Climate System: Removal & Installation Saab 9-3 II

To remove

1. Drain the refrigerant from the A/C system, see «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Drain the coolant from the car by loosening the coolant hoses from the heat exchanger by the connections from the heat exchanger and blow with compressed air. Use personal protection equipment. Place a container under the car to collect the coolant.
3. Dismantle «DASHBOARD»(ref-275837-S07144653642007122900000) .
4. Remove «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
5. Dismantle the expansion valve's PAD connections
6. Dismantle «STEERING WHEEL MEMBER»(ref-275870-S17641668302007122900000) .
7. Carefully lift out the heating and ventilation unit. Take care not to spill any coolant from the heat exchanger. Have a cloth ready.

Scheme 32

1. Fit the heating and ventilation unit by lifting the heating and ventilation unit into its position. Exercise care so that the heat exchanger pipe enters the rubber seal correctly, in the bulkhead partition, without damaging the seal. NOTE: Take care so that the drainage pipe aligns correctly.
2. Adjustment the oil quantity in the A/C compressor according to Filling and adjusting the compressor oil.
3. Replace the sealing washers and fit the expansion valve's PAD connections. Tightening torque 15 Nm (11 lbf ft)
4. Fit «STEERING WHEEL MEMBER»(ref-275870-S17641668302007122900000) .
5. Fit «DASHBOARD»(ref-275837-S07144653642007122900000) .
6. Fit «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
7. Vacuum pump the A/C system and fill with refrigerant. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
8. Fill with coolant and «BLEEDING THE COOLING SYSTEM»(ref-275852-S41098468482007122900000) .

Scheme 33

Scheme 34

1. Drain the refrigerant from the A/C system. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Dismantle the windscreen wipers, use «85 80 144 PULLER, WINDSCREEN WIPER ARM»(ref-275884-S24533917022007122900000) .
3. Open the clips on the bulkhead partition cover and remove «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
4. Dismantle «WINDSCREEN WIPER ASSEMBLY»(ref-275863-S41261808992007122900000) .
5. Open the clips on the fresh-air filter housing and take out the fresh-air filter.
6. Dismantle the fresh-air filter housing.
7. Dismantle the high and low pressure pipe's PAD connection from the expansion valve and carefully lift out the pipe. Plug the pipe and the expansion valve. IMPORTANT: The A/C receiver and the compressor oil absorb moisture from the air, which can then not be removed. Plug all connections that are opened immediately.
8. Dismantle the expansion valve. Plug the openings.

Scheme 35

Scheme 36

1. Adjust the oil quantity in the A/C system. See «FILLING AND ADJUSTING THE COMPRESSOR OIL»(ref-275884-S16316339272007122900000) .
2. Fit the expansion valve. Tightening torque 15 Nm (11 lbf ft)
3. Insert the high and low pressure pipe into position, replace the sealing washers and fit the pipe's PAD connection to the expansion valve. Tightening torque 15 Nm (11 lbf ft)
4. Fit the fresh-air filter housing. Make sure the clips lock.
5. Fit the fresh-air filter in the fresh-air filter housing.
6. Fit «WINDSCREEN WIPER ASSEMBLY»(ref-275863-S41261808992007122900000) .
7. Fit «BULKHEAD COVER»(ref-275838-S29414109442007122900000) .
8. Fit the windscreen wipers Tightening torque 20 Nm (15 lbf ft)
9. Vacuum pump and fill the A/C system. See «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
10. Check the performance of the A/C system. See «A/C SYSTEM PERFORMANCE TEST»(ref-275884-S19834467772007122900000) .

Compressor, To remove and To fit, Z18XE

Scheme 37

Scheme 38

1. Air conditioning, draining, see method description «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
2. Remove the multi-belt IMPORTANT: Close lines and connections.
3. Remove the refrigerant line as follows: Unscrew bolt (1) Pull away block joint, refrigerant line (2)
4. Remove the compressor as follows: Unplug the connector (2) - Release and unplug Unscrew bolt (1) Remove the compressor (3) IMPORTANT: Only when replacing the compressor
5. Compressor oil, filling see method description «FILLING AND ADJUSTMENT OF COMPRESSOR OIL»(ref-275884-S13168331182007122900000) .

