Intake System, Petrol: Removal & Installation Saab 9-3 I

To remove

1. Undo the overcentre catches on the rubber elbow and withdraw the mass air flow sensor.
2. Undo the overcentre catches to release the air cleaner cover.
3. Lift off the cover and remove the filter element.

Fitting Air Cleaner Filter Element (B204i). Scheme 36

1. Clean the air collector casing (the lower part of the air cleaner).
2. Fit a new filter element. Place the bottom of the filter element (with sealing edge) in the air collector casing.
3. Fit the cover on the air cleaner and the mass air flow sensor.

Removing Air Cleaner Filter Element (B204L/E/R). Scheme 37

1. Remove the hose clip from the connecting hose.
2. Undo the overcentre catches holding the cover in place.
3. Lift off the cover and remove the filter element.

Fitting Air Cleaner Filter Element (B204L/E/R). Scheme 38

1. Clean the air collector casing (the lower part of the air cleaner).
2. Fit a new filter element. Place the bottom of the filter element (with sealing edge) in the air collector casing.
3. Fit the cover on the air cleaner and the connecting hose.

Removing Air Cleaner Filter Element (B235R). Scheme 39

1. Remove the hose clip between the connecting hose and the turbo intake pipe.
2. Unplug the connector from the mass air flow sensor.
3. Detach the mass air flow sensor's lead from the cable clamps on the air collector casing's cover.
4. Remove the air collector casing's cover by releasing the overcentre catches and undoing the 4 screws.
5. Lift off the air collector casing's cover and lift out the air cleaner filter element.

Fitting Air Cleaner Filter Element (B235R). Scheme 40

1. Blow the air collector casing clean with compressed air.
2. Fit the filter element in place.
3. Fit the air collector casing's cover in place, fasten the overcentre catches and tighten the screws.
4. Attach the connecting hose to the turbo intake pipe.
5. Plug in the mass air flow sensor's connector but first spray the connector with Kontakt 61, part no. 30 21 763.
6. Fasten the mass air flow sensor's lead to the cable clamps on the air collector casing's cover. Adjust the lead so that it will not be exposed to damage by nipping or chafing.

Removing Air Collector Casing (B204i/L/E/R). Scheme 41

1. Remove the cover and air cleaner filter element.
2. Undo the bush nuts keeping the air collector casing in place.
3. Lift out the air collector casing.

Fitting Air Collector Casing (B204i/L/E/R). Scheme 42

1. Lift the air collector casing into place.
2. Fit the bush nuts holding the air collector casing in place.
3. Fit the air cleaner filter element and cover.

Removing Air Collector Casing (B235R). Scheme 43

1. Remove the venting valve from its mounting by the air collector casing.
2. Undo the hose clip between the connecting hose and turbo intake pipe.
3. Unplug the connector from the mass air flow sensor.
4. Detach the mass air flow sensor's lead from the cable clamps on the air collector casing's cover and from the cable clip by one of the rubber bushes.
5. Remove the air collector casing's cover by releasing the overcentre catches and undoing the 4 screws.
6. Lift off the air collector casing's cover and lift out the air cleaner filter element.
7. Undo the 3 nuts securing the casing to the rubber bushes. (Scheme 44): Lifting Out The Air Collector Casing
8. Lift out the air collector casing.

Scheme 44

1. Blow the air collector casing clean with compressed air and lift it into place. Line up the air collector casing's inlet pipe with the resonator.
2. Adjust the position of the air collector casing to bring it as close to the engine as possible while at the same time doing up the nuts by hand. This is so that it will be easier to fit the air collector casing's cover.
3. Tighten the 3 nuts against the rubber bushes.
4. Fit the filter element in place. see scheme 22: Fitting Air Collector Casing (B235R)
5. Fit the air collector casing's cover in place, fasten the overcentre catches and tighten the screws.
6. Attach the connecting hose to the turbo intake pipe.
7. Fasten the mass air flow sensor's lead to the cable clamps on the air collector casing's cover and the cable clip to one of the rubber bushes.
8. Plug in the mass air flow sensor's connector but first spray the connector with Kontakt 61, part no. 30 21 763.
9. Secure the venting valve to its mounting by the air collector casing.

Unhooking Resonator (B235R). Scheme 45

1. Position the car on a lift and raise it.
2. Remove the spoiler shields (right and left).
3. Undo the screw and unhook the resonator by pressing it up and slightly outwards.

Hooking Resonator (B235R). Scheme 46

1. Hook the resonator in place and fit the screw.
2. Fit the spoiler shields.
3. Lower the car to the floor.

Removing Mass Air Flow Sensor (B204i). Scheme 47

1. Unplug the connector.
2. Undo the hose clips on the connecting pipe.
3. Remove the mass air flow sensor.

Fitting Mass Air Flow Sensor In Place B204i). Scheme 48

1. Fit the mass air flow sensor in place.
2. Fit the hose clips on the connecting pipe.
3. Plug in the connector.

Removing Temperature Sensor (B235R). Scheme 49

1. Unplug the connector from the temperature sensor on the turbo delivery pipe
2. Remove the temperature sensor.

Fitting Temperature Sensor (B235R). Scheme 50

1. Fit the temperature sensor. If necessary, fit a new sealing washer.
2. Spray the connector with Kontakt 61, part. no. 20 31 763, and plug it in.

Removing Hose Clip Between Connecting Hose & Turbo Intake Pipe. Scheme 51

1. Remove the hose clip between the connecting hose and the turbo intake pipe.
2. Unplug the connector from the mass air flow sensor.
3. Detach the mass air flow sensor's lead from the cable clamps on the air collector casing's cover.
4. Remove the air collector casing's cover by releasing the overcentre catches and undoing the 4 screws.
5. Lift off the air collector casing's cover.
6. Undo the clip to detach the hose from the mass air flow sensor. (Scheme 53): Removing Mass Air Flow Sensor (B235R)
7. Remove the mass air flow sensor, 2 screws.

Fitting Mass Air Flow Sensor (B235R). Scheme 52

Scheme 53

1. Coat the mass air flow sensor's rubber seal with non-acidic vaseline, part no. 30 06 665. If necessary, change the rubber seal.
2. Fit the mass air flow sensor, 2 screws. IMPORTANT: Fit the mass air flow sensor in the intake air pipe with the arrow pointing in the direction of flow.
3. Attach the hose to the mass air flow sensor.
4. Fit the air collector casing's cover in place, fasten the overcentre catches and tighten the screws. see scheme 32: Attaching Hose To Mass Air Flow Sensor
5. Attach the connecting hose to the turbo intake pipe.
6. Plug in the mass air flow sensor's connector but first spray the connector with Kontakt 61, part no. 30 21 763.
7. Fasten the mass air flow sensor's lead to the cable clamps on the air collector casing's cover. Adjust the lead so that it will not be exposed to damage by nipping or chafing.