Saab 9 3 M03 User Manual

SCdefault  
900  
Installation instructions  
·
MONTERINGSANVISNING INSTALLATION INSTRUCTIONS  
·
MONTAGEANLEITUNG INSTRUCTIONS DE MONTAGE  
SITdefault  
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-  
12788928 3  
1
2
F920A012  
Fuel line kit  
1 Fuel line (pump-heater)  
2 Fuel line (tank to pump)  
Saab 9-3 M03-  
4 12788928  
F920A013  
Electrical connection kit  
Wiring harness  
Saab 9-3 M03-  
12788928 5  
Important  
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:  
S Provide good ventilation! Use approved extrac-  
tors for removing fuel fumes if they are availa-  
ble.  
S Use protective gloves! Prolonged contact with  
fuel can cause skin irritation.  
S Keep a class BE fire extinguisher close at  
hand. Observe the risk of sparks, e.g. in con-  
nection with breaking electrical circuits, short  
circuiting, etc.  
S Smoking is absolutely forbidden.  
S 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 the emptying unit.  
Saab 9-3 M03-  
12788928 7  
6
5
5
4
5
5
F920A014  
1 Disconnect the negative battery cable.  
2 Remove the cap from the expansion tank.  
3 Raise the car.  
4 Remove the bolts from the forward section of  
the exhaust system.  
5 Remove the exhaust system.  
6 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-  
8 12788928  
9
7
8
14  
8
15  
37mm  
94mm  
10  
11  
F920A015  
7 Unplug the connector at the front of the fuel tank  
and detach the wiring harness from its mounting.  
16 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.  
8 Place a pillar jack under the fuel tank and undo  
the tank mounting straps.  
Tightening torque 4 Nm (3 lbf ft)  
9 Separate the fuel lines using tool 83 95 261 and  
plug the fuel line tank connections in order to  
prevent fuel spill.  
17 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.  
10 Remove the filler pipe hose from the fuel tank.  
18 Fit the fuel tank mounting straps.  
11 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.  
Tightening torque 24 Nm (18 lbf ft)  
19 Plug in the connector at the front of the fuel tank  
and fit the wiring harness into its mounting.  
12 Lower the fuel tank completely and lift away to a  
work bench.  
20 Fit the drain plug in the bottom of the coolant  
pump.  
13 Mark the position of the hole where the heater  
fuel pipe is to be inserted.  
21 Lower the vehicle until it is just over the floor.  
14 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.  
Saab 9-3 M03-  
12788928 9  
26  
26  
22  
23 23  
24  
25  
26  
23  
22  
22  
F920A016  
22 Unplug the connector from the air mass sensor,  
separate the intake hose and remove the air fil-  
ter cover. Remove the hose from the air filter  
cover (if such a hose is fitted).  
26 Fit the heater mounting bracket to the bulkhead.  
Tightening torque 24 Nm (18 lbf ft)  
Using benzine, clean an area between the sus-  
pension strut mounting bolts on the top of the  
right-hand suspension turret nearest to the  
engine. Remove the extra label from the heater  
and affix it to the cleaned area.  
23 Remove from the turbo intake pipe the small  
hose to the control valve (APC valve) and the  
hose to the carbon filter vent-valve. Remove the  
intake pipe.  
24 Remove the heat shield from the turbo compres-  
sor (two screws and a catch).  
Important  
Under no circumstances may this label conceal  
any part of another label or plate.  
25 Remove the coolant hoses from the connections  
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  
37  
35  
27  
28  
32  
31  
34  
36  
29  
29  
F920A017  
27 Fit the 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.  
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.  
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.  
Tightening torque 9 Nm (6.5 lbf ft)  
Bend the connector mounting back into its orig-  
inal shape.  
32 Fit the connector into its mounting and reposi-  
tion the cable tie around the connector.  
28 Connect the other coolant hose to the heat  
exchanger connection.  
33 Connect the lower coolant hose to the heater  
and tighten the hose clip.  
29 Remove the control valve (APC valve) and  
remove the crankcase ventilation hose from the  
turbo compressor.  
34 Connect the upper coolant hose to the heater  
and tighten the hose clip.  
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.  
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  
38  
38  
38  
38  
38  
38  
38  
38  
38  
38  
38  
38  
F920A018  
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  
43  
43  
43  
43  
40  
43  
42  
42  
41  
F920A019  
39 Locate the "Pre Acc" outlet between the engine  
bay main fuse box and the front wing and  
remove any adhesive tape or dummy connector.  
43 Fasten the wiring harness with cable ties (x7).  
Position the "Pre-Acc" outlet between the wiring  
harness and the front wing.  
40 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  
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.  
Important  
The wiring harness must be located in the seals by  
the front wings.  
41 Connect the ground cable to the front grounding  
point (G30A) in the engine bay main fuse box.  
42 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".  
Saab 9-3 M03-  
12788928 13  
49  
50  
F920A020  
45 Raise the car.  
46 Pull down the fuel pump wiring harness.  
47 Thread the fuel pump fuel line up between the  
heater and the longitudinal frame member.  
48 Connect the fuel line to the heater.  
49 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  
clip.  
50 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  
51  
53  
57  
54  
56  
54  
55  
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 Fit the fuel pump with vibration damper and pro-  
tective cover onto the bracket.  
Important  
The smaller diameter connection should point  
towards the centre of the 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  
58  
58  
59  
59  
59  
59  
59  
F920A022  
58 Manoeuvre the heater exhaust pipe up towards  
the heater and fit the end of the pipe onto the  
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 lbf ft)  
59 Fit the vehicle exhaust system.  
Tightening torque 22 Nm (16.5 lbf ft)  
60 Lower the vehicle until it is just over the floor.  
Saab 9-3 M03-  
16 12788928  
62 62  
61  
64  
62  
63  
69  
63  
F920A023  
61 Fit the heat shield to the turbo compressor (two  
screws and a catch).  
68 Start the heater by pushing 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).  
62 Fit the 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-  
ter cover (if such a hose is fitted).  
69 Fit the cover over the bulkhead space, fit the  
bonnet seal and the wiper arms.  
70 Adjust the clock/date.  
64 Fill with coolant and check the system for leaks.  
Fit the expansion tank cap.  
71 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.  
65 Connect the negative battery 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  
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”.  
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-  

York Ymb Hw User Manual
T Tech 12 Volt Power Supply Jump Starter Jncxf User Manual
Sony Bp Il75 User Manual
Radio Shack Tad 3809 User Manual
Panasonic Kx Fp181e User Manual
Omega 22040c User Manual
Mitsubishi Mr Slim Pc42ek User Manual
LG LG H525N User Manual
CRAFTSMAN 390.252156 User Manual
ACER EXTENSA 5620 User Manual