Charging System - Component Location, Removal & Installation: Removal & Installation Saab 9-3 I

To remove

Note. If the car is fitted with a radio other than Saab's original, check that the customer has the radio code before you begin work.

Scheme 28

Scheme 29

Scheme 30

1. Drape protective covers over the front wings.
2. Disconnect the battery's negative cable.
3. Remove the air-filter canister and the induction hose between the canister and the throttle body. (Scheme 28): Removing Air-Filter Canister And Induction Hose Between Canister And Throttle Body
4. Remove the belt tensioner.
5. Raise the car and remove the right front wheel.
6. Remove the cover over the belt circuit.
7. Undo the generator's connecting cables. (Scheme 29): Removing Generator Connecting Cables
8. Undo the generator's two retaining bolts.
9. Undo the nuts holding the exhaust pipe up at the manifold.
10. Remove the rubber hanger of the front exhaust pipe. (Scheme 30): Removing Rubber Hanger Of Front Exhaust Pipe
11. Cautiously press the catalyst to the left and take out the generator.

Scheme 31

Scheme 32

Scheme 33

1. Clean the attachment points of the generator and coat them with Vaseline so as to prevent oxidation.
2. Cautiously press the catalyst to the left and put in the generator.
3. Fix the generator into place with the two retaining bolts. (Scheme 31): Installing Generator With Retaining Bolts
4. Connect the cables to the generator.
5. Fit the exhaust pipe back into place at the manifold.
6. Fit the rubber hanger of the front exhaust pipe back into place. (Scheme 32): Installing Rubber Hanger Of Front Exhaust Pipe
7. Fit the cover of the belt circuit back into place.
8. Put the front wheel back on and lower the car.
9. Fit the belt tensioner and the multigroove V-belt. (Scheme 33): Installing Belt Tensioner And Multigroove V-Belt Check that the belt is running true on all pulleys.
10. Fit the air-filter canister.
11. Refit the hose between the air-filter canister and the throttle body.
12. Connect the battery's negative cable.
13. Set the clock and program in the radio code if any.

Note. If the car is fitted with a radio other than Saab's original, check that the customer has the radio code before you begin work.

Scheme 34

Scheme 35

Scheme 36

Scheme 37

Scheme 38

Scheme 39

1. Disconnect the battery's negative cable.
2. Raise the car.
3. Remove the cover under the car. (Scheme 34): Removing Cover Under Car
4. Remove the cover over the belt circuit.
5. Slacken the multigroove V -belt and disengage it from the generator. (Scheme 35): Removing V-Belt
6. Undo the generator's connecting cables. (Scheme 36): Removing Generator's Connecting Cables
7. Remove the bolt from the lower generator bracket.
8. Lower the car.
9. Drape protective covers over the front wings.
10. Remove the contact housing of the mass air flow sensor. (Scheme 37): Removing Contact Housing Of Mass Air Flow Sensor
11. Remove the air hose, including the mass air flow sensor, between the air filter and the engine.
12. Disengage the fuel hoses from their attachments.
13. Snip the belt tie holding the hoses to the supplementary heater.
14. Disconnect the hose leading to the control valve's wastegate under the turbocharger. (Scheme 38): Detaching Wastegate WARNING: The turbocharger may be hot enough to cause hand burns.
15. Detach the wastegate.
16. Remove the upper retaining bolt of the generator. (Scheme 39): Removing Upper Retaining Bolt Of Generator
17. Raise the generator.

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

1. Clean the attachment points of the generator and coat them with Vaseline so as to prevent oxidation.
2. Put the generator into position.
3. Secure it with the upper bolt, without making it really tight. (Scheme 40): Installing Upper Generator Bolt
4. Raise the car.
5. Fit the bolt of the lower bracket. Tightening torque: 35 N.m (26 lbf ft).
6. Mount the belt, check its position on all pulleys and remove the tension reliever so that the belt is tensioned. (Scheme 41): Mounting Belt
7. Refit the generator's connecting cables.
8. Fit the cover over the belt circuit. (Scheme 42): Installing Lower Cover
9. Put the lower cover back into place.
10. Lower the car.
11. Make the upper bolt tight. Tightening torque: 35 N.m (26 lbf ft).
12. Fit the control valve's wastegate. (Scheme 43): Installing Control Valve's Wastegate
13. Connect the hose to the wastegate.
14. Apply a new strap tie to hold the hoses of the supplementary heater.
15. Replace the air hose with the mass air flow sensor between the air filter and the engine. (Scheme 44): Installing Air Hose With Mass Air Flow Sensor Between Air Filter And Engine
16. Refit the fuel hoses.
17. Connect the contact housing to the mass air flow sensor.
18. Connect the battery's negative cable.
19. Set the clock and program in the radio code if any.

