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900 Installation instructions
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MONTERINGSANVISNING INSTALLATION INSTRUCTIONS
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MONTAGEANLEITUNG INSTRUCTIONS DE MONTAGE
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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-
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2 12 788 928 3 21 22 11 6 4 5 2 20 14 18 1 9 8 19 16 7 15 13 17 12 10 F920A011 Heater mounting kit 1 Petrol heater 2 Holder 3 Exhaust system 4Bolt M6x100 5 Nut M8 (x3) 6 Nut M6 (x2) 7 Coolant hoses/pipes 8Bolt 9 Hose clip (x3) 10 Fuel Pump 11 Cable tie (x20) 12 Protective cover, petrol pump 13 Bracket, fuel pump 14 Vibration damper 15 Clamp 16 Nut M6 (x2) 17 Screw (x2) 18 Joint hose 19 Joint hose 20 Hose clip, fuel line (x4) 21 Hose 22 Hose clip (x2) (One is mounted on hose (21)) Saab 9-3 M03-
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12 788 928 3 1 2 F920A012 Fuel line kit 1 Fuel line (pump-heater) 2 Fuel line (tank to pump) Saab 9-3 M03-
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4 12 788 928 F920A013 Electrical connection kit Wiring harness Saab 9-3 M03-
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12 788 928 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: 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. Keep a class BE fire extinguisher close at hand. Observe the risk of sparks, e.g. in con- nection with breaking
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6 12 788 928 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 fue
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12 788 928 7 6 5 4 5 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-
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8 12 788 928 9 7 8 14 8 15 37mm 94mm 10 11 F920A015 7 Unplug the connector at the front of the fuel tank 16 Remove the hose which is connected to the fuel and detach the wiring harness from its mounting. 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 17 Place the fuel tank on a pillar jack, lift the
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12 788 928 9 26 26 22 23 23 24 25 26 23 22 22 F920A016 22 Unplug the connector from the air mass sensor, 26 Fit the heater mounting bracket to the bulkhead. separate the intake hose and remove the air fil- Tightening torque 24 Nm (18 lbf ft) ter cover. Remove the hose from the air filter Using benzine, clean an area between the sus- cover (if such a hose is fitted). pension strut mounting bolts on the top of the 23 Remove from the turbo intake pipe the small right-hand suspension turret nearest
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10 12 788 928 37 35 28 27 32 31 34 36 29 29 F920A017 27 Fit the hose clips (including the old clip) onto the 31 Protect the suspension turret and from above new coolant hoses. Connect the hose/pipe manoeuvre the heater into place on its mount- assembly between the thermostat housing con- ing. nection and the heat exchanger connection nearest to the expansion tank. Do not screw the Note assembly to the bulkhead. The connector mounting can be bent slightly to facilitate assembly. Important The hea
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12 788 928 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-
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12 12 788 928 43 43 43 43 40 43 42 42 41 F920A019 39 Locate the "Pre Acc" outlet between the engine 43 Fasten the wiring harness with cable ties (x7). bay main fuse box and the front wing and Position the "Pre-Acc" outlet between the wiring remove any adhesive tape or dummy connector. harness and the front wing. 40 Plug the wiring harness from the installation set into the connector on the heater and route it Important through the bulkhead space to the "Pre Acc" Check that the drainage hose at t
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12 788 928 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 lin
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14 12 788 928 53 51 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
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12 788 928 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-
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16 12 788 928 62 62 61 64 62 63 69 63 F920A023 61 Fit the heat shield to the turbo compressor (two 68 Start the heater by pushing the "CUSTOMIZE" screws and a catch). button on the SIDC, select "Parking heater", push "SET", select "Manual control", push 62 Fit the turbo intake pipe and then connect to the “SET”, select “Heater on”, push “SET” and pipe the small hose from the control valve (APC check that the heater starts ( it has a delay of valve) and the hose from the carbon filter vent about
