Engine Management System Motronic E9: Removal & Installation Saab 9-3 II

To remove

1. Remove the upper engine cover.
2. Detach the ground cables and unplug the connectors of the engine control module. IMPORTANT: Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275842-S26624887112007122900000) .
3. Remove the engine control module with mounting and move it aside. The lower hole of the mounting is slotted.
4. Unplug the atmospheric pressure sensor connector.
5. Remove the cable duct from the plate bracket.
6. Remove the plate bracket from the intake manifold.
7. Detach the brake vacuum hose from the intake manifold.
8. Remove the holder and check valves for crankcase ventilation and tank bleeding.
9. Unplug the ignition coil connectors. At cylinder 4, the ignition coil must be loosened and lifted slightly in order to unplug the connector.
10. Remove the ignition coil.

Scheme 635

Scheme 636

Scheme 637

Scheme 638

1. Fit the ignition coil. At cylinder 4, the connector must be plugged in before the ignition coil is fitted.
2. Plug in the ignition coil connectors.
3. Fit the holder and check valves for crankcase ventilation and tank bleeding.
4. Attach the brake vacuum hose to the intake manifold.
5. Fit the plate bracket to the intake manifold.
6. Fit the cable duct to the plate bracket.
7. Plug in the atmospheric pressure sensor connector.
8. Fit the engine control module with mounting. The lower hole of the mounting is slotted.
9. Attach the ground cables to the engine control module and plug in the connectors. 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) .
10. Replace the upper engine cover.

Scheme 639

Scheme 640

Scheme 641

1. Remove the upper engine cover.
2. Unplug the upper connector of the engine control module.
3. Unplug the 7-pin connector.
4. Remove the nut and move the cable duct aside.
5. Detach the brake vacuum hose from the intake manifold.
6. Remove the bracket holding the crankcase ventilation pipes to the intake manifold.
7. Unplug the connector from the EVAP canister purge valve.
8. Detach the hoses from the valve.
9. Lift up the bracket with the valve and detach the pipe.
10. Remove the valve from the bracket.

Scheme 642

Scheme 643

Scheme 644

1. Fit the valve to the bracket.
2. Attach the pipe to the valve and bracket. Position the bracket.
3. Attach the hose to the valve.
4. Plug in the connector of the EVAP canister purge valve.
5. Fit the bracket holding the crankcase ventilation pipes to the intake manifold.
6. Attach the brake vacuum hose to the intake manifold.
7. Reposition the cable duct and fit the nut.
8. Plug in the 7-pin connector.
9. Plug in the upper connector of the engine control module.
10. Remove the upper engine cover.

Scheme 645

Scheme 646

Scheme 647

1. Raise the car.
2. Remove the rear catalytic converter.
3. Remove the bracket between the front exhaust pipe and the engine using «32 025 061 CROW FOOT SPANNER»(ref-275849-S21760354062007122900000) .
4. Undo the cable fixing from the heat shield.
5. Remove the heat shield.
6. Unplug the crankshaft sensor connector.
7. Remove the sensor.

Scheme 648

Scheme 649

Scheme 650

1. Fit the sensor using a new O-ring lightly coated with acid-free Vaseline. Tightening torque 10 Nm (7 lbf ft)
2. Plug in the connector.
3. Fit the heat shield.
4. Secure the cable to the heat shield.
5. Fit the bracket to the engine and front exhaust pipe. Tightening torque to engine: 23 Nm (17 lbf ft) Tightening torque to exhaust pipe: 40 Nm (30 lbf ft) Tightening torque to heat shield: M6 = 9 Nm (6 lbf ft) M10 = 38 Nm (28 lbf ft)
6. Fit rear catalytic converter using a new gasket.
7. Lower the car.

Scheme 651

1. Raise the car.
2. Remove the secondary air injection pump.
3. Remove the knock sensor.
4. Unplug the knock sensor connector.

