Saab 9-3 M03- User's Manual
Contents
1. Saab 9 3 M03 16 17 18 19 20 21 F920A015 Remove the hose which is connected to the fuel filler pipe the hose clip must be split with a saw and fit the hose from the set Tightening torque 4 Nm 3 Ibf ft Place the fuel tank on a pillar jack lift the tank slightly and connect the fuel filler vent hose Lift the fuel tank completely and connect the remaining fuel lines Fit the fuel tank mounting straps Tightening torque 24 Nm 18 Ibf ft Plug in the connector at the front of the fuel tank and fit the wiring harness into its mounting Fit the drain plug in the bottom of the coolant pump Lower the vehicle until it is just over the floor 12788928 9 22 23 23 24 25 E T j gt i SIG ZF Ni d A i F920A016 22 Unplug the connector from the air mass sensor 26 Fitthe heater mounting bracket to the bulkhead separate the intake hose and remove the air fil Tightening torque 24 Nm 18 Ibf ft ter cover Remove the hose from the air filter cover if such a hose is fitted Using benzine clean an area between the sus pension strut mounting bolts on the top of the 23 Remove from the turbo intake pipe the small right hand suspension turret nearest to the hose to the control valve APC valve and the engine Remove the extra label from the heater hose to the carbon filter vent valve Remove the and affix it to the cleaned area intake pipe 24 Remove t2. clip Open the clips on the underside of the floor and locate the fuel line in the grooves Close the clips and fasten the fuel line with cable ties x7 between the clips Saab 9 3 M03 14 12788928 A L F920A021 51 Position the fuel pump bracket up against the vehicle floor on the right hand side in front of the fuel tank and drill holes using a 3 5 mm drill 52 Deburr the holes and remove loose swarf and paint particles Clean with Teroson Cleaner FL and apply Standox 1K primer Apply a finishing coat 53 Fitthe fuel pump with vibration damper and pro tective cover onto the bracket Important The smaller diameter connection should point towards the centre ofthe car and slightly forwards The protective cover should be positioned under the pump 54 Connect the fuel lines to the fuel pump using a joint hose and two hose clips for each connec tion The joint hose which has a smaller diame ter at one end should be arranged so that this end fits onto the smaller diameter connection of the pump Attach the long fuel line to the pump bracket by threading a cable tie through the hole in the bracket 55 Connect the wiring harness to the fuel pump 56 Attach the harness to the bracket using a cable tie 57 Screw the bracket with the pump assembly onto the floor of the vehicle Saab 9 3 M03 12788928 15 58 Manoeuvre the heater exhaust pipe up towards the heater and fit the end of the pipe onto th
3. risk of sparks e g in con nection with breaking electrical circuits short circuiting etc e Smoking is absolutely forbidden Use protective goggles Important The flexible bellows on the forward section of the exhaust system must not be bent more than 5 from its neutral alignment This means that if the forward section is hanging free the bellows must not be bent further than the amount already caused by the weight of the system Excessive loading of the pipe can lead to residual deformations in the components which can cause noise leakage and eventually failure Saab 9 3 M03 6 12788928 Preparations Reduction of fuel pressure 1 Let the engine idle 2 Remove fuse No 2 fuel pump from the electri cal centre located in front of the battery in the engine compartment 3 When the engine has stopped the ignition key must be turned to the OFF position 4 Refit the fuse Emptying the fuel tank Important Pay attention to cleanliness when working on the fuel system Prevent dirt from entering the tank and fuel lines Be careful not to damage the non return valve in the fuel tank when inserting and removing the suc tion pipe of the emptying unit The fuel tank is not fitted with a drain plug Where work on the fuel system requires emptying of the fuel tank this is done with an emptying unit via the filler pipe Before emptying read carefully through the instruc tions supplied with t
