LEMON Manuals: Even more car manuals for everyone
Home >> Saab >> 2003 >> 9-5 Arc, 4D Sedan >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Turbocharger System >> Adjustment-Replacement >> Turbo, 4-cyl. >> To remove

To remove

WARNING: Take care if the car is warm. The coolant is hot and there is also a risk of burning yourself on the exhaust manifold.
  1. Open the expansion tank cap to release the system pressure.
    Fig 1: Illustration For Steps 1, 3, 4
    G03656353Courtesy of SAAB-SCANIA OF AMERICA, INC.
  2. Raise the car.
  3. Remove the lower front cover.
  4. Drain off the coolant.
  5. Remove the turbo stays.
    Fig 2: Illustration For Steps 5-7
    G03656354Courtesy of SAAB-SCANIA OF AMERICA, INC.
  6. Loosen the return oil nipple and the pipe from the turbo to the cylinder block. Plus the hole in the block.
  7. Loosen the oil pipe between the oil filter adapter and the turbo (at the turbo).
  8. Lower the car to the floor.
  9. Remove the bypass pipe and valve.
    Fig 3: Illustration For Steps 9-13, 15, 16
    G03656355Courtesy of SAAB-SCANIA OF AMERICA, INC.
    NOTE: There is an O-ring on the bypass pipe attachment to the turbo intake pipe.
  10. Unplug the connector from the control valve.
  11. Unplug the mass air flow sensor connector.
  12. Loosen the hoses to the turbo and diaphragm housing.
  13. Unscrew the crankcase breather pipe's banjo bolt from the intake manifold and unscrew the bolt from the camshaft cover.
  14. Bend the pipe and wiring aside.
  15. Remove the engine lifting eye.
  16. Remove the mass air flow sensor and air hose.
  17. Remove the exhaust manifold heat shield. The heat shield is attached with a nut and two clips underneath.
    Fig 4: Illustration For Steps 17-21
    G03656356Courtesy of SAAB-SCANIA OF AMERICA, INC.
  18. Undo the quick coupling on the bleeder hose using 83 95 261 TOOL, FUEL LINE .
  19. Undo the intake manifold's V-clamp at the turbo.
  20. Lift out the intake manifold.
  21. Undo the hose clip on the hose between the charge air cooler and the turbo (at the turbo). Plug the hose to prevent dirt entering the hose, use plug 83 94 595 PLUG, TURBO HOSE  or similar.
  22. Loosen the front exhaust system from the turbo.
  23. Carefully lower the front exhaust system away from the turbo.
    IMPORTANT: The flexible bellow on the front section of the exhaust system must not be bent more than 5° from its neutral line. This means that if the front exhaust system is left hanging freely, it must not be bent more than by its own weight.

    If the strain on the pipe is too great, its component parts will be permanently deformed. This can cause noise, leaks and eventually complete breakdown.

  24. Remove the oil pipe from the oil filter adapter. Collect the copper washers.
    Fig 5: Illustration For Steps 24-29
    G03656357Courtesy of SAAB-SCANIA OF AMERICA, INC.
  25. Undo the coolant pipe by the turbo. Keep the copper washers safe.
  26. Slacken the coolant pipe bolt by the coolant pump.
  27. Detach the coolant return pipe from the cylinder head and also from the pressure sensor bracket. Collect the copper washers.
  28. Undo the coolant return pipe bolt by the turbo.
  29. Undo the nuts securing the turbo to the exhaust manifold.
    NOTE: Apply motor oil or the like to the nuts and carefully undo them.
  30. Remove the turbo.
    Fig 6: Illustration For Steps 30
    G03656358Courtesy of SAAB-SCANIA OF AMERICA, INC.
scientia non olet · About LEMON Manuals