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Body: Component Locations Saab 9-4X I

Exterior/interior Trim 28 illustrations ~1839 words

Special Tools

Illustration Tool Number/Description CH 904 Base Frame CH 24319-B J 24319-B Steering Linkage and Tie Rod Puller CH 43631 J 43631 Ball Joint Remover CH 45725 J 45725 Bushing Remover/Installer CH 49289 Centering Adapter CH 49290 Mounting Engine-Transmission DT 39580 J 39580 Engine Support Stand EN 47649 Engine Bridge EN 47650 Carrier Frame

Scheme 217

Scheme 217: Special Tools
Scheme 217: Special Tools

Scheme 218

Scheme 218
Scheme 218

Scheme 219

Scheme 219
Scheme 219

Scheme 220

Scheme 220
Scheme 220

Scheme 221

Scheme 221
Scheme 221

Scheme 222

Scheme 222: Structure Identification
Scheme 222: Structure Identification
NumberDescriptionMaterialProcedure
1Radiator Support AssemblyMILD STEELFRONT END UPPER TIE BAR REPLACEMENT
2Front Wheelhouse AssemblyMILD STEELFRONT WHEELHOUSE PANEL REPLACEMENT
3Upper PlenumMILD STEELPLENUM UPPER PANEL REPLACEMENT
4Body Side OuterMILD STEEL A-Pillar and Roof Rail Reinforcements ULTRA HIGH STRENGTH STEELCenter Pillar Sectioning Body Side Outer Panel Sectioning QUARTER OUTER PANEL SECTIONING
5Outer Roof PanelMILD STEELROOF OUTER PANEL REPLACEMENT
6Rear End PanelMILD STEELBODY REAR END PANEL REPLACEMENT
7Rear Floor PanelMILD STEELREAR COMPARTMENT FLOOR PANEL SECTIONING
8Rear Rail AssemblyMILD STEELREAR RAIL REPLACEMENT
9Rear WheelhouseMILD STEELREAR WHEELHOUSE INNER PANEL REPLACEMENT
10Center pillarReinf-C/Plr Otr, Reinf-C/Plr Inr Lwr, Reinf-C/Plr Ctr MILD STEEL Reinf-C/Plr Inr, C/Plr Inr, Reinf-C/Plr Otr Upr DUAL PHASE STEELCENTER PILLAR OUTER PANEL REINFORCEMENT REPLACEMENT
11Rear DoorMILD STEELREAR SIDE DOOR OUTER PANEL REPLACEMENT
12Front Side DoorMILD STEELFRONT SIDE DOOR OUTER PANEL REPLACEMENT
13Side Door Impact BeamsULTRA HIGH STRENGTH STEELNot Serviced
14Rocker PanelULTRA HIGH STRENGTH STEELROCKER INNER PANEL REINFORCEMENT REPLACEMENT
15Front Hinge PillarMILD STEELFRONT INNER HINGE PILLAR BODY REPLACEMENT or FRONT HINGE PILLAR BODY SECTIONING
16Upper RailMILD STEELFRONT COMPARTMENT UPPER SIDE RAIL REPLACEMENT
17Front Rail AssemblyMILD STEELFRONT COMPARTMENT FRONT HALF RAIL REPLACEMENT

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

Scheme 223

Scheme 223: Removal Procedure
Scheme 223: Removal Procedure

Scheme 224

Scheme 224
Scheme 224
  1. Refer to «WARNING: APPROVED EQUIPMENT FOR COLLISION REPAIR»(ref-652229-S12579365752014082300000) . Refer to «WARNING: HANDLING GLASS AND SHEET METAL»(ref-652229-S08961136482014082300000) . NOTE: Before beginning the repair, refer to «METAL PANEL BONDING»(ref-652247-S20962079342014082300000) for proper adhesive applicator preparations and general information. Disable the supplemental inflatable restraint (SIR) system. Refer to «SIR DISABLING AND ENABLING»(ref-652256-S30261659692014082300000) .
  2. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible to factory specifications. Refer to «BODY DIMENSIONS»(ref-652247-S22361932072014082300000) .
  5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary.
  6. NOTE: Do not damage any inner panels or reinforcements. Record the number and location of the original welds for installation of the service part. Locate and drill out all factory welds (1).
  7. Remove the damaged tie bar assembly (1).