Scheme 652

1. Plug in the connector.
2. Fit the knock sensor at the angle (Scheme 652)and tighten it to the correct torque. Tightening torque 23 Nm (17 lbf ft)
3. Fit the secondary air injection pump.
4. Lower the car.

Scheme 653

Scheme 654

1. Raise the car.
2. Remove the rear catalytic converter.
3. Remove the bracket between the front exhaust pipe and the engine using «32 025 061 CROW FOOT SPANNER»(ref-275849-S21760354062007122900000) .
4. Undo the cable fixing from the heat shield.
5. Remove the heat shield.
6. Unplug the knock sensor connector.
7. Remove the knock sensor.

Scheme 655

Scheme 656

1. Fit the knock sensor at the angle illustrated and tighten it to the correct torque. Tightening torque 23 Nm (17 lbf ft)
2. Plug in the connector.
3. Fit the heat shield.
4. Secure the cable to the heat shield.
5. Fit the bracket to the engine and front exhaust pipe. Tightening torque to engine: 23 Nm (17 lbf ft) Tightening torque to exhaust pipe: 40 Nm (30 lbf ft) Tightening torque to heat shield: M6 = 9 Nm (6 lbf ft) M10 = 38 Nm (28 lbf ft)
6. Fit rear catalytic converter using a new gasket.
7. Lower the car.

Scheme 657

1. Remove the upper engine cover. IMPORTANT: Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275842-S26624887112007122900000) .
2. Press down the catch and unplug the connector from the sensor.
3. Remove the sensor from the bracket.

Scheme 658

1. Fit the sensor to the bracket. 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. Replace the upper engine cover.

Scheme 659

Scheme 660

Scheme 661

Scheme 662

Scheme 663

1. «DRAINING, COOLING SYSTEM»(ref-275856-S12898389582007122900000)
2. Lower the car.
3. Remove the upper engine cover.
4. Detach the turbocharger intake hose. IMPORTANT: When removing the air cleaner casing cover, be careful not to damage the brake vacuum pump sensor.
5. Remove the air cleaner casing cover and the air cleaner.
6. Detach the intake hose and remove the air cleaner casing.
7. Remove the coolant pipe from the port.
8. Position a jack under the oil sump and relieve the load on the engine mounting.
9. Remove the engine pad from the body and bracket.
10. Unplug the connector from the intake air sensor.
11. Detach the upper turbocharger delivery pipe from the throttle body and detach the lower delivery pipe.
12. Remove the P-clamp of the servo pipe.
13. Remove the engine bracket.
14. Detach the coolant hose from the port.
15. Remove the position sensor connector.
16. Remove the position sensor.

Scheme 664

Scheme 665

Scheme 666

Scheme 667

Scheme 668

1. Fit the position sensor using a new O-ring coated with a thin layer of acid-free Vaseline. Tightening torque 10 Nm (7.5 lbf ft)
2. Plug in the connector.
3. Fit the coolant hose to the port.
4. Fit the engine bracket. Tightening torque, M12: 93 Nm (69 lbf ft) Tightening torque, M10: 42 Nm (31 lbf ft)
5. Fit the P-clamp of the servo pipe.
6. Fit the upper turbocharger delivery pipe to the throttle body and the lower delivery pipe.
7. Plug in the connector to the intake air sensor.
8. Fit and adjust the engine pad to the body. Tighten the bolts between the engine pad and the bracket. The engine pad and bracket should be aligned with each other. Tightening torque to engine: 45 Nm + 90° (33 lbf ft + 90°) Tightening torque to body: 50 Nm + 180° (37 lbf ft + 180°)
9. Remove the jack.
10. Fit the coolant pipe to the port using a new O-ring coated with a thin layer of acid-free Vaseline.
11. Fit the air cleaner casing and intake hose.
12. Fit the air cleaner and the air cleaner casing cover.
13. Fit the turbocharger inlet hose.
14. Fit the upper engine cover.
15. «BLEEDING AND CHARGING THE COOLING SYSTEM»(ref-275856-S10550426312007122900000) .
16. «TEST PRESSURIZING THE COOLING SYSTEM»(ref-275856-S41791158062007122900000) .