Note. If the car is fitted with a radio other than Saab's original, check that the customer has the radio code before you begin work.

Scheme 45

Scheme 46

Scheme 47

Scheme 48

Scheme 49

Scheme 50

1. Disconnect the battery's negative cable.
2. Raise the car.
3. Remove the cover under the car. (Scheme 45): Removing Cover Under Car
4. Remove the cover over the belt circuit.
5. Slacken the multigroove V -belt and disengage it from the generator. (Scheme 46): Removing V-Belt
6. Undo the generator's connecting cables. (Scheme 47): Removing Generator'S Connecting Cables
7. Remove the bolt from the lower generator bracket.
8. Lower the car.
9. Drape protective covers over the front wings.
10. Remove the contact housing of the mass air flow sensor.
11. Remove the air hose, mass air flow sensor and air -filter canister. (Scheme 48): Removing Air Hose, Mass Air Flow Sensor And Air -Filter Canister
12. Disengage the fuel hoses from their attachments.
13. Snip the strap tie that holds the hoses of the supplementary heater.
14. Disconnect the hose leading to the control valve's wastegate under the turbocharger. (Scheme 49): Detaching Wastegate WARNING: The turbocharger may be hot enough to cause hand burns.
15. Detach the wastegate.
16. Remove the upper retaining bolt of the generator. (Scheme 50): Removing Upper Retaining Bolt Of Generator
17. Remove the three screws for the engine mounting on the right structural member and press the engine forward.
18. Raise the generator.

Scheme 51

Scheme 52

Scheme 53

Scheme 54

Scheme 55

1. Clean the attachment points of the generator and coat them with Vaseline so as to prevent oxidation.
2. Carefully position the generator.
3. Put the generator into place and fit its upper retaining bolt without making it tight. (Scheme 51): Installing Generator'S Upper Retaining Bolt
4. Put the engine in position and fit the 3 dismantled screws.
5. Raise the car.
6. Fit the generator's lower retaining bolt. Tightening torque: 35 N.m (26 lbf ft).
7. Mount the belt, check its position on all pulleys and remove the tension reliever so that the belt is tensioned. (Scheme 52): Mounting Belt
8. Refit the generator's connecting cables.
9. Fit the cover over the belt circuit. (Scheme 53): Installing Lower Cover
10. Put the lower cover back into place.
11. Lower the car.
12. Make the upper bolt tight. Tightening torque: 35 N.m (26 lbf ft).
13. Fit the control valve's wastegate. (Scheme 54): Installing Control Valve's Wastegate
14. Connect the hose to the wastegate.
15. Secure the hoses of the supplementary heater with a new strap tie. (Scheme 55): Installing Air Hose, Mass Air Flow Sensor And Air -Filter Canister
16. Reconnect the air hose, mass air flow sensor and air -filter canister.
17. Refit the fuel hoses.

Scheme 56

Scheme 57

Scheme 58

Scheme 59

1. Remove the lower cover from the engine. (Scheme 56): Removing Lower Cover From Engine
2. Relieve the belt tensioner by turning the belt tensioner counter -clockwise (towards the rear of the car) with a 19 mm wrench. Lift off the multigroove V -belt. (Scheme 57): Removing V-Belt
3. Remove the engine cover. (Scheme 58): Removing Engine Cover
4. Unplug the intake air temperature sensor's connector and the mass air flow sensor's connector.
5. Disconnect the crankcase ventilation hose from the camshaft cover.
6. Remove the air cleaner with the mass air flow sensor and hoses.
7. Disengage the fuel hoses from their attachments.
8. Place a receptacle under the engine and detach the coolant hose from the generator bracket. (Scheme 59): Identifying Coolant Hose From The Generator Bracket
9. Remove the top generator mounting bolt and undo the bottom one so that the generator can be rotated downwards.
10. Remove the generator bracket from the cylinder head.