4. MONTERINGSANVISNING INSTALLATION INSTRUCTIONS MONTAGEANLEITUNG INSTRUCTIONS DE MONTAGE Saab 9 3 M03 Engine cabin heater Accessories Part No Group Date Instruction Part No Replaces 12 787 161 9 87 42 Jun 02 12 788 928 Saab 9 3 M03 2 12788928 Heater mounting kit ON OO 0 P VI gt ao O O 12 13 14 15 16 17 18 19 2 21 2 eo N Petrol heater Holder Exhaust system Bolt M6x100 Nut M8 x3 Nut M6 x2 Coolant hoses pipes Bolt Hose clip x3 Fuel Pump Cable tie x20 Protective cover petrol pump Bracket fuel pump Vibration damper Clamp Nut M6 x2 Screw x2 Joint hose Joint hose Hose clip fuel line x4 Hose Hose clip x2 One is mounted on hose 21 Saab 9 3 M03 O 20 14 18 F920A011 12788928 3 F920A012 Fuel line kit 1 Fuel line pump heater 2 Fuel line tank to pump Saab 9 3 M03 4 12788928 F920A013 Saab 9 3 M03 12788928 5 Important AN WARNING Work on the heater involves dismantling the vehi cle fuel system and emptying the fuel tank When carrying out the work the following points should therefore be observed e Provide good ventilation Use approved extrac tors for removing fuel fumes if they are availa ble Use protective gloves Prolonged contact with fuel can cause skin irritation e Keep a class BE fire extinguisher close at hand Observe the
5. back into its orig inal shape 32 Fit the connector into its mounting and reposi tion the cable tie around the connector 33 Connect the lower coolant hose to the heater and tighten the hose clip 34 Connect the upper coolant hose to the heater and tighten the hose clip 35 Attach the coolant pipe mounting to the brake pipe cover plate on the bulkhead 36 Connect the crankcase ventilation hose to the turbo compressor and fit the control valve APC valve 37 Connect the inlet hose of the heater to the fixing in the hole in the longitudinal frame member Important Check that the drainage hose is free from the intake hose If the wiring harness channel on the heater is severely bent the drainage can be affect ed Saab 9 3 M03 12788928 11 co o lt e e o LL 38 Remove the wiper arms using puller 85 80 144 Remove also the bonnet seal and the cover over the bulkhead space Saab 9 3 M03 12 12788928 39 40 43 43 I LE TES la ij e GEES A WAS NETT amu SLO i NEN H Ge 19A Locate the Pre Acc outlet between the engine bay main fuse box and the front wing and remove any adhesive tape or dummy connector Plug the wiring harness from the installation set into the connector on the heater and route it through the bulkhead space to the Pre Acc outlet adjacent to the engine compartment elec trical centre Important The wiring harnes
6. e exhaust port of the heater Fasten the exhaust pipe to the floor of the vehicle with the two nuts Tightening torque 5 Nm 3 5 Ibf ft 59 Fit the vehicle exhaust system Tightening torque 22 Nm 16 5 Ibf ft 60 Lower the vehicle until it is just over the floor Saab 9 3 M03 16 12788928 lo M ET X A FE A 61 Fitthe heat shield to the turbo compressor two 68 screws and a catch 62 Fitthe turbo intake pipe and then connect to the pipe the small hose from the control valve APC valve and the hose from the carbon filter vent valve 63 Fit the air filter cover and plug the connector into the air mass sensor Attach the hose to the air fil 69 ter cover if such a hose is fitted 64 Fill with coolant and check the svstem for leaks 70 Fit the expansion tank cap 71 65 Connect the negative batterv cable 66 Connect the diagnostic tool select car and mod el year select All select Add Remove select the accessory and then Add 67 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 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 up to the MAX level Saab 9 3 M03 F920A023 Start the heater by pushi
7. he emptying unit Saab 9 3 M03 WN Oo A AW A C Disconnect the negative battery cable Remove the cap from the expansion tank Raise the car Remove the bolts from the forward section of the exhaust system Remove the exhaust system Place a receptacle under the engine open the drain plug on the bottom of the coolant pump and drain the coolant Saab 9 3 M03 FATO wa vd 12788928 7 8 oo 10 11 12 13 14 12788928 MA A a GA vili Unplug the connector at the front ofthe fuel tank and detach the wiring hamess from its mounting Place a pillar jack under the fuel tank and undo the tank mounting straps Separate the fuel lines using tool 83 95 261 and plug the fuel line tank connections in order to prevent