Scheme 39

1. Fit the compressor as follows: Tighten the bolt (1) (20 Nm) Plug in the connector (2)
2. Fit the refrigerant line as follows: Change the seal (1) Attach the refrigerant line (2) Tighten the bolt (20 Nm)
3. Fit the multi-belt.
4. Air conditioning, draining and filling see method description «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .
5. When fitting a new compressor the following running-in instructions must be followed: Open all air vents on the dashboard. Start the car's engine and allow idling speed to stabilize (approx. 5 seconds). Set the fan to max. Switch on the air conditioning and allow it to run uninterrupted for at least 2 minutes at an engine speed less than 1500 r/min.

Compressor clutch, To remove and To fit, Z18XE

Scheme 40

1. Air conditioning, draining, see method description «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000)
2. Remove the compressor, see method description «COMPRESSOR, TO REMOVE AND TO FIT, Z18XE»(ref-275884-S28286165712007122900000)
3. Remove the compressor clutch (1): Instructions: Secure the compressor using protective jaws on the holder in a screw vice Unscrew nut (2) - hold still with MKM-6319-1 (3) Pull the compressor clutch away upwards (4) Remove the spacer

Scheme 41

1. Fit the compressor clutch: Fit the spacer. Instructions: Re-use removed spacers. Fit the compressor clutch. Tighten nut (20 Nm) - hold still with MKM-6319-1 (3)
2. Adjust the compressor clutch's clearance: Check the clearance of the compressor clutch. Desired value: 0.3 - 0.7 mm Instructions: Check the gap between clutch (2) and the friction surface of the belt pulley (3) at 4 points (indicated with arrows) using a feeler gauge (1). Calculate the mean value. Correct the gap measurement. Instructions: add or remove spacers (4)
3. Fit the compressor. See method description, «COMPRESSOR, TO REMOVE AND TO FIT, Z18XE»(ref-275884-S28286165712007122900000)
4. Air conditioning, draining and filling see method description «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .

Scheme 42

1. Nut
2. Compressor clutch
3. Spacer washer
4. Circlip
5. Belt pulley, compressor
6. Circlip
7. Solenoid coil, compressor
8. Drain screw, compressor oil
9. Compressor
10. Overpressure valve, compressor
11. Block joint screw cover

Scheme 43

1. Remove the compressor clutch see method description, «COMPRESSOR CLUTCH, TO REMOVE AND TO FIT, Z18XE»(ref-275884-S05256969602007122900000)
2. Remove the compressor belt pulley see method description, «COMPRESSOR BELT PULLEY, TO REMOVE AND TO FIT, Z18XE»(ref-275884-S05642034902007122900000) .
3. Remove the felt sealing ring: Prise off the felt sealing ring (1)
4. Remove the lock ring: Remove the circlip (2) - Use KM-J-4245
5. Remove the compressor's sealing ring: Pull off the compressor's sealing ring (6) Instructions: Place tool KM-6018-4 (3) on the sealing ring. Put the heel of the tool into the recess (4) in the sealing ring and turn °90 (5). Withdraw the sealing ring with KM-6018-4 (6)
6. Clean the compressor housing: Clean the seat of the sealing ring in the compressor housing

Scheme 44

Scheme 45

1. Fit the protective collar: Fit the protective collar on the compressor shaft (1) - Use MKM-6319-4
2. Fit the compressor's sealing ring: Instructions: Moisten the sealing ring with mineral oil (part no. 90 01 8100, catalogue no. 19 49 870) before fitting: Insert the compressor's sealing ring Instructions: Press the sealing ring over the protective collar in the compressor housing until the groove (3) is visible. - MKM-6319-4 Remove the protective collar
3. Fit the lock ring: Instructions: The bevelled side against the sealing ring. Fit the circlip (1) - Use KM-J-4245 (2)
4. Adjust the compressor's sealing ring: Instructions: in order to attain a degree of running-in of the new sealing ring Screw on the shaft nut Turn the compressor shaft Unscrew the shaft nut
5. Fit the felt sealing ring: Instructions: Press in the felt sealing ring until it reaches the same height as the edge of the housing. Fit the new felt sealing ring (3)
6. Fit the compressor belt pulley see method description, «COMPRESSOR BELT PULLEY, TO REMOVE AND TO FIT, Z18XE»(ref-275884-S05642034902007122900000) .
7. Fit the compressor clutch see method description, «COMPRESSOR CLUTCH, TO REMOVE AND TO FIT, Z18XE»(ref-275884-S05256969602007122900000) .
8. Air conditioning, draining and filling see method description «DRAINING AND FILLING THE REFRIGERANT»(ref-275884-S13168331182007122900000) .

