Trionic T8 Fuel Control System: Removal & Installation Saab 9-3 II

To remove

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1. Reduce the fuel pressure by removing fuse 2 (Underhood electric center 727, petrol engine) while the engine is running. Turn the ignition key to LOCK once the engine has stopped.
2. Fit the fuse again.
3. Remove the upper engine cover.
4. Remove the inlet and return fuel pipes from the fuel rail. Use a support so that the lower connection on the fuel inlet pipe does not come loose. Use absorbent to collect any fuel spill and detach the pipe from its attachments on the camshaft cover.
5. Plug the connections on the pipes and the fuel rail.
6. Remove the cover over the ignition coils and unplug the ignition coil connectors starting with cylinder 4.
7. Unplug the connectors to the throttle body and coolant temperature sensor.
8. Unplug the connectors to CDM and the oxygen sensors.
9. Detach the cable duct and bend it forward.
10. Detach the vacuum hose from the fuel pressure regulator.
11. Remove the bolts, loosen the fuel rail and pull it up together with the injectors. Plug the holes in the cylinder head.
12. Unplug the connector from the injector/s (pull out the blue lock one step and press down the 20 black lock tab to loosen the connector).
13. Remove the injector attaching clips. Press the clip link to open it and detach with a screwdriver.
14. Remove the injector/s. Collect any fuel spill.

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1. Inspect the O-ring for the injector sleeve in the cylinder head and if necessary remove the sleeve with special tool «87 91 360»(ref-275835-S28401973262007122900000) Extractor, change the O-ring and fit the sleeve sparingly lubricated with Vaseline.
2. Fit the injector's with new O-rings sparingly lubricated with Vaseline (blue to fuel rail connection and black to cylinder head) to the fuel rail. Adjust their positions so that the attachment clip is located in the correct groove on the injector. Check the attachment.
3. Plug in the injector connectors, making sure they are locked.
4. Remove the plugs and fit the fuel rail to the cylinder head. Tightening torque 10 Nm (7 lbf ft).
5. Fit the vacuum hose to the fuel pressure regulator.
6. Refit the cable duct and plug in the connectors to CDM, oxygen sensors and the connector for the exhaust temperature sensor.
7. Refit the cable duct and plug in the connectors to the throttle body and coolant temperature sensor. Make sure the coolant hose is not under the cable duct.
8. Plug in the connectors to the ignition coils. Make sure to locate the ignition coil cables so they are not pinched.
9. Fit the cover over the ignition coils.
10. Fit new O-rings sparingly lubricated with Vaseline to the fuel inlet and return pips.
11. Connect the fuel inlet and return pipes to the fuel rail. Secure the pipes to the mounting on the camshaft cover.
12. Connect an exhaust extractor. Start the engine and check for fuel leaks.
13. Switch off the engine.
14. Replace the upper engine cover.

The level switch is used on engine variant B207R only

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1. Remove the oil sump as described in «OIL SUMP»(ref-275854-S23517497792007122900000) .
2. Remove the connector clip.
3. Make a note of how the cables are run and secured.
4. Remove the oil level sensor.

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1. Fit the oil level sensor to the oil pan.
2. Fit the connector with a new O-ring sparingly lubricated with Vaseline.
3. Check the location of the cables and that they are secured properly, adjust as necessary.
4. Fit the retaining clip.
5. Fit the oil sump as described in «TO FIT»(ref-275854-S03400881192007122900000) .

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1. Remove the cover over the ignition coils.
2. Remove the ignition coil.
3. Unplug the ignition coil connector.

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1. Plug in the connector.
2. Fit the ignition coil. Tightening torque 20 Nm (15 lbf ft).
3. Make sure to locate the ignition coil cables so they are not pinched.
4. Fit the cover over the ignition coils. Tightening torque 8 Nm (6 lbf ft).

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1. Remove the upper engine cover.
2. Remove the connector.
3. Press the lock and hose fast coupling from the valve (exhaust hose to turbo inlet and intake manifold).
4. Carefully bend out the console catch and remove the valve from the console.
5. Press the lock in, release the inlet hose fast coupling, and remove the valve.

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1. Fit the valve to the console and fold back the catch which retains the valve.
2. Connect the hoses to the valve, check that the fast couplings are locked.
3. Attach the connector.
4. Replace the upper engine cover.

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1. Remove the upper engine cover.
2. Remove the crankshaft position sensor.
3. Unplug the crankshaft position sensor connector.

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1. Plug in the connector and fit the crankshaft position sensor with a new O-ring sparingly lubricated with Vaseline.
2. Fit the upper engine cover.

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1. Remove the battery cover and undo the negative (-) battery cable.
2. Raise the car.
3. Disconnect the starter motor positive (+) cable and move it to one side.
4. Remove the starter motor retaining bolts and move aside the starter motor.
5. Unplug the crankshaft position sensor connector.
6. Remove the crankshaft position sensor.

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1. Fit the crankshaft position sensor with a new O-ring sparingly lubricated with Vaseline.
2. Plug in the connector.
3. Fit the starter motor. Tightening torque 40 Nm (30 lbf ft).
4. Connect the starter motor positive (+) cable.
5. Lower the car.
6. Connect the negative (-) battery cable and fit the battery cover.
7. Check «PROCEDURES AFTER DISCONNECTING THE BATTERY»(ref-275860-S17719632962007122900000) .

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1. Move the seat as far back as possible.
2. Remove the center console front side piece.
3. Remove the 2 sound insulating baffle screws from the climate housing and instrument panel.
4. Lower the sound insulating baffle and unplug the connector to the position sensor.
5. Remove the three position sensor nuts.

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1. Fit the three position sensor nuts. Tightening torque 8 Nm (6 lbf ft).
2. Plug in the connector to the position sensor.
3. Fit the 2 sound insulating baffle screws to the climate housing and instrument panel.
4. Fit the center console front side piece.
5. Adjust the seat position.

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1. Remove the upper engine cover.
2. Carefully press down the catch with a screwdriver and unplug the connector.
3. Remove the sensor.

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1. Fit the sensor with a new O-ring sparingly lubricated with Vaseline.
2. Plug in the connector.
3. Replace the upper engine cover.

Carry out PROCEDURES BEFORE DISMANTLING THE CONTROL MODULE .

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1. Ignition key in LOCK position.
2. Remove the upper engine cover.
3. Carefully press down the catches and carefully unplug the connectors from the control module one at a time so that the connection pins, etc. are not damaged.
4. Remove the control module.

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1. Fit the control module. Do not forget the ground cable. Tightening torque 10 Nm (7 lbf ft) 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 connectors and check that they are locked.
3. Fit the upper engine cover. Carry out «MEASURES AFTER CHANGING THE CONTROL MODULE»(ref-275869-S36767608072007122900000) .

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.

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.