Scheme 669

Scheme 670

Scheme 671

1. «DRAINING, COOLING SYSTEM»(ref-275856-S12898389582007122900000) .
2. Lower the car.
3. Remove the upper engine cover.
4. Detach the turbocharger intake hose. IMPORTANT: When removing the air cleaner casing cover, be careful not to damage the brake vacuum pump sensor.
5. Remove the air cleaner casing cover and the air cleaner.
6. Detach the intake hose and remove the air cleaner casing.
7. Detach the coolant hose from the engine and move it aside.
8. Remove the position sensor connector.
9. Remove the solenoid valve.

Scheme 672

Scheme 673

Scheme 674

1. Fit the position sensor using a new O-ring coated with a thin layer of acid-free Vaseline. Tightening torque 10 Nm (7.5 lbf ft)
2. Attach the connector to the position sensor.
3. Reposition and fit the coolant hose.
4. Fit the air cleaner casing and intake hose.
5. Fit the air cleaner and the air cleaner casing cover.
6. Fit the turbocharger inlet hose.
7. Replace the upper engine cover.
8. «BLEEDING AND CHARGING THE COOLING SYSTEM»(ref-275856-S10550426312007122900000) .

Scheme 675

1. Remove the battery cover and coolant pipe.
2. Unplug the bypass valve connector.
3. Remove the bypass valve bolts and lift away the valve.

Scheme 676

Scheme 677

Scheme 678

Scheme 679

Scheme 680

1. Drain the coolant.
2. Lower the car.
3. Remove the upper engine cover.
4. Detach the turbocharger intake hose. IMPORTANT: When removing the air cleaner casing cover, be careful not to damage the brake vacuum pump sensor.
5. Remove the air cleaner casing cover and the air cleaner.
6. Detach the intake hose and remove the air cleaner casing.
7. Remove the coolant pipe from the port.
8. Position a jack under the oil sump and relieve the load on the engine mounting.
9. Remove the engine pad from the body and bracket.
10. Unplug the connector from the intake air sensor.
11. Detach the upper turbocharger delivery pipe from the throttle body and detach the lower delivery pipe.
12. Remove the P-clamp of the servo pipe.
13. Remove the engine bracket.
14. Detach the coolant hose from the port.
15. Remove the solenoid valve connector.
16. Remove the solenoid valve. NOTE: Be careful not to damage the seal!

Scheme 681

Scheme 682

Scheme 683

Scheme 684

Scheme 685

1. Fit the solenoid valve. Tightening torque 10 Nm (7.5 lbf ft) NOTE: Be careful not to damage the seal!
2. Plug in the connector.
3. Fit the coolant hose to the port.
4. Fit the engine bracket. Tightening torque, M12: 93 Nm (69 lbf ft) Tightening torque, M10: 42 Nm (31 lbf ft)
5. Fit the P-clamp of the servo pipe.
6. Fit the upper turbocharger delivery pipe to the throttle body and the lower delivery pipe.
7. Plug in the connector to the intake air sensor.
8. Fit and adjust the engine pad to the body. Tighten the bolts between the engine pad and the bracket. The engine pad and bracket should be aligned with each other. Tightening torque to engine: 45 Nm + 90° (30 lbf ft + 90°) Tightening torque to body: 50 Nm + 180° (37 lbf ft + 180°)
9. Remove the jack.
10. Fit the coolant pipe to the port using a new O-ring coated with a thin layer of acid-free Vaseline.
11. Fit the air cleaner casing and intake hose.
12. Fit the air cleaner and the air cleaner casing cover.
13. Fit the turbocharger inlet hose.
14. Fit the upper engine cover.
15. Fill with coolant.
16. Pressure test the cooling system.

