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Home >> Saab >> 2004 >> 9-3 Linear, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Basic Engine >> Adjustment-Replacement >> Cylinder head >> To remove

To remove

  1. Apply wing covers and remove battery cover and negative battery cable.
  2. Open the cap on the expansion tank.
  3. Unplug the oxygen sensors and carefully take down the cables.
    WARNING: Take care as the engine can be very hot.
    Fig 1: Illustration For Step 3-4
    G03707794Courtesy of SAAB-SCANIA OF AMERICA, INC.
  4. Remove the heat shield over the turbocharger.
  5. Undo the turbocharger oil delivery pipe.
    Fig 2: Illustration For Step 5-7
    G03707795Courtesy of SAAB-SCANIA OF AMERICA, INC.
  6. Remove the nuts for the catalytic converter connection with the turbocharger.
  7. Raise the car and remove the front right wheel and right wing liner.
    Fig 3: Illustration For Step 8
    G03707796Courtesy of SAAB-SCANIA OF AMERICA, INC.
  8. Disconnect and bend aside one side of the lower spoiler shield. CV: Remove the front subframe chassis reinforcement.
    Fig 4: Illustration For Step 9
    G03707797Courtesy of SAAB-SCANIA OF AMERICA, INC.
  9. Place a receptacle under the car, connect a hose to the radiator and drain the coolant.
    Fig 5: Illustration For Steps 10
    G03707798Courtesy of SAAB-SCANIA OF AMERICA, INC.
  10. Remove the lower turbocharger pressure pipe.
    Fig 6: Illustration For Step 11
    G03707799Courtesy of SAAB-SCANIA OF AMERICA, INC.
  11. Undo the catalytic converter bracket from the cylinder block.
  12. Use protective goggles. Place a receptacle under the car, connect a hose and open the cock on the coolant pump to drain the remaining coolant.
    Fig 7: Illustration For Steps 20-23
    G03707800Courtesy of SAAB-SCANIA OF AMERICA, INC.
  13. Close the cock.

    Tightening torque 20 Nm (15 lbf ft)  .

