Charging and Starting System: Component Locations Saab 9-4X I

Special Tools

Illustration Tool Number/Description EL 38758 EL 50074 J 38758 Parasitic Draw Test Switch EL 50313 EL 42000 EL 50076 J 42000 Battery Tester

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1. DT 47825-10 Adapter Harness
2. DT 47825-20 Adapter Harness
3. DT 48616-10 Adapter Harness

For equivalent regional tools, refer to SPECIAL TOOLS .

1. DT 47825-10 - Wiring harness adapter
2. DT 47825-20 - Wiring harness adapter
3. DT 48616-10 - Wiring harness adapter

For equivalent regional tools, see SPECIAL TOOLS .

EL 42000 Battery Tester

For equivalent regional tools, refer to SPECIAL TOOLS .

EL 42000 Battery Tester

For equivalent regional tools, refer to SPECIAL TOOLS .

EL 38758 Parasitic Draw Test Switch

For equivalent regional tools, refer to SPECIAL TOOLS .

Location (pos)

1. 01 - Front
2. 02 - Rear
3. 03 - Left
4. 04 - Right Hand
5. 05 - All
6. 06 - Upper
7. 07 - Center
8. 08 - Lower
9. 09 - Service Information

1. 01 - Front
2. 02 - Rear
3. 03 - Left
4. 04 - Right Hand
5. 05 - All
6. 06 - Upper
7. 07 - Center
8. 08 - Lower
9. 09 - Service Information

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1. Reposition the ECM and the battery cover.
2. Disconnect the current sensor.
3. Remove the negative battery cable clamp (1) and the left front radiator support ground terminal (2).
4. Remove the battery fuse block cover (1).
5. Remove the battery positive nut (2) from battery fuse block and detach retainer (3) from the battery tray.
6. Remove the secondary air injection pump. See «SECONDARY AIR INJECTION PUMP REPLACEMENT»(ref-652236-S20280889082014082300000) .
7. Remove the battery positive terminal (4) and nut (1) from the starter solenoid.
8. Remove the battery negative engine block ground bolt (1) and the harness retainer bolt (2).
9. Slide the protective boot (2) and remove the generator nut (3) along with the battery positive terminal (4).
10. Remove the battery positive and negative cable from the vehicle. NOTE: Observe how the battery positive and negative cable was routed within the engine compartment.

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1. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) . Install the battery positive terminal (4) and nut (3) to the back of the generator and tighten to 15 Nm (11 lb ft).
2. Install the battery positive terminal (4) and nut (1) to the starter motor solenoid and tighten to 15 Nm (11 lb ft).
3. Install the negative battery ground bolt (1) to the engine block and tighten to 45 Nm (33 lb ft)
4. Refit the secondary air pump attachment bracket on the engine block. See «SECONDARY AIR INJECTION PUMP REPLACEMENT»(ref-652236-S20280889082014082300000) .
5. Install the ground terminal (2) to the left front radiator support and tighten to 25 (18 lb ft)
6. Install the battery post negative terminal clamp (1) and tighten to 12 Nm (9 lb ft).
7. Install the positive battery cable terminal and nut (2) to the battery fuse block. Tighten to 15 Nm (11 lb ft).
8. Install the battery fuse block cover (1).

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1. Remove the ground wire terminal on the negative battery clamp.
2. Disconnect the current sensor from the engine harness.
3. Remove the negative battery cable clamp (1) and the left front radiator support ground terminal (2).
4. Remove the battery fuse block cover (1).
5. Remove the battery positive nut (2) from battery fuse block and detach retainer (3) from the battery tray.
6. Remove the nut (1) from underneath the protective boot behind the generator.
7. Remove the battery positive cable terminal from the generator.
8. Remove the starter solenoid nut (2) and battery positive cable terminal from the starter solenoid.
9. Remove the negative battery cable bolt (3) and terminal from the back of the left cylinder head.
10. Remove the harness retainer band clip nut (4).
11. Remove the harness retainer band clip bolt (5).
12. NOTE: Note Observe how the battery positive and negative cable was routed within the engine compartment. Remove the battery positive and negative cable (6).