Scheme 686

1. Remove the solenoid valve.
2. Remove the seal with a screwdriver.

Scheme 687

1. Clean the sealing surfaces.
2. Lightly coat the new seal with acid-free Vaseline.
3. Fit the seal using special tool 32 025 066. (EN-46103).
4. Fit the solenoid valve.

Scheme 688

Scheme 689

Scheme 690

1. Drain the coolant.
2. Lower the car.
3. Remove the upper engine cover.
4. Detach the turbocharger intake hose. IMPORTANT: When removing the air cleaner casing cover, be careful not to damage the brake vacuum pump sensor.
5. Remove the air cleaner casing cover and the air cleaner.
6. Detach the intake hose and remove the air cleaner casing.
7. Detach the coolant hose from the engine and move it aside.
8. Remove the solenoid valve connector.
9. Remove the solenoid valve. NOTE: Be careful not to damage the seal.

Scheme 691

Scheme 692

Scheme 693

1. Fit the solenoid valve. Tightening torque 10 Nm (7.5 lbf ft) NOTE: Be careful not to damage the seal.
2. Attach the connector to the solenoid valve.
3. Reposition and fit the coolant hose.
4. Fit the air cleaner casing and intake hose.
5. Fit the air cleaner and the air cleaner casing cover.
6. Fit the turbocharger inlet hose.
7. Replace the upper engine cover.
8. Fill with coolant.

Scheme 694

1. Remove the solenoid valve.
2. Remove the seal with a screwdriver.

Scheme 695

1. Clean the sealing surfaces.
2. Lightly coat the new seal with acid-free Vaseline.
3. Fit the seal using special tool 32 025 066 (EN-46103).
4. Fit the solenoid valve.

Scheme 696

Scheme 697

Scheme 698

1. Generator (2)
2. Starter motor (4)
3. Ignition switch unit (20)
4. Brake light switch (29)
5. Relay, fuel pump (102)
6. Clutch switch, cruise control (133)
7. Brake switch, cruise control (134)
8. Cruise control switch (141, included in 703)
9. Relay, A/C compressor (156)
10. Main relay, engine management system (229)
11. Relay, secondary air injection pump (324)
12. Relay, +50 (517)
13. Mass air flow sensor (205)
14. Boost pressure control valve (179a)
15. Coolant temperature sensor (202)
16. Injectors (206a-f)
17. Level sensor, engine oil (243)
18. Ignition coil with integrated power amplifier (320a-f)
19. Solenoid valve, EVAP canister purge (321)
20. Motor, secondary air injection pump (326)
21. Crankshaft position sensor (345)
22. Accelerator pedal position sensor (379)
23. Knock sensor, front cylinder bank (516F)
24. Knock sensor, rear cylinder bank (516R)
25. Atmospheric pressure sensor (539)
26. Position sensor, intake camshaft, front cylinder bank (555F)
27. Position sensor, intake camshaft, rear cylinder bank (555R)
28. Manifold absolute pressure sensor (585)
29. Solenoid valve, shut-off EVAP (588)
30. Preheated oxygen sensor, front (592)
31. Preheated oxygen sensor, rear (593)
32. Throttle body actuator unit (604)
33. Solenoid valve, turbo by-pass (605)
34. Control module, Motronic E9, V6 petrol (608)
35. A/C pressure sensor (620)
36. Fuel pressure sensor, fuel rail (653)
37. Intake air sensor (688) contains: Intake air temperature sensor (407) Charge air pressure sensor (603)
38. Fuel pump unit (689) contains: Level sensor, fuel (46) Engine, fuel pump (323)
39. Solenoid valve, intake camshaft, front cylinder bank (695F)
40. Solenoid valve, intake camshaft, rear cylinder bank (695R)
41. Engine oil pressure sensor (696)
42. Control module, fuel pump (697)
43. Relay unit, radiator fans (706a)
44. Column Integration Module (703, contains 141)

Scheme 699

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.