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Table of contents for the manual
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Page 1
Saab 9-3 M03- 900 Installation instructions SCdefault MONTERINGSANVISNING · INSTALLATION INSTRUCTIONS MONTAGEANLEITUNG · INSTRUCTIONS DE MONTAGE SITdefault Saab 9-3 M03- Engine/cabin he ater Accessories Part No. Group Date Instruction Part No. Replaces 12 787 161 9:87-42 Jun 02 12 788 928[...]
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Page 2
2 12 788 928 Saab 9-3 M03- Heater mounting kit 1 Petrol heat er 2 Holder 3 Exhaust system 4B o l t M 6 x 1 0 0 5 Nut M8 (x3) 6 Nut M6 (x2) 7 Coolant hoses/pipes 8B o l t 9 Hose clip (x3) 10 Fuel Pump 1 1 Cable tie (x20 ) 12 Protective cover , petrol pum p 13 Bracket, fuel pump 14 Vi bration damper 15 Clamp 16 Nut M6 (x2) 17 Screw (x2) 18 Joint hose[...]
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Page 3
12 788 928 3 Saab 9-3 M03- Fuel line kit 1 Fuel line (pump-hea ter) 2 Fuel line (t ank to pump) F920A012 1 2[...]
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Page 4
4 12 788 928 Saab 9-3 M03- Electrical connection kit Wiring harness F920A013[...]
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Page 5
12 788 928 5 Saab 9-3 M03- Important WA R N I N G Work on the heater involve s dismantling t he vehi- cle fuel system and emptyin g the fuel tan k. When carrying out the work the following points should therefore be obser ved: · Provide good ventilation! Use appro ved extrac- tors for removing fuel fume s if they are availa- ble. · Use protective[...]
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Page 6
6 12 788 928 Saab 9-3 M03- Preparations Reduction of fuel pressur e 1 Let the engine idle. 2 Remove fuse No. 2 (fuel pump) from th e electri- cal centre located in fron t of the battery in the engine comp artment. 3 When the engine has stoppe d the ignition key must be turned to the OFF position. 4 Refit the fuse. Emptying the fuel t ank The fuel t[...]
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Page 7
12 788 928 7 Saab 9-3 M03- 1 Disconnect the negative batter y cable. 2 Remove the cap fro m the expansion tank. 3 Raise the car . 4 Remove the b olts from the forward se ction of the exhaust system. 5 Remove the exhaust system. 6 Place a recept acle under the engine, op en the drain plug on the bo ttom of the coolant pump and drain the coolant. F92[...]
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Page 8
8 12 788 928 Saab 9-3 M03- 7 Unplug the connector at the fron t of the fuel t ank and detach the wiring harness from its moun ting. 8 Place a pillar jack un der the fuel t ank and undo the tank mountin g straps. 9 Separ ate the fuel lines using tool 83 95 261 and plug the fuel line t ank connections in order to prevent fuel spill. 10 Remove the fil[...]
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Page 9
12 788 928 9 Saab 9-3 M03- 22 Unplug the connector fr om the air mass se nsor , 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). 23 Remove from the turbo int ake pipe the sma ll hose to the control valve (APC valve) and the hose to the carbon filte r vent-valve. Remov[...]
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Page 10
10 12 788 928 Saab 9-3 M03- 27 Fit the hose clip s (including the old clip) o nto the new coolant ho ses. Connect the hose /pipe assembly between the thermost at housing con- nection and the heat exchanger connection nearest to the exp ansion t ank. Do not screw the assembly to the bulkhead. 28 Connect the othe r coolant hose to the heat exchanger [...]
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Page 11
12 788 928 11 Saab 9-3 M03- 38 Remove th e wiper arms using pu ller 85 80 144. Remove also the bonnet seal and the cover over the bulkhead sp ace. F920A018 38 38 38 38 38 38 38 38 38 38 38 38[...]
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Page 12
12 12 788 928 Saab 9-3 M03- 39 Locate the "Pre Acc" outlet between the eng ine bay main fuse box and the front wing and remove any adhesi ve tap e or dummy connector . 40 Plug the wiring harness from the inst allation set into the connector on the heater and ro ute it through the bulkhead space to the "Pre Acc" outlet adjacent t[...]
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Page 13
12 788 928 13 Saab 9-3 M03- 45 Raise the car . 46 Pull down the fuel pump wiring harness. 47 Thread the fuel pu mp fuel line up between the heater and the lo ngitudinal frame memb er . 48 Connect the fuel l ine 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 locate d in t[...]
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Page 14
14 12 788 928 Saab 9-3 M03- 51 Position the fuel pump bracket up against the vehicle floor , on the righ t-hand side in fron t of the fuel tank, and drill holes using a 3.5 mm drill. 52 Deburr the holes and remove loose swarf and paint p articles. Clean with T eroson Cleaner FL and apply S tandox 1K primer . Apply a finishing coat. 53 Fit the fuel [...]
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Page 15
12 788 928 15 Saab 9-3 M03- 58 Manoeuvre the heater exhaust pi pe up towards the heater and fit the end of the pi pe onto the exhaust port of the heater . Fasten the exhaust pipe to the floor of the vehicle with th e two nuts. Tight ening torque 5 Nm (3.5 lbf ft) 59 Fit the vehicle exhaust system. Tight ening torque 22 Nm (16.5 lbf ft) 60 Lower the[...]
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Page 16
16 12 788 928 Saab 9-3 M03- 61 Fit the heat shield to the turbo compressor (two screws and a catch). 62 Fit the turbo int ake pipe and th en connect to the pipe the small hose from th e control valve (APC valve) and the hose fro m the carbon filter vent valve. 63 Fit the air filter co ver and plug the connector into the air mass sensor . Att ach th[...]