Front Suspension: Removal & Installation Saab 9-3 II

To remove

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1. Clamp the return hose with «30 07 739 HOSE PINCH-OFF PLIERS»(ref-275876-S01843260832007122900000) .
2. Detach the pipes from the bracket on the top of the steering gear. Leave the bolt and clamp in place.
3. Set the wheels and steering wheel to the straight-ahead position. Fix the steering wheel to the dashboard using woven tape or lock the steering wheel with the steering column lock.
4. Remove the upper bumper shell attachments.
5. Hang two «83 95 212 STRAPS»(ref-275876-S25609733142007122900000) in place over the radiator member and the radiator unit so that they are accessible from below.
6. Raise the car.
7. Remove the front «WHEEL»(ref-275842-S20194743172007122900000) .
8. Remove the lower front cover. CV: Remove «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
9. Bind the radiator unit tightly with the straps.
10. Remove the radiator brackets from the subframe.
11. Remove the exhaust system. IMPORTANT: The flexible bellow on the front section of the exhaust system must not be bent more than 5° from its neutral line. This means that if the front exhaust system is left hanging freely, it must not be bent more than by its own weight. If the strain on the pipe is too great, its component parts will be permanently deformed. This can cause noise, leaks and eventually complete breakdown.
12. Remove the engine torque rod from the subframe.
13. Remove the bolt and nut which attach the suspension arm to the steering swivel member on both sides. Left-hand suspension arm and cars with xenon lights: Remove the level sensor.
14. Remove the nut holding the track rod ends to the steering swindle member on both sides. Remove the track rod using «87 91 287 PULLER, 150 MM»(ref-275840-S14782061502007122900000) .
15. Remove the anti-roll bar links from the anti-roll bar. Counterhold with a thin 17 mm open wrench so that the ball joint does not rotate.
16. Remove the steering shaft joint from the steering gear. RHD: LHD
17. Open the clips that secure the power steering pipe to the subframe.
18. Position «83 95 311 TROLLEY LIFT»(ref-275876-S15758916622007122900000) underneath. Fit «83 94 801 PARENT FIXTURE»(ref-275876-S26333905402007122900000) , «83 95 188 BASIC FIXTURE»(ref-275876-S13922925782007122900000) , «83 95 170 ADAPTER»(ref-275876-S03822204352007122900000) and «83 96 137 CENTERING TOOL, SUBFRAME - BODY»(ref-275876-S05271366232007122900000) . Fit in the locating pins and use the adapters to adjust the height for even contact.
19. Remove the front part of the wing liner and fold away slightly.
20. Remove the subframe bolts on both sides. Remove the stays from the body.
21. Lower the subframe slightly.
22. Pull out the suspension arms ball-and-socket joints from the steering swivel members.
23. Place a receptacle beneath the car. Detach the delivery line and return line from the steering gear. Plug the lines. LHD: RHD
24. Lower the subframe.
25. Replace the anti-roll bar bushes. IMPORTANT: Replace one side at a time. IMPORTANT: Do not lubricate the bushing or anti-roll bar when removing/installing.
26. Remove the bolts of the left anti-roll bar bush.
27. Remove the cap from the bush.
28. Remove the upper bush. NOTE: The removed bush must not be reused. It must be replaced.
29. Fit the upper bush, centered in the cap.
30. Position the lower bush on the subframe, centered between the bolt holes.
31. Fit the cap with upper bush to the subframe. Tighten the bolts alternatingly until the lower bush's catches engage in the cap. NOTE: Use M8x30 mm bolts.
32. Replace the temporary bolts (M8x30 mm) with the original bolts and tighten. Tightening torque 18 Nm (13 lbf ft).
33. Replace the right anti-roll bar bush following the same method.