Scheme 60

Scheme 61

Scheme 62

Scheme 63

1. Clean away any gasket remains on the sealing surface.
2. Fit the generator bracket to the cylinder head. Tightening torque: 20 N.m (15 lbf ft). (Scheme 60): Installing Generator Bracket To Cylinder Head
3. Rotate the generator back into position and tighten the bolts. Tightening torque: 35 N.m (26 lbf ft).
4. Connect the coolant hose to the generator bracket.
5. Refit the fuel hoses. (Scheme 61): Installing Fuel Hoses
6. Put back the air cleaner with the mass air flow sensor and hoses. Plug in the intake air temperature sensor's connector and the mass air flow sensor's connector.
7. Connect the crankcase ventilation hose to the camshaft cover.
8. Put back the engine cover.
9. Position the multigroove V-belt on all the pulleys. Relieve the belt tensioner by turning it anti -clockwise (towards the rear of the car) with a 19 mm spanner. Check the position of the belt on all the pulleys. (Scheme 62): Positioning Multigroove V-Belt On All Pulleys
10. Put back the lower engine cover. (Scheme 63): Installing Lower Engine Cover
11. Fill with coolant, check the integrity of the system and bleed as necessary.

Scheme 64

Scheme 65

Scheme 66

1. Turbo engine: Detach the air cleaner and move it to the side. (Scheme 64): Detaching Air Cleaner (Turbo Engine)
2. B204i and B234i: Remove the air cleaner and intake hose between the upper part of the air filter holder and the throttle body. (Scheme 65): Removing Air Cleaner (B204i And B234i)
3. Loosen the belt tensioner using a pivot handle and lift away the belt. IMPORTANT: Be very careful that the belt tensioner is not damaged at its end position!
4. Remove the belt tensioner, use a 8 mm Allen key. (Scheme 66): Removing Belt Tensioner

Scheme 67

Scheme 68

Scheme 69

1. Fit the belt tensioner. Tightening torque: 45 N.m (33 lbf ft) (Scheme 67): Installing Belt Tensioner
2. Loosen the belt tensioner using a pivot handle and insert a 3 mm drill bit for example into the hole.
3. Mount the belt, check its position on all pulleys and release the locking so that the belt is tensioned.
4. B204i and B234i: Fit the air cleaner and intake hose between the upper part of the air filter holder and the throttle body. (Scheme 68): Fitting Air Cleaner And Intake Hose (B204i And B234i)
5. Turbo engine: Fit the air cleaner. (Scheme 69): Installing Air Cleaner (Turbo Engine)
6. Start the engine and allow it to idle for a short while, then stop the engine and check that the belt is set correctly.

Scheme 70

Scheme 71

Scheme 72

Scheme 73

1. Raise the car and take off the right front wheel.
2. Remove the cover over the drive assembly. (Scheme 70): Removing Cover Over Drive Assembly
3. Remove the cover over the belt circuit.
4. Relieve the belt tensioner and disengage the belt. (Scheme 71): Disengaging Belt
5. Changing a belt-tensioner wheel (Scheme 72): Identifying Belt-Tensioner Wheel Poke off the cover housing over the belt -tensioner wheel. Screw the wheel off and fit a new one. Screw on the wheel and fit the cover housing. Continue with step 2.
6. Changing a damper (Scheme 73): Identifying Damper Detach the belt tensioner from the engine. Change the damper.

Scheme 74

1. Fit the belt tensioner and tighten the upper bolt first. Tightening torque 42 N.m (31 lbf ft). (Scheme 74): Fitting Belt Tensioner Tighten the lower bolt. Tightening torque 23 N.m (17 lbf ft).
2. Mount the belt, check its position on all pulleys and remove the tension reliever so that the belt is tensioned.
3. Refit the cover over the belt circuit.
4. Refit the cover over the drive assembly. see scheme 97: Installing Cover Over Drive Assembly
5. Fit the right front wheel and lower the car.

The method is described with the generator removed.

1. Remove the three bolts/nuts that hold the protective housing on the generator.
2. Remove the two bolts that hold the regulator and then pull it up.

The generator brushes are mounted on the regulator and the unit is changed as a whole.