  14. Undo the turbocharger coolant pipe.
  15. Remove the stay between the exhaust manifold and the cylinder block.
  16. Remove the oil return pipe from the turbocharger.
    IMPORTANT: If the flexible part of the return oil pipe is bent, the resulting restriction may become permanent and cause damage to the turbocharger.
  17. Remove the stay between the intake manifold and the cylinder block.
    Fig 8: Illustration For Steps 24, 25
    G03707801Courtesy of SAAB-SCANIA OF AMERICA, INC.
  18. Disconnect the starter motor positive cable.
  19. Lower the car and remove the upper engine cover.
    Fig 9: Illustration For Steps 29, 30
    G03707802Courtesy of SAAB-SCANIA OF AMERICA, INC.
  20. Remove the turbocharger delivery hose from the throttle body and the turbo delivery pipe
  21. Detach the hoses and remove the turbo inlet pipe. Unplug the mass air flow sensor connector. Plug the turbo inlet.
    Fig 10: Illustration For Steps 21-23
    G03707803Courtesy of SAAB-SCANIA OF AMERICA, INC.
  22. Remove the air cleaner cover and the air cleaner. Detach the inlet hose and remove the air cleaner casing.
    Fig 11: Illustration For Step 32
    G03707804Courtesy of SAAB-SCANIA OF AMERICA, INC.
    WARNING: The work involved in removing the fuel pipe requires working with the vehicle's fuel system. The following points should therefore be heeded in conjunction with these measures:
    • Have a class BE fire extinguisher on hand! Be aware of the risk of sparks, i.e. in connection with electric circuits, short-circuiting, etc.
    • Absolutely No Smoking!
    • Ensure good ventilation! If there is approved ventilation for evacuating fuel fumes then this must be used.
    • Wear protective gloves! Prolonged exposure of the hands to fuel can cause irritation to the skin.
    • Wear protective goggles.
  23. Release any pressure in the fuel system by carefully pressing the service valve needle. Collect any fuel spill. Detach both fuel lines from the fuel rail while gripping the lower nut. Plug the fuel lines. Use 82 92 948 Plugs, A/C system assy.
    Fig 12: Illustration For Step 23, 24
    G03707805Courtesy of SAAB-SCANIA OF AMERICA, INC.
  24. Disconnect the quick-release coupling for the ventilation line and detach the fuel lines and ventilation lines from the clips on the camshaft cover. Bend up the ventilation hose from the intake manifold and place it on the camshaft cover.
  25. Remove cover over ignition coils.
    Fig 13: Illustration For Step 35
    G03707806Courtesy of SAAB-SCANIA OF AMERICA, INC.
  26. Unplug ignition coil connectors. Unplug connector to turbocharger solenoid valve and undo cable clips.
    Fig 14: Illustration For Step 36
    G03707807Courtesy of SAAB-SCANIA OF AMERICA, INC.
  27. Unplug A/C pressure sensor connector, connector to coolant temperature sensor, engine control module, bypass valve solenoid valve, throttle body, intake manifold pressure sensor, atmospheric pressure sensor, IDM module, oil pressure sensor and ground cable on engine control module.
    Fig 15: Illustration For Step 37-39
    G03707808Courtesy of SAAB-SCANIA OF AMERICA, INC.
  28. Detach hose from turbocharger wastegate and solenoid valve.
  29. Detach the cable duct and bracket from the camshaft cover. Move away the engine wiring harness.
  30. Remove wiring harness nuts from oil filter housing and intake manifold and detach the wiring harness.
    Fig 16: Illustration For Steps 40
    G03707809Courtesy of SAAB-SCANIA OF AMERICA, INC.
  31. Remove the ignition coils.
    Fig 17: Illustration For Step 41-43
    G03707810Courtesy of SAAB-SCANIA OF AMERICA, INC.
  32. Detach crankcase ventilation hose from camshaft cover.
  33. Undo ground cable from camshaft cover.
  34. Remove the camshaft cover.
    Fig 18: Illustration For Step 44
    G03707811Courtesy of SAAB-SCANIA OF AMERICA, INC.
  35. Zero the engine by turning the crankshaft clockwise until the mark on the crankshaft pulley agrees with the mark on the timing cover, cyl. 1 cams on intake and exhaust camshaft must be pointing in/up.
    Fig 19: Illustration For Steps 45
    G03707812Courtesy of SAAB-SCANIA OF AMERICA, INC.
  36. Detach coolant hose from pipe and cylinder head.
    Fig 20: Illustration For Steps 46, 47
    G03707813Courtesy of SAAB-SCANIA OF AMERICA, INC.
  37. Place a jack with wood block under the oil sump and relieve the right-hand engine pad. Remove the right-hand engine mounting.
  38. Detach coolant hose from pipe on cylinder head. Detach vacuum hose from brake servo.
    Fig 21: Illustration For Steps 48, 49
    G03707814Courtesy of SAAB-SCANIA OF AMERICA, INC.
  39. Cars with secondary air injection pump:  Remove pump pipe and upper retaining bolt from intake manifold.
  40. Undo power steering pump.
  41. Remove bolt for dipstick tube. Unplug the connector and detach it from the pipe.
    Fig 22: Illustration For Steps 53-55
    G03707815Courtesy of SAAB-SCANIA OF AMERICA, INC.
  42. Remove the chain tensioner. Use 83 96 129 OIL FILTER TOOL B207 
    Fig 23: Illustration For Step 57-61
    G03707816Courtesy of SAAB-SCANIA OF AMERICA, INC.
  43. Undo the camshaft sprockets. Grip the respective camshaft on its flats.
  44. Tie a cable tie around the exhaust camshaft sprocket and chain, remove the camshaft sprockets and lower the exhaust camshaft sprocket with chain.
  45. Remove the plug from the cylinder head.
  46. Remove the bolt for the chain guide on the intake side, move away the guide and refit the bolt.
  47. Remove the cylinder head in the order shown in the illustration.
    Fig 24: Illustration For Step 61, 62
    G03707817Courtesy of SAAB-SCANIA OF AMERICA, INC.
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