Saab B235 User's Manual
Contents
1. Ki MONTERINGSANVISNING INSTALLATION INSTRUCTIONS SAAB MONTAGEANLEITUNG INSTRUCTIONS DE MONTAGE Saab 9 5 B205 B235 Parking heater Accessories Part No Group Date Instruction Part No Replaces 32 025 650 32 026 240 9 87 31 Oct 07 53 29 271 53 29 271 Sep 05 CG E930A393 Extension cable Connector plug and connector cable Holder Screw x2 M05 Screw Star washer Heating element Locking clip Cable tie x5 Clips Screw x2 MO6 12 Nut x2 M06 ON Oo Om SS Go M A i O O Saab 9 5 B205 B235 2 5329271 mzz m tin ee ae E930A260 1 Read fully through the installation instructions and check that all the parts are present in the kit 2 Lay covers on the wings and remove the cap on the coolant system expansions tank Z WARNING Take care if the engine is hot The coolant will also be hot You could get burnt if you brush against the exhaust manifold 3 Raise the car Use a receptacle to collect the coolant Remove the air shield behind the bumper connect a hose open the drain plug and drain the coolant 4 Lower the car to a suitable working height for fit ting the connector plug to the bumper shell Saab 9 5 B205 B235 9329271 3 bh A8 5 M05 Mark out the location for the holder for the supply connector plug The arrow on the holder should point forwards Make holes with a brad awl E930A261 6 M05 Pla2. ce the supply connector plug in the holder so that the cover opens upwards Fit the holder to the bumper Proceed to step 12 Saab 9 5 B205 B235 4 5329271 C 9 10 WA el Ja Te HOE E930A395 7 MO6 Tape the spoiler using woven tape for example to prevent damage to the paintwork 8 MO6 Mark out the location for the holder for the supply connector plug using a bradawl on the rib see illustration The arrow on the holder should point forwards 9 MOEG Drill two 6 mm holes in the rib Bend the rib down using a hammer handle for example in order to facilitate access Fit a plastic hose to the drill to prevent damage to the paintwork 10 MO6 Position the supply connector plug in the holder and secure it with screw and nut The cover must open towards the number plate 11 MO06 Remove the tape Saab 9 5 B205 B235 12 13 a Lei Raise the car and close the drain plug Insert the supply connector cable between the radiator and the subframe Locate the cable connection on top of the gearbox Drill a 3 5 mm diameter hole for the ground cable in the underside of the left hand structural member Scrape off any paint to ensure a good ground connection and secure the ground cable with a screw and lock washer place the lock washer between the ground cable terminal and the body Apply light anti corrosion agent part no 30 15 971 Secure the ground cable along the supply cable Fit th
3. e air shield and lower the car Saab 9 5 B205 B235 5329271 5 E930A394 6 5329271 E930A396 17 Remove the engine cover and disconnect any hoses and electrical connections from the turbo charger delivery pipe Remove the turbocharger delivery pipe between the charge air cooler and the throttle body including the bypass pipe and the heat shield over the exhaust manifold Plug the holes Saab 9 5 B205 B235 5329271 7 PZ 5 VU QN AN Ly S Ja uo f y Ve TI Sa z i DESCH Je TH dl fr b Si SS l mao SH lt i E930A397 If necessary disconnect the cable to the lower 24 Aut Secure the supply connector cable to the Re oa N CA oxygen sensor and remove the frost plug using tool 260 147 020 Use for example a 17 mm socket Apply acid free petroleum jelly part no 30 06 665 or equivalent to the heating element O ring Fit the heating element so that the electrical connection is directed towards the left hand side of the car and the connection is between the coolant pipes and under the turbocharger cool ant pipe Do not tighten the nut holding the heat ing element Adjust the position of the heating element so that it is free from contact with the coolant pipes Tighten the nut Tightening torque 3 5 Nm 2 5 Ibf ft Connect and secure the cable to the lower oxy gen sensor Apply acid free petroleum jelly part no 30 15 286 or equi
4. up to the MAX level 29 Check that the cooling system does not leak and that the heater works 30 Place the installation instructions in the car and draw the customer s attention to the user instructions Saab 9 5 B205 B235 5329271 9 tis TC a ee ye a B lt 7 ES Pa a ee ee Net ee l wa A mech Le LLL 8 E930A073 A Branch cable set B Timer kit Saab 9 5 B205 B235 10 5329271 User instructions The extension cable must be made of oil resist ant rubber and approved for outdoor use with a cross sectional area of at least 3x1 5 mm The engine heater must be connected to a grounded outlet only Handle all cables with care Pay particular atten tion to the risk of pinching between the bonnet and the body of the car and the risk of cuts on sharp metal components A WARNING Check regularly the ground connection between the ground pin in the connector plug the heater casing and the car body Inspect regularly the extension cable for damage or ageing Damaged cables must be renewed immediately Note The function of the heater will be at risk if there are impurities in the coolant the coolant level is too low or if there is air in the system there is ice slush in the system radiator sealant is used Saab 9 5 B205 B235
5. valent to the O ring on the supply connector cable and connect the cable to the heating element Fit the lock clip over the connection A click should be heard when the lock clip is fitted cor rectly lower cable by the battery tray with the clips included in the kit Man Secure the supply connector cable to the left hand structural member with a strap Z WARNING Make sure that the cable does not make contact with sharp edges or hot surfaces Be aware of the turbo unit Scrapes and heat damage can cause a short circuit Saab 9 5 B205 B235 8 5329271 25 Check the ground connection between the ground pin on the connector plug the heater casing and the car body 26 Fit the heat shield lubricate the bypass pipe O ring with acid free petroleum jelly and fit the tur bocharger delivery pipe including the bypass pipe Connect the vacuum hose to the bypass pipe and the hoses and connector to the turbo charger delivery pipe Fit the engine cover 27 Fill up with coolant and check the system for leaks 28 Bleed the cooling system in the following way Note The A C or ACC should be turned OFF Fill the coolant system to the MAX level Close the expansion tank cap Start the engine and run to operating temperature at varying engine speeds until the radiator fan cuts in Carefully open the expansion tank cap and top up to the MAX level Close the cap Switch off the engine and if necessary top the coolant
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