Scheme 225

Scheme 225: Installation Procedure
Scheme 225: Installation Procedure

Scheme 226

Scheme 226
Scheme 226

Scheme 227

Scheme 227
Scheme 227
  1. NOTE: If the location of the original plug welds cannot be determined or structural weld-thru adhesive was present, space plug weld holes every 40 mm (1 1/2 in) apart. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel (1).
  2. Prepare all mating surfaces as necessary.
  3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces.
  4. Place the crossmember on the vehicle using the 3-dimensional measuring equipment (1). Secure the crossmember in place with clamps.
  5. Plug weld accordingly (1).
  6. Clean and prepare all welded surfaces.
  7. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
  8. Paint the repair area. Refer to «BASECOAT/CLEARCOAT PAINT SYSTEMS»(ref-652267-S18850513642014082300000) .
  9. Install all related panels and components.
  10. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
  11. Activate the SIR system. Refer to «SIR DISABLING AND ENABLING»(ref-652256-S30261659692014082300000) .

Scheme 228

Scheme 228: Removal Procedure
Scheme 228: Removal Procedure

Scheme 229

Scheme 229
Scheme 229

Scheme 230

Scheme 230
Scheme 230

Scheme 231

Scheme 231
Scheme 231
  1. See «WARNING: APPROVED EQUIPMENT FOR COLLISION REPAIR»(ref-652229-S12579365752014082300000) and «WARNING: HANDLING GLASS AND SHEET METAL»(ref-652229-S08961136482014082300000) Disable the supplemental inflatable restraint (SIR) system. Refer to «SIR DISABLING AND ENABLING»(ref-652256-S30261659692014082300000) .
  2. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible to factory specifications. Refer to «BODY DIMENSIONS»(ref-652247-S22361932072014082300000) .
  5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary. Refer to «ANTI-CORROSION TREATMENT AND REPAIR»(ref-652267-S41342353542014082300000) .
  6. Remove the front tie bar. Refer to «FRONT END UPPER TIE BAR REPLACEMENT»(ref-652247-S01549557992014082300000) .
  7. NOTE: Do not damage any inner panels or reinforcements. Locate and drill out all factory welds. Note the number and location of the welds for installation of the front wheelhouse.
  8. Remove the damaged front wheelhouse.

Scheme 232

Scheme 232: Installation Procedure
Scheme 232: Installation Procedure

Scheme 233

Scheme 233
Scheme 233

Scheme 234

Scheme 234
Scheme 234

Scheme 235

Scheme 235
Scheme 235
  1. NOTE: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
  2. Prepare all mating surfaces as necessary.
  3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces.
  4. Position the front wheelhouse to the vehicle using 3-dimensional measuring equipment. Clamp the front wheelhouse into place.
  5. Plug weld accordingly.
  6. Replace the tie bar. Refer to «FRONT END UPPER TIE BAR REPLACEMENT»(ref-652247-S01549557992014082300000) .
  7. Clean and prepare all welded surfaces.
  8. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
  9. Paint the repair area. Refer to «BASECOAT/CLEARCOAT PAINT SYSTEMS»(ref-652267-S18850513642014082300000) .
  10. Install all related panels and components.
  11. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
  12. Activate the SIR system. Refer to «SIR DISABLING AND ENABLING»(ref-652256-S30261659692014082300000) .

Scheme 236

Scheme 236: Removal Procedure
Scheme 236: Removal Procedure

Scheme 237

Scheme 237
Scheme 237
  1. Refer to «WARNING: APPROVED EQUIPMENT FOR COLLISION REPAIR»(ref-652229-S12579365752014082300000) . Refer to «WARNING: HANDLING GLASS AND SHEET METAL»(ref-652229-S08961136482014082300000) . Disable the supplemental inflatable restraint (SIR) system. Refer to «SIR DISABLING AND ENABLING»(ref-652256-S30261659692014082300000) .
  2. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible to factory specifications. Refer to «BODY DIMENSIONS»(ref-652247-S22361932072014082300000) .
  5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary.
  6. NOTE: Do not damage any inner panels or reinforcements. Record the number and location of the original welds for installation of the service part. Locate and drill out all factory welds (1).
  7. Remove the damaged front upper outer rail (1).

Scheme 238

Scheme 238: Installation Procedure
Scheme 238: Installation Procedure

Scheme 239

Scheme 239
Scheme 239

Scheme 240

Scheme 240
Scheme 240
  1. NOTE: If the location of the original plug welds cannot be determined or structural weld-thru adhesive was present, space plug weld holes every 40 mm (1 1/2 in) apart. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel (1).
  2. Prepare all mating surfaces as necessary.
  3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces.
  4. Place the front upper outer member on the vehicle using the 3-dimensional measuring equipment (1). Clamp the front upper outer member in place.
  5. Plug weld accordingly (1).
  6. Clean and prepare all welded surfaces.
  7. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
  8. Paint the repair area. Refer to «BASECOAT/CLEARCOAT PAINT SYSTEMS»(ref-652267-S18850513642014082300000) .
  9. Install all related panels and components.
  10. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
  11. Activate the SIR system. Refer to «SIR DISABLING AND ENABLING»(ref-652256-S30261659692014082300000) .

