place the lower cover of a casing of transmission and tighten bolts.
4. On the models equipped with system of a turbo-supercharging insert and tighten bolts of fastening of a bracket of an oil tube of system of a turbo-supercharging to transmission.

All models

 PERFORMANCE ORDER

1. Absolutely wipe contact surfaces, then establish and tighten an oil filter (see the Head Routine maintenance).
2. Establish a bracket of a back support of the engine and tighten bolts.
3. Establish a basic bracket of the bearing of a power shaft in a back part of the block of cylinders, at the same time entering shlitsevy a shaft into lengthening of a power shaft. Insert and tighten bolts.
4. On early models install the generator on a bracket of the bearing of a power shaft and on a bracket of the pump of system of hydrostrengthening of a wheel, tighten fixing bolts. Connect a wire of a starter and tighten a nut. Connect a wire of an alarm lamp of battery charging to a back part of the generator.
5. Establish into place a starter together with a persistent bar (The head Sistemy of start and a charge).

Installation into place

Installation is into place made as it should be, the return to a removal order taking into account the next additional moments:

   a) All nuts and bolts have to be tightened with the required effort.
   b) All available copper washers on unions have to be replaced.
   c) Where is available, pull a driving compressor belt of the air conditioning system (see the Head Routine maintenance).
   d) Where is available, pump over hydraulic system of coupling (see the Head Stsepleniye).
   e) Connect and adjust an accelerator rope tension (see the Head Toplivnaya and exhaust systems).
   f) Make sure that all wires are connected, and all nuts and bolts are tightened.
   j) Fill in the engine and transmission with oil / liquid of the necessary grade in the required quantity (see the Head Routine maintenance).
   h) Fill in the cooling system (see the Head Routine maintenance).
   i) Check level and, in case of need, produce dolivany liquids of system of hydrostrengthening of a wheel (see the Head Routine maintenance).