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1. Install the retainers that hold the battery cable harness to the battery tray. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) .
2. Install the battery cable harness to the engine block with retainer (4). Tighten to 9 Nm (80 lb in).
3. Install the battery cable harness to the engine block with retainer (5). Tighten to 45 Nm (33 lb ft).
4. Install the negative battery cable terminal and bolt (3) to the left rear cylinder head. Tighten to 45 Nm (33 lb ft).
5. Install the battery positive cable terminal and nut (2) to the starter solenoid. Tighten to 15 Nm (11 lb ft).
6. Install the battery positive cable terminal and nut (1) to the back of the generator. Tighten to 15 Nm (11 lb ft).
7. Install the positive battery cable terminal and nut (2) to the battery fuse block. Tighten to 15 Nm (11 lb ft).
8. Install the battery fuse block cover (1).
9. Install the ground terminal (2) to the left front radiator support and tighten to 25 (18 lb ft).
10. Install the battery post negative terminal clamp (1) and tighten to 12 Nm (9 lb ft).
11. Connect the current sensor to the engine harness.
12. Attach the ground terminal to the negative clamp post.

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1. Remove the battery fuse block/engine control module cover.
2. Disconnect the negative battery terminal (1). Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000)
3. Remove the negative battery ground terminal (2).
4. Remove the auxiliary negative battery ground bolt (2).
5. Remove the engine block battery ground terminal (1) and bolt (2).
6. Remove the negative battery cable (3).

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1. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) . Install the negative battery cable harness (3) to the engine block with retainer (1) and bolt (2). Tighten to 45 Nm (33 lb ft).
2. Install the negative battery ground bolt (2) and retainer. Tighten to 22 Nm (16 lb ft).
3. Install the negative battery post clamp (1). Tighten to 9 Nm (80 lb in).

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1. Remove the battery fuse block cover/engine control module (ECM).
2. Loosen the auxiliary negative battery post terminal nut (1) and remove the auxiliary negative battery post clamp.
3. Remove the auxiliary negative battery ground bolt (2).
4. Remove the auxiliary negative battery terminal (1) and bolt (2) from the left front engine block.
5. Remove the auxiliary negative battery cable.

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1. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) . Install the auxiliary negative battery cable harness (3) to the engine block with retainer (1) and bolt (2). Tighten to 45 Nm (33 lb ft).
2. Install the auxiliary negative battery ground bolt (2) and retainer. Tighten to 22 Nm (16 lb ft).
3. Install the auxiliary negative battery post clamp (1). Tighten to 9 Nm (80 lb in)

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1. Remove the battery fuse block cover (1).
2. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000)
3. Remove the auxiliary battery positive terminal nut (2) from the fuse block.
4. Remove the nut (1) from the rear of the generator
5. Remove the nut (2) from the starter solenoid.
6. Remove the auxiliary battery positive cable from the vehicle.

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1. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) . Install the auxiliary battery positive cable nut (2) to the fuse block. Tighten to 15 Nm (11 lb ft).
2. Install the auxiliary battery positive terminal nut (1) to the back of the generator. Tighten to 15 Nm (11 lb ft).
3. Install the auxiliary battery positive terminal nut (2) to the starter solenoid. Tighten to 15 Nm (11 lb ft).
4. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000)

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1. Turn OFF the ignition.
2. Disconnect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
3. Remove the secondary air injection pump. Refer to «SECONDARY AIR INJECTION PUMP REPLACEMENT»(ref-652236-S20280889082014082300000) .
4. Remove the battery positive cable nut (1) and terminal (4) from the starter.
5. Remove the engine wiring harness nut (2) and the engine harness terminal (3) from the starter solenoid.
6. Remove the starter mounting bolts (1).
7. Remove the starter (2) from the engine.

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1. Install the starter motor (2).
2. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) . Install the starter motor mounting bolts (1) and tighten to 58 Nm (43 lb ft).
3. Install the battery positive cable terminal (4) and nut (1) to the starter motor solenoid and tighten to 15 Nm (9 lb ft).
4. Install the engine harness (3) and nut (2) to the starter motor solenoid and tighten to 6 Nm (53 lb in).
5. Reposition and install the secondary air injection pump and bracket. Refer to «SECONDARY AIR INJECTION PUMP REPLACEMENT»(ref-652236-S20280889082014082300000) .
6. Connect the battery negative cable.