fuel spill Remove the filler pipe hose from the fuel tank Carefully lower the fuel tank until the joint in the carbon filter vent hose becomes accessible Separate the joint in the carbon filter vent hose and the joint in the fuel filler vent hose Lower the fuel tank completely and lift away to a work bench Mark the position of the hole where the heater fuel pipe is to be inserted Drill a 10 5 mm hole in the tank Important Be careful to prevent drill swarf from falling into the tank 15 Push the fuel pipe into the tank until the seal locates against the tank and fasten the pipe to the other fuel lines with a cable tie on each side of the fuel line holder
8. he heat shield from the turbo compres Important sor two screws and a catch Under no circumstances may this label conceal 25 Remove the coolant hoses from the connections any part of another label or plate to the heat exchanger and remove from the ther mostat housing the hose which is nearest to the expansion tank Important Retain the hose clip it is required for re assembly Saab 9 3 M03 10 12788928 27 Fitthe hose clips including the old clip onto the new coolant hoses Connect the hose pipe assembly between the thermostat housing con nection and the heat exchanger connection nearest to the expansion tank Do not screw the assembly to the bulkhead Important The heat shield on the hose should be slid towards the thermostat housing so that the hose clip fits into the cut out in the heat shield 28 Connect the other coolant hose to the heat exchanger connection 29 Remove the control valve APC valve and remove the crankcase ventilation hose from the turbo compressor 30 Remove the plugs from the heater inlet and out let ports Push aside the cable tie holding the heater connector and detach the connector from its mounting on the heater F920A017 31 Protect the suspension turret and from above manoeuvre the heater into place on its mount ing Note The connector mounting can be bent slightly to facilitate assembly Tightening torque 9 Nm 6 5 Ibf ft Bend the connector mounting
9. ng the CUSTOMIZE button on the SIDC select Parking heater push SET select Manual control push SET select Heater on push SET and check that the heater starts it has a delay of about 1 minute If necessary top up the cooling system engine switched off Fit the cover over the bulkhead space fit the bonnet seal and the wiper arms Adjust the clock date Programme the heater Turn the ignition switch to the ON position push the CUSTOMIZE but ton on the SIDC select Parking heater push SET select Manual control and check that the heater starts or select Timer setting Tim er select a timer A B or C programme in a suitable time and push SET Check that the heater starts at the programmed time Select Manual control press SET select Heater off press SET and check that the heater stops Select Back press SET select Finish and press SET
10. s must be located in the seals by the front wings i e i KERT 41 42 Connect the ground cable to the front grounding point G30A in the engine bay main fuse box Connect the wiring harness to the four pole Pre Acc outlet Note If the four pole Pre Acc outlet is already used connect into the existing connector as follows Unplug Pre Acc remove the seal from the connector on the heater wiring harness and detach the cables from the connector block fit the cables into the connector which was plugged into Pre Acc red cable RD in posi tion 1 and green cable GN in position 2 Plug in the connector to Pre Acc A 43 CN F920A019 43 Fasten the wiring harness with cable ties x7 Position the Pre Acc outlet between the wiring harness and the front wing Important Check that the drainage hose at the filter is cor rectly fitted 44 Thread the fuel pump wiring harness down alongside the fuel lines against the back edge of the frame member Saab 9 3 M03 45 46 47 48 49 50 12788928 13 va us o mie E pe ee Raise the car Pull down the fuel pump wiring harness Thread the fuel pump fuel line up between the heater and the longitudinal frame member Connect the fuel line to the heater Fit the fuel pump fuel line into the clips on the underside of the vehicle floor The fuel line should be located in the upper groove of each
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