The Saab 900 Engine, renowned for its durability and performance, occasionally requires removal for major repairs or replacement. This guide provides a detailed walkthrough of removing a Saab 900 engine, specifically a 1993 non-turbo 900i model. While variations exist across different Saab 900 models, the core principles remain largely consistent. This method differs slightly from the Bentley manual but offers a practical approach for DIY enthusiasts.
This engine removal process involves a series of steps that must be completed before lifting the engine from the engine bay. Completing these tasks in a specific order simplifies the process, making it achievable even for a single person.
The image above illustrates the necessary tools. Beyond those pictured, essential items include an engine hoist, trolley jack, axle stands, Allen keys, WD-40 penetrating oil, and a custom wooden tool (detailed later). While not strictly required, a deep socket set and a breaker bar prove beneficial.
Crucial Safety Precaution: Disconnect the battery before commencing any work. This is paramount for safety.
Before You Begin:
- Thoroughly review this guide.
- Apply WD-40 to all fasteners that appear potentially difficult to remove.
- Photograph electrical connectors prior to disconnection for easier reassembly.
Comprehensive Tool List:
- Socket set (8mm to 19mm)
- Deep socket set
- Short breaker bar (longer than ratchets)
- Ring spanners (assorted sizes)
- Side cutters (for cable ties)
- Torx keys (or suitable Torx screw removal tool)
- Flat-blade and Phillips screwdrivers (assorted sizes)
- Two axle stands (3-tonne capacity recommended)
- Spike or nail punch
- Hammer
- Socket extension bars
- Engine hoist
- Trolley jack
- Small piece of 2×2 softwood scrap (for a custom tool)
- WD-40 penetrating oil
- Allen keys (assorted sizes)
- Large, shallow bucket (for collecting fluids)
- Soft material (e.g., old carpet) to protect the bonnet
- 2ft tube fitting the clutch slave cylinder bleed nipple
- String or cord (to support the exhaust system)
Step-by-Step Saab 900 Engine Removal
1. Bonnet Removal
Prepare a safe space for the bonnet before removal, ideally using old carpet or cardboard placed on upturned buckets.
Disconnect the windscreen washer jet supply line by pulling the tube from the T-piece.
Remove the bonnet hinge bolts. Carefully lift the bonnet, supporting it in the middle at both the front and back, and place it in the prepared area. Avoid leaning the bonnet vertically against anything as it can easily be damaged by wind.
2. Suspension Preparation
Fabricate a “special tool” from the 2×2 softwood scrap. This tool will secure the front right suspension in a relaxed, unsprung position, preventing full extension when the car is raised.
Split the wood into appropriately sized wedges to fit snugly between the upper wishbone and the body.
With the car on the ground, insert the wedges into the gap. Turning the steering wheel to the right can provide additional clearance. This is also a good time to apply WD-40 to the upper and lower ball joint fasteners.
This initial phase sets the stage for the subsequent steps in the Saab 900 engine removal process. Following these instructions carefully ensures a smooth and efficient removal. Subsequent steps will cover disconnecting components and preparing the engine for lifting.