Compressor belt pulley, To remove and To fit, Z18XE

Scheme 46

1. Remove the compressor clutch see method description, «COMPRESSOR CLUTCH, TO REMOVE AND TO FIT, Z18XE»(ref-275884-S05256969602007122900000)
2. Remove the compressor belt pulley: Remove the circlip (1) Position the removal adapter on the housing - Use MKM-6319-3 (2) Pull off the compressor belt pulley - Use MKM-8433 (3) with MK-J-33025 (4)

Scheme 47

1. Fit the compressor belt pulley: Press the compressor belt pulley onto the housing - Use MKM-6319-2 (1) Fit the circlip
2. Fit the compressor clutch see method description, «COMPRESSOR CLUTCH, TO REMOVE AND TO FIT, Z18XE»(ref-275884-S05256969602007122900000)

Scheme 48

1. Remove the compressor belt pulley see method description, «COMPRESSOR BELT PULLEY, TO REMOVE AND TO FIT, Z18XE»(ref-275884-S05642034902007122900000)
2. Remove the compressor solenoid coil: Remove the cable kit (1) - 2x Unscrew bolt Remove the circlip (2) Remove the solenoid coil (3)

Add/Remove

When you program a key/remote control, change a control module or fit an electrical accessory, you need to access a new menu called "Add/Remove". The menu option marries and separates components in relation to the car. During "divorcing", critical data can be copied from a control module which is later loaded into the new control module. Remember that any SPS programming should be done before an "Add" operation. You must also retrieve "Security Access" for control modules included in the car's immobilization function. This is retrieved via RS 232 from TIS 2000 when the diagnostic tool requests it. You can also retrieve security access in advance and then kept it for the entire time you are working on the car in question, even if you disconnect the diagnostic tool now and again. Key programming and some activations that concern the central locking system and electric window lifts, for example, are also protected and require security access.

1. Remove «GLOVE BOX»(ref-275837-S35412718882007122900000) . The air recirculation flap stepping motor is located on the fan housing's outer end.
2. Dismantle the stepping motor's connector by pressing in the lock and pulling out the connector.
3. Dismantle the air recirculation flap's stepping motor.

When you program a key/remote control, change a control module or fit an electrical accessory, you need to access a new menu called "Add/Remove". The menu option marries and separates components in relation to the car. During "divorcing", critical data can be copied from a control module which is later loaded into the new control module. Remember that any SPS programming should be done before an "Add" operation. You must also retrieve "Security Access" for control modules included in the car's immobilization function. This is retrieved via RS 232 from TIS 2000 when the diagnostic tool requests it. You can also retrieve security access in advance and then kept it for the entire time you are working on the car in question, even if you disconnect the diagnostic tool now and again. Key programming and some activations that concern the central locking system and electric window lifts, for example, are also protected and require security access.

When the control module is to be replaced

1. Place the old control module in the return packaging without touching its pins.
2. Keep the new control module in its packaging as long as possible.

Before removing a control module, Tech 2 must be used to separate the control module from the car. From the "All" menu, select the control module under "And/Remove". Then select "Remove" and follow the instructions. The ignition key must be in the ON position. TIS 2000 may be required. Once the control module has been separated from the car, turned the ignition key to the OFF position. The control module can then be removed. Carry out the "Remove" action with Tech 2 even if the control module cannot be contacted or is completely missing because data in other control modules must be changed.

The action involves the following

Security codes will be reset, bus lists updated, data in other control modules updated and data that may have to be written into a new control module read and displayed.

When the component is to be replaced

1. Place the component in the return packaging without touching its pins.
2. Keep the new component in its packaging for as long as possible.