Exhaust System V6: Overview Saab 9-3 II

Scheme 18

1. Raise the car.
2. Undo the nuts of the exhaust pipe clamp.
3. Remove the exhaust system.

Scheme 19

1. Fit and adjust the exhaust system so it hangs neutrally. For cars with visible tailpipe, adjust such so that it is in the centre of the tailpipe opening in the rear bumper.
2. Tighten the exhaust pipe clip. Tightening torque 40 Nm (30 lbf ft).
3. Lower the car.
4. Attach the exhaust hoses and start the engine. Check that there are no exhaust system leaks.

Scheme 20

1. Raise the car.
2. Undo the nuts of the exhaust pipe clamp.
3. Cut the exhaust pipe to the specified measurement - 130 mm. Use 83 95 667 Pipe cutter/exhaust system. Hang up the silencer using 83 95 212 Strap.
4. Remove the front silencer.

Scheme 21

1. Clean the joints and connecting pipe.
2. Fit the joint clamps.
3. Fit the front pipe with new rubber mountings.
4. If necessary, replace the rubber mountings of the rear silencers.
5. Adjust the joint clamps so that the pipe joints are centered in them. The opening should face the rear.
6. Adjust the front and rear silencers so they hang evenly.
7. For cars with visible tailpipe, adjust this so that it hangs in the centre of the tailpipe cutout in the rear bumper.
8. Tighten the joint clamp nuts. Tightening torque 40 Nm (30 lbf ft)
9. Tighten the front exhaust pipe clip. Tightening torque 40 Nm (30 lbf ft)
10. Lower the car.
11. Attach the exhaust hoses and start the engine. Check that there are no exhaust system leaks.

Scheme 22

1. Raise the car.
2. Cut the exhaust pipe to the specified measurement - 130 mm on the side to be replaced. Cut the pipe perpendicularly. Use 83 95 667 Pipe cutter/exhaust system.
3. Remove the rear silencer.

Scheme 23

1. Clean the cut to remove burrs and dirt.
2. Fit the joint clamp to the pipe. The opening should face the rear.
3. Fit the rear silencer with new rubber mountings.
4. If necessary, replace the rubber mountings of the front silencer and the other rear silencer.
5. Adjust the joint clamp so that the pipe ends are in the centre of the clamp.
6. Adjust the front and rear silencers so they hang evenly.
7. If the tale pipe is visible: Check that the tail pipe is in the centre of the recess and flush with the rear bumper.
8. Tighten the nuts on the clamp. Tightening torque 40 Nm (30 lbf ft).
9. Lower the car.
10. Connect an exhaust hose and start the engine. Check the exhaust system for leaks.

Scheme 24

Scheme 25

1. Remove Front catalytic converter, B284E. See «CATALYTIC CONVERTER»(ref-275845-S38532962342007122900000) .
2. Raise the car.
3. Remove the heat shield from the exhaust manifold.
4. Lower the car.
5. Detach the intermediate exhaust pipe from the turbocharger and the exhaust manifold.

Scheme 26

Scheme 27

1. Attach the intermediate exhaust pipe to the turbocharger and the front exhaust manifold. Use a new gasket and coat the studs with 90 513 210 Universal paste. Fit all nuts. IMPORTANT: The conical side of the nut should face the centre exhaust pipe.
2. Tighten the nuts as illustrated - first on the exhaust manifold and then on the turbocharger. Tightening order 2a, 2b, 2c and 2d alternatingly on the turbocharger. Tightening torque 30 Nm (22 lbf ft) IMPORTANT: The surfaces should align with one another when the nuts are fitted. Check using a feeler gauge. If the surfaces are not flat or the pipe is deformed, the centre exhaust pipe and/or exhaust manifold must be replaced.
3. Raise the car.
4. Fit the heat shield on the exhaust manifold. Tightening torque, bolts: 10 Nm (7 lbf ft)
5. Lower the car.
6. Fit Front catalytic converter, aut. B284E. See «CATALYTIC CONVERTER»(ref-275845-S38532962342007122900000) .

Scheme 28

Scheme 29

Scheme 30

Scheme 31

Scheme 32

1. Remove Fan cowling, B284. See «FAN COWLING»(ref-275856-S35084604422007122900000) .
2. Detach the intake manifold of the secondary air injection pump from the pump.
3. Detach the discharge pipe of the secondary air injection pump from the pump.
4. Unplug the intake air sensor connector (688).
5. Remove the turbocharger delivery pipe.
6. Remove the dipstick tube.
7. Remove the heat shield of the front exhaust manifold.
8. Detach the intermediate exhaust pipe from the turbocharger and the front exhaust manifold.
9. Remove the bolts holding the secondary air pipe in place and raise it slightly. NOTE: Lubricate the studs and nuts with rust removal oil and carefully loosen.
10. Remove the exhaust manifold.

Scheme 33

Scheme 34

Scheme 35

Scheme 36

Scheme 37

1. Clean the contact surfaces from gasket residue and soot.
2. Fit the exhaust manifold using new bolts and a new gasket. Tightening torque 20 Nm (15 lbf ft).
3. Fit the secondary air pipe using a new gasket. Tightening torque 23 Nm (17 lbf ft)
4. Attach the intermediate exhaust pipe to the front exhaust manifold and the turbocharger. Use a new gasket and coat the studs with 90 513 210 Universal paste. Fit all nuts. IMPORTANT: The conical side of the nut should face the centre exhaust pipe.
5. Tighten the nuts as illustrated - first on the exhaust manifold and then on the turbocharger. Tightening order 4a, 4b, 4c, and 4d alternatingly on the turbocharger. Tightening torque 30 Nm (22 lbf ft) IMPORTANT: The surfaces should align with one another when the nuts are fitted. Check using a feeler gauge. If the surfaces are not flat or the pipe is deformed, the centre exhaust pipe and/or exhaust manifold must be replaced.
6. Fit the heat shield of the front exhaust manifold. Tightening torque 10 Nm (7 lbf ft)
7. Fit the dipstick pipe with new O-rings.
8. Fit the turbocharger delivery pipe.
9. Plug in the intake air sensor connector (688).
10. Attach the discharge pipe of the secondary air injection pump to the pump.
11. Fit the intake manifold of the secondary air injection pump to the pump.
12. Fit Fan cowling, B284. See «FAN COWLING»(ref-275856-S35084604422007122900000) .

US/CA

Scheme 38

Aero

Scheme 39

Other

Scheme 40

The exhaust system is designed to discharge the engine exhaust gases with a low flow resistance, low noise level and long life.

The exhaust system comprises the following components: a front section with catalytic converter, an intermediate exhaust pipe and two rear silencers.

Both silencers are combined resonance and absorption silencers.

The exhaust system is available in two versions depending on the shape of the fuel tank.

US/CA has one variant while the remaining markets have another variant.

To compensate for increasing flow loses due to the routing of the pipes, the intermediate pipe of cars for the US/CA market has a larger diameter. The Aero model has visible tailpipes - one on each side - while other models have hidden tailpipes.