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1. Turn OFF the ignition.
2. Disconnect the battery negative cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
3. Remove the heat shield (2) from the starter.
4. Remove the left catalytic cylinder head nuts and reposition catalytic converter away from cylinder head.
5. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-652230-S26645367622014082300000)
6. Disconnect the knock sensor connector.
7. Remove the battery positive nut (1) and the engine harness connector (2), from the starter solenoid (3).
8. Remove the starter motor bolts (1).
9. Remove the starter motor (2).

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1. Install the starter motor (2).
2. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) . Install the starter motor mounting bolts. Tighten to 58 Nm (43 lb ft).
3. Install the battery positive cable and engine harness connector to the starter. Tighten the battery positive cable nut (1) to 15 Nm (9 lb ft).
4. Install the engine harness connector to the starter solenoid.
5. Install the starter heat shield (2) and tighten the bolt (1) to 7 Nm (62 lb in).
6. Connect the knock sensor connector.
7. Install the left catalytic converter to the cylinder head.

Tighten

1. First Pass: 20 Nm (15 lb ft)
2. Final pass 46 Nm (34 lb ft)

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1. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
2. Remove the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-652231-S13574774562014082300000) .
3. Reposition the positive battery cable boot at the generator terminal.
4. Disconnect the engine harness electrical connector (1) from the generator.
5. Remove the positive battery cable nut (3) at the generator.
6. Remove the positive battery cable terminal (4) from the generator.
7. Remove the idler pulley bolt (1) and idler pulley (2). Refer to «DRIVE BELT IDLER PULLEY REPLACEMENT»(ref-652231-S13574774562014082300000) .
8. Remove the generator bolts (3).
9. NOTE: When removing the generator from the vehicle, it may be necessary to maneuver the generator to remove it from the vehicle. Remove the generator (4).

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1. Position the generator (4) to the engine.
2. Loosely install the generator bolts (3).
3. Install the idler pulley. Refer to «DRIVE BELT IDLER PULLEY REPLACEMENT»(ref-652231-S13574774562014082300000) .
4. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) . Tighten the generator bolts (3) in the sequence shown to 58 Nm (43 lb ft).
5. Install the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-652231-S13574774562014082300000) .
6. Connect the engine harness electrical connector (1) to the generator.
7. Install the positive battery cable terminal (4) to the generator.
8. Install the positive battery cable nut (3) at the generator and tighten to 15 Nm (11 lb ft).
9. Position the positive battery cable boot at the generator terminal.
10. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .

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1. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
2. Reposition the positive battery cable boot at the generator terminal.
3. Disconnect the engine harness electrical connector (1) from the generator.
4. Remove the positive battery cable nut (2) at the generator.
5. Remove the positive battery cable terminal (3) from the generator.
6. Remove the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-652231-S13574774562014082300000) .
7. Remove the idler pulley bolt (1) and idler pulley (2). Refer to «DRIVE BELT IDLER PULLEY REPLACEMENT»(ref-652231-S13574774562014082300000) .
8. Remove the generator bolts (3).
9. NOTE: When removing the generator from the vehicle, it may be necessary to maneuver the generator to remove it from the vehicle. Remove the generator (4).

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1. Position the generator (4) to the engine.
2. Loosely install the generator bolts (3).
3. Install the idler pulley. Refer to «DRIVE BELT IDLER PULLEY REPLACEMENT»(ref-652231-S13574774562014082300000) .
4. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) . Tighten the generator bolts in the sequence shown to 50 Nm (37 lb ft).
5. Install the drive belt. Refer to «DRIVE BELT REPLACEMENT»(ref-652231-S13574774562014082300000) .
6. Connect the engine harness electrical connector to the generator (1).
7. Install the positive battery cable terminal to the generator.
8. Install the positive battery cable nut at the generator and tighten to 15 Nm (11 lb ft).
9. Position the positive battery cable boot at the generator terminal.
10. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .

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