Scheme 241

Scheme 241: Removal Procedure
Scheme 241: Removal Procedure
  1. Refer to «WARNING: APPROVED EQUIPMENT FOR COLLISION REPAIR»(ref-652229-S12579365752014082300000) . Refer to «WARNING: HANDLING GLASS AND SHEET METAL»(ref-652229-S08961136482014082300000) . Disable the supplemental inflatable restraint (SIR) system. Refer to «SIR DISABLING AND ENABLING»(ref-652256-S30261659692014082300000) .
  2. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
  3. Remove all related panels and components.
  4. Repair as much of the damage as possible to factory specifications. Refer to «BODY DIMENSIONS»(ref-652247-S22361932072014082300000) .
  5. Note the location and remove the sealers and anti-corrosion materials from the repair area, as necessary.
  6. NOTE: Do not damage any inner panels or reinforcements. Locate and drill out all factory welds. Note the number and location of the welds for installation of the plenum top panel.
  7. Remove the damaged plenum top panel.

Scheme 242

Scheme 242: Installation Procedure
Scheme 242: Installation Procedure
  1. NOTE: If the location of the original plug weld holes can not be determined, space the plug weld holes every 40 mm (1 1/2 in) apart. Some panels may have structural weld-thru adhesive. It is necessary to replace the weld-thru adhesive with an additional spot weld between each factory spot weld. Drill 8 mm (5/16 in) plug weld holes in the service part as necessary in the locations noted from the original panel.
  2. Prepare all mating surfaces as necessary.
  3. Apply GM-approved Weld-Thru Coating or equivalent to all mating surfaces.
  4. Position the plenum top panel to the vehicle using 3-dimensional measuring equipment. Clamp the plenum top panel into place.
  5. Plug weld accordingly.
  6. Clean and prepare all welded surfaces.
  7. Apply the sealers and anti-corrosion materials to the repair area, as necessary.
  8. Paint the repair area. Refer to «BASECOAT/CLEARCOAT PAINT SYSTEMS»(ref-652267-S18850513642014082300000) .
  9. Install all related panels and components.
  10. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-652241-S38358954022014082300000) .
  11. Activate the SIR system. Refer to «SIR DISABLING AND ENABLING»(ref-652256-S30261659692014082300000) .

EN 49411 Angle Meter

For equivalent regional tools, refer to SPECIAL TOOLS .

Scheme 243

Scheme 243: Removal Procedure
Scheme 243: Removal Procedure
  1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-652230-S26645367622014082300000) .
  2. Remove the rear tire and wheel assemblies. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-652234-S18162824462014082300000) .
  3. Remove the rear muffler assembly. Refer to «EXHAUST MUFFLER REPLACEMENT (LAU)»(ref-652240-S40705104932014082300000) or «EXHAUST MUFFLER REPLACEMENT (LF1)»(ref-652240-S40846863702014082300000) .
  4. Disconnect the stabilizer shaft from stabilizer shaft links. Refer to «STABILIZER SHAFT REPLACEMENT»(ref-652269-S17875919072014082300000) .
  5. Remove the left park brake cable from the support. Refer to «PARKING BRAKE REAR CABLE REPLACEMENT - LEFT SIDE (FRONT WHEEL DRIVE)»(ref-652264-S34513402752014082300000) or «PARKING BRAKE REAR CABLE REPLACEMENT - LEFT SIDE (ALL WHEEL DRIVE)»(ref-652264-S29904371342014082300000) .
  6. Remove the right park brake cable from the support. Refer to «PARKING BRAKE REAR CABLE REPLACEMENT - RIGHT SIDE (FWD)»(ref-652264-S14454950442014082300000) or «PARKING BRAKE REAR CABLE REPLACEMENT - RIGHT SIDE (ALL WHEEL DRIVE)»(ref-652264-S10689707462014082300000) .
  7. Remove the rear axle lower control arms from the vehicle. Refer to «REAR AXLE LOWER CONTROL ARM REPLACEMENT»(ref-652268-S28985295812014082300000) .
  8. Remove the adjust links from the from the vehicle. Refer to «ADJUST LINK REPLACEMENT»(ref-652268-S05091175982014082300000) .
  9. Remove rear axle upper control arm inner fasteners. Refer to «REAR AXLE UPPER CONTROL ARM REPLACEMENT»(ref-652268-S01774238572014082300000) .
  10. Position a transmission jack under the rear support and firmly secure the support to the jack with straps.
  11. Mark the position of the support to the body with