Intake System V6: Removal & Installation Saab 9-3 II

To remove

Scheme 1057

1. Remove the bolts holding the intake manifold to the radiator member.
2. Detach the connector.
3. Detach the hose clips and remove the mass air flow sensor.

Scheme 1058

1. Fit the mass air flow sensor and tighten the hose clips. IMPORTANT: Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275842-S26624887112007122900000) .
2. Plug in the connector.
3. Fit the bolts holding the intake manifold to the radiator member.

Before replacement, PROCEDURE BEFORE CONTROL MODULE REMOVAL (2006) or PROCEDURES BEFORE DISMANTLING THE CONTROL MODULE (2007) must be carried out.

Scheme 1059

Scheme 1060

Scheme 1061

1. Remove the engine cover.
2. Remove the power steering fluid reservoir bolt. Put the reservoir aside.
3. Unplug the connector of the intake air sensor (688).
4. Remove the charge air pipe.
5. Remove the throttle body bolts.
6. Unplug the connector and lift away the throttle body.

Scheme 1062

Scheme 1063

Scheme 1064

1. Clean the sealing surfaces. Position the throttle body using a new seal. Plug in the connector.
2. Fit the throttle body bolts. Tightening torque 9 Nm
3. Replace the charge air pipe.
4. Plug in the connector of the intake air sensor (688).
5. Position the power steering fluid reservoir and fit the bolt.
6. Fit the engine cover.
7. If a new throttle body has been fitted: Connect the diagnostic tool for programming. Select Diagnosis / Select model year / Saab 9-3 Sport (9440) / All / Add/Remove / Other components / 2.8T - Replaced Throttle Body .

Scheme 1065

1. Detach the connector.
2. Remove the sensor.

Scheme 1066

1. Fit the sensor using a new O-ring lightly coated with vaseline. IMPORTANT: Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275842-S26624887112007122900000) .
2. Fit the connector.

Scheme 1067

Scheme 1068

Scheme 1069

Scheme 1070

Scheme 1071

Scheme 1072

Scheme 1073

Scheme 1074

1. Remove the engine cover.
2. Remove the power steering fluid reservoir bolt. Put the reservoir aside.
3. Unplug the connector of the intake air sensor (688).
4. Detach the upper charge air pipe.
5. Remove the throttle body bolts.
6. Unplug the connector and lift away the throttle body.
7. Detach the ground cable of the control module.
8. Unplug the engine control module connectors (608A and 608B).
9. Detach the engine breather pipe.
10. Detach the cable duct and move it aside.
11. Remove the atmospheric pressure sensor bracket.
12. Detach the bracket of the injectors' wiring harness.
13. Detach the brake servo pipe from the intake manifold.
14. Remove the bolt and detach the crankcase ventilation pipes from the intake manifold.
15. Remove the intake manifold bolts.
16. Carefully raise the intake manifold.
17. Remove the gaskets.

Scheme 1075

Scheme 1076

Scheme 1077

Scheme 1078

Scheme 1079

Scheme 1080

Scheme 1081

Scheme 1082

1. Clean the sealing surfaces and fit new gaskets. Carefully position the intake manifold.
2. Fit the intake manifold bolts. Tightening torque 23 Nm (17 lbf ft)
3. Attach the crankcase ventilation pipes to the intake manifold and fit the bolt.
4. Attach the brake servo pipe to the intake manifold.
5. Attach the bracket of the injectors' wiring harness.
6. Fit the atmospheric pressure sensor bracket.
7. Fit the cable duct.
8. Attach the engine breather pipe.
9. Plug in the engine control module connectors (608A and 608B).
10. Attach the ground cable of the control module.
11. Position the throttle body using a new gasket. Plug in the connector.
12. Fit the throttle body bolts. Tightening torque 9 Nm (7 lbf ft).
13. Replace the charge air pipe.
14. Plug in the connector of the intake air sensor (688).
15. Position the power steering fluid reservoir and fit the bolt.
16. Fit the engine cover.

Scheme 1083

Scheme 1084

Scheme 1085

1. Remove the bolts holding the turbocharger intake manifold from the radiator member.
2. Detach the pipe from the air cleaner casing cover. IMPORTANT: When removing the air cleaner casing cover, be careful not to damage the brake vacuum pump sensor.
3. Remove the air cleaner casing cover.
4. Remove the filter element.
5. Cover the turbo inlet hose and blow the air cleaner casing clean.

Scheme 1086

Scheme 1087

Scheme 1088

1. Fit a new air filter.
2. Fit the air cleaner casing cover.
3. Attach the pipe to the air cleaner casing cover.
4. Fit the bolts holding the intake manifold to the radiator member.