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1. Lift the frame. Fit the ball joints for the suspension arms in the steering swivel member.
2. Attach the delivery line and return line to the steering gear. Fit new O-rings. Tightening torque 28 Nm (21 lbf ft) LHD: RHD: Make sure that the lines are correctly positioned against the bracket on the top of the steering gear. IMPORTANT: Make sure that the return line (line with the short nut) is connected to the lower of the two connections. The steering gear will be destroyed if the lines are mixed up!
3. Lift the subframe into place and align «83 96 137 CENTERING TOOL, SUBFRAME - BODY»(ref-275876-S05271366232007122900000) with the locating holes in the body.
4. Attach the power steering pipe to the plastic clips on the subframe.
5. Lift the subframe so that the inner sections of the bushes are pressing against the body. Fit the front subframe bolts on both sides. Tightening torque 75 Nm +135° (55 lbf ft +135°)
6. Fit the stays and the rear subframe bolts on both sides. Enter the rear stay bolts before tightening the subframe bolts. Tightening torque 75 Nm +135° (55 lbf ft +135°) Lower and pull away the trolley lift.
7. Tighten the rear stay bolts. Tightening torque 90 Nm +45° (66 lbf ft +45°)
8. Fit the engine torque rod to the subframe. Tightening torque, rear torque rod 80 Nm (59 lbf ft) Tightening torque, front torque rod 60 Nm +90° (44 lbf ft +90°)
9. Set up «83 96 145 CENTERING TOOL, SUBFRAME - ENGINE»(ref-275876-S33252037272007122900000) and check that the engine and gearbox are correctly positioned in relation to the subframe. Remove the centering tool.
10. Fit the suspension arms to the steering swivel members. WARNING: Press up the pin carefully. The groove in the pin must be visible in the screw hole in the spindle housing. If the rubber gaiter is pressed down, it will not seal properly to the swivel pin. Tightening torque 50 Nm (37 lbf ft) Left-hand suspension arm and cars with xenon lights: Fit the level sensor.
11. Install the anti-roll bar links to the anti-roll bar. Counterhold with a thin 17 mm open wrench so that the ball joint does not rotate. Tightening torque 64 Nm (47 lbf ft)
12. Fit the track rod ends to the steering swivel members. Tightening torque 35 Nm (26 lbf ft)
13. Attach the steering shaft joint to the steering gear. Clean the threads and apply «THREAD LOCKING ADHESIVE, LOCTITE 242»(ref-275876-S15006184582007122900000) to the threads. WARNING: Check that the bolt fits into the groove on the pinion shaft. LHD: Tightening torque 30 Nm (22 lbf ft) RHD: Tightening torque 30 Nm (22 lbf ft)
14. Fit the radiator brackets to the subframe. Tightening torque 47 Nm (35 lbf ft) NOTE: Check that the upper radiator unit support is placed correctly.
15. Remove the straps.
16. Fit the exhaust system. IMPORTANT: Take care so as not to crack the flex bellows. Tightening torque 25 Nm (18 lbf ft)
17. Fit the front part of the wing liner on both sides of the car.
18. CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) . Fit the lower front cover.
19. Fit the «WHEEL»(ref-275842-S20194743172007122900000) .
20. Lower the car to the floor.
21. Attach the pipes to the bracket on the top of the steering gear.
22. Fit the upper bumper shell attachments.
23. Remove the hose pinch-off pliers and fill with «POWER STEERING FLUID»(ref-275874-S19720564482007122900000) .
24. Remove the steering wheel fixing.
25. «BLEEDING THE POWER STEERING SYSTEM»(ref-275874-S14538374012007122900000) and check for leaks.
26. Check the straight-ahead position of the steering wheel when driving on a level road. Adjust if necessary.

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1. Clamp the return hose with «30 07 739 HOSE PINCH-OFF PLIERS»(ref-275876-S01843260832007122900000) .
2. Fix the steering wheel to the dashboard with woven tape or the like. LHD: straight ahead RHD: approx. 20° to the right.
3. Remove the upper bumper shell attachments.
4. Remove the air filter cover. IMPORTANT: Be careful of the electrical connection to the brake vacuum valve.
5. Detach the hose between the air filter and mass air flow sensor. Remove the mass air flow sensor with hose.
6. Hang two «83 95 212 STRAPS»(ref-275876-S25609733142007122900000) in place over the radiator member and the radiator unit so that they are accessible from below.
7. Raise the car.
8. Remove the front wheels.
9. Remove the lower front cover. CV: Remove «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
10. Bind the radiator unit tightly with the straps.
11. Remove the radiator brackets from the subframe.
12. Remove the front section of the exhaust system. IMPORTANT: Be careful with the flexible part. It must not be bent by more than 5°.
13. Remove the engine torque rod from the subframe.
14. Remove the bolt and nut which attach the suspension arm to the steering swivel member on both sides. Left-hand suspension arm and cars with xenon lights: Remove the level sensor.
15. Remove the nut holding the track rod ends to the steering swindle member on both sides. Remove the track rod using «87 91 287 PULLER, 150 MM»(ref-275840-S14782061502007122900000) .
16. Remove the anti-roll bar links from the anti-roll bar. Counterhold with a thin 17 mm open wrench so that the ball joint does not rotate.
17. RHD: Place a receptacle under the car. Detach the delivery line and return line from the steering gear. Plug the lines.
18. Remove the steering shaft joint from the steering gear.
19. Open the clips that secure the power steering pipe to the subframe.
20. Position «83 95 311 TROLLEY LIFT»(ref-275876-S15758916622007122900000) underneath. Fit «83 94 801 PARENT FIXTURE»(ref-275876-S26333905402007122900000) , «83 95 188 BASIC FIXTURE»(ref-275876-S13922925782007122900000) , «83 95 170 ADAPTER»(ref-275876-S03822204352007122900000) and «83 96 137 CENTERING TOOL, SUBFRAME - BODY»(ref-275876-S05271366232007122900000) . Fit in the locating pins and use the adapters to adjust the height for even contact.
21. Remove the front part of the wing liner and fold away slightly.
22. Remove the subframe bolts on both sides. Remove the stays from the body.
23. Lower the subframe slightly.
24. Pull out the suspension arms ball-and-socket joints from the steering swivel members.
25. Place a receptacle beneath the car. Detach the delivery line and return line from the steering gear. Plug the lines. LHD: RHD: Remove the delivery pipe from the clip on the steering gear.
26. Lower the subframe.
27. Replace the anti-roll bar bushes. IMPORTANT: Replace one side at a time. IMPORTANT: Do not lubricate the bushing or anti-roll bar when removing/installing. Remove the bolts of the left anti-roll bar bush. Remove the cap from the bush. Remove the upper bush. NOTE: The removed bush must not be reused. It must be replaced. Fit the upper bush, centered in the cap. Position the lower bush on the subframe, centered between the bolt holes. Fit the cap with upper bush to the subframe. Tighten the bolts alternatingly until the lower bush's catches engage in the cap. NOTE: Use M8x30 mm bolts. Replace the temporary bolts (M8x30 mm) with the original bolts and tighten. Tightening torque 18 Nm (13 lbf ft). Replace the right anti-roll bar bush following the same method.

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1. Lift the frame. Fit the ball joints for the suspension arms in the steering swivel member.
2. LHD: Fit the delivery line and return line to the steering gear using new O-rings. Tightening torque 12 Nm (9 lbf ft).
3. Lift the subframe into place and align «83 96 137 CENTERING TOOL, SUBFRAME - BODY»(ref-275876-S05271366232007122900000) with the locating holes in the body.
4. Attach the power steering pipe to the plastic clips on the subframe.
5. Lift the subframe so that the inner sections of the bushes are pressing against the body. Fit the front subframe bolts on both sides. Tightening torque 75 Nm +135° (55 lbf ft +135°)
6. Fit the stays and the rear subframe bolts on both sides. Enter the rear stay bolts before tightening the subframe bolts. Tightening torque 75 Nm +135° (55 lbf ft +135°) Lower and pull away the trolley lift.
7. Tighten the rear stay bolts. Tightening torque 90 Nm +45° (66 lbf ft +45°)
8. RHD: Attach the delivery line and return line to the steering gear using new O-rings. Fit the delivery pipe in the clips on the steering gear. Tightening torque 12 Nm (9 lbf ft).
9. Fit the engine torque rod to the subframe. Tightening torque, rear torque rod 80 Nm (59 lbf ft) Tightening torque, front torque rod 60 Nm +90° (44 lbf ft +90°)
10. Set up «83 96 145 CENTERING TOOL, SUBFRAME - ENGINE»(ref-275876-S33252037272007122900000) and check that the engine and gearbox are correctly positioned in relation to the subframe. Remove the centering tool.
11. Fit the suspension arms to the steering swivel members. WARNING: Press up the pin carefully. The groove in the pin must be visible in the screw hole in the spindle housing. If the rubber gaiter is pressed down, it will not seal properly to the swivel pin. Tightening torque 50 Nm (37 lbf ft) Left-hand suspension arm and cars with xenon lights: Fit the level sensor.
12. Install the anti-roll bar links to the anti-roll bar. Counterhold with a thin 17 mm open wrench so that the ball joint does not rotate. Tightening torque 64 Nm (47 lbf ft)
13. Fit the track rod ends to the steering swivel members. Tightening torque 35 Nm (26 lbf ft)
14. Attach the steering shaft joint to the steering gear. Clean the threads and apply Thread locking adhesive, Loctite 242 to the threads. WARNING: Check that the bolt fits into the groove on the pinion shaft. Tightening torque 30 Nm (22 lbf ft)
15. Fit the radiator brackets to the subframe. Tightening torque 47 Nm (35 lbf ft) NOTE: Check that the upper radiator unit support is placed correctly.
16. Remove the straps.
17. Fit the front exhaust pipe section. Tightening torque 30 Nm (22 lbf ft) Clamp: Tightening torque 40 Nm (30 lbf ft) IMPORTANT: Be careful with the flexible part. It must not be bent by more than 5°.
18. Fit the front part of the wing liner on both sides of the car.
19. CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) . Fit the lower front cover.
20. Fit the «WHEEL»(ref-275842-S20194743172007122900000) .
21. Lower the car to the floor.
22. Fit the upper bumper shell attachments.
23. Attach the hose with mass air flow sensor to the turbocharger and attach the hose between the mass air flow sensor and the air filter.
24. Fit the air filter cover.
25. Remove the hose pinch-off pliers and fill with «POWER STEERING FLUID»(ref-275874-S19720564482007122900000) .
26. Remove the steering wheel fixing.
27. «BLEEDING THE POWER STEERING SYSTEM»(ref-275874-S14538374012007122900000) and check for leaks.
28. Check the straight-ahead position of the steering wheel when driving on a level road. Adjust if necessary.

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1. Set the front wheels in the straight-ahead position and lock the steering wheel.
2. Remove the bumper shell's upper mounting (A).
3. Hang two «83 95 212 STRAPS»(ref-275876-S25609733142007122900000) over the radiator member.
4. Raise the car.
5. CV: Remove «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
6. Z19: Remove the lower engine cover (A).
7. Remove the lower front cover (B).
8. Remove the front section of the wing liners, 1 x nut (A), and fold aside slightly.
9. Hang up the radiator unit using «83 95 212 STRAP»(ref-275876-S25609733142007122900000) .
10. Z18XE: Remove the exhaust system.
11. Z19: Remove the front exhaust pipe (A) or the whole exhaust system.
12. Remove the bolts (B) for the engine's torque rod.
13. Detach the anti-roll bar links (A) from the anti-roll bar. Counterhold with a thin 17 mm open wrench to ensure that the ball joint is not rotated.
14. Remove the steering shaft joint (A) from the steering gear.
15. Undo the EHPS wiring harness clips from the holder.
16. On cars with Xenon headlamps: Unplug the connector and undo the cable clip for the headlamps' angle sensors.
17. Set under «83 95 311 TROLLEY LIFT»(ref-275876-S15758916622007122900000) with «83 94 801 PARENT FIXTURE»(ref-275876-S26333905402007122900000) , «83 95 188 BASIC FIXTURE»(ref-275876-S13922925782007122900000) and «83 96 137 CENTERING TOOL, SUBFRAME - BODY»(ref-275876-S05271366232007122900000) .
18. Remove the subframe's front bolts on both sides (A).
19. Remove the subframe's rear bolts (A) and remove the bolts (B) for the stays and then the stays.
20. Lower the subframe approx. 160 mm
21. Remove the anti-roll bar bush: IMPORTANT: Replace one side at a time. IMPORTANT: Do not lubricate the bushing or anti-roll bar when removing/installing. Remove the bolts (A) for the left-hand anti-roll bar bush. Remove the clamp (A) from the lower bush. Remove the upper bush. NOTE: The removed bush must not be reinstalled. It must be replaced.

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1. Fit the anti-roll bar bush: Fit the upper bush (A) centered in the clamp. Position the lower bush (A) on the subframe, centered between the bolt holes. Fit the clamp with upper bush to the subframe. Tighten the bolts (A) alternatingly until the catches (B) of the lower bush engage in the clamp. NOTE: Use M8x30 mm bolts. Replace the temporary bolts (A) (M8x30 mm) with the original bolts and tighten. Tightening torque 18 Nm (13 lbf ft). Replace the right anti-roll bar bush following the same method.
2. Lift the subframe into place and align «83 96 137 CENTERING TOOL, SUBFRAME - BODY»(ref-275876-S05271366232007122900000) with the locating holes in the body. Before fitting: press up the locating pins on both sides (B). Check that the pins on both sides of the radiator are correctly seated in the subframe's holder. Apply Vaseline to the rubber guides.
3. Lift the subframe so that the inner sections of the bushes are pressing against the body. Fit the subframe's front bolts on both sides (A). Tightening torque 75 Nm +135° (55 lbf ft +135°)
4. Fit the stays and the subframe's rear bolts (A) on both sides. Insert the rear stay bolts before tightening the subframe bolts. Tightening torque 75 Nm +135° (55 lbf ft +135°)
5. Tighten the rear stay bolts (B). Tightening torque 90 Nm +45° (66 lbf ft +45°)
6. Lower and pull away the trolley lift.
7. Set up «83 96 145 CENTERING FIXTURE, SUBFRAME - ENGINE»(ref-275876-S33252037272007122900000) . Check that the engine is correctly positioned in relation to the subframe. Remove the centering fixture.
8. Fit the anti-roll bar links (A) to the anti-roll bar. Counterhold with a thin 17 mm open wrench to ensure that the ball joint is not rotated. Tightening torque 65 Nm (48 lbf ft)
9. Fit the bolts (B) for the engine's torque rod. Tightening torque, front bolt, 60 Nm +90° (44 lbf ft +90°) Tightening torque, rear bolt, 80 Nm (59 lbf ft)
10. Z18XE: Fit the exhaust system.
11. Z19: Fit the front exhaust pipe (A). Lubricate the threads using 30 20 971 Screw-thread paste. Tightening torque, exhaust flanges, 22 Nm (16 lbf ft) Tightening torque, mounting to gearbox, 19 Nm (14 lbf ft)
12. Fit the EHPS wiring harness clips to the holder.
13. On cars with Xenon headlamps: Plug in the connector for the headlamps' angle sensors and fit the cable clip to the subframe.
14. Fit the steering shaft joint to the steering gear (A). Check that the front wheels are in the straight-ahead position. Clean the threads and apply 74 96 268 Thread locking adhesive to the threads. Tightening torque 30 Nm (22 lbf ft). WARNING: Check that the bolt fits into the groove on the pinion shaft.
15. Remove the straps.
16. Z19: Fit the lower engine cover (A).
17. Fit the lower front cover (B).
18. Fit the front section of the wing liners, 1 x nut (A).
19. CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
20. Lower the car to the floor.
21. Fit the bumper shell's upper mounting (A).

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1. Raise the car.
2. Remove the appropriate rear wheel.
3. Unplug the wheel sensor connector (A).
4. Remove the anti-roll bar screw (B) from the steering swivel member.
5. Remove the anti-roll bar link: Lubricate the damping rubber with Vaseline, non-acidic. Press the link away from the anti-roll bar using a suitable tool.

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1. Fit a new link to the anti-roll bar: Lubricate the damping rubber with Vaseline, non-acidic. Press the link into the anti-roll bar using a suitable tool. Check that the link is correctly aligned on the anti-roll bar.
2. Fit the anti-roll bar link onto the steering swivel member using a new screw (B). Tightening torque 53 Nm (39 lbf ft)
3. Plug in the wheel sensor connector (A).
4. Fit the «WHEEL»(ref-275842-S20194743172007122900000) .
5. Lower the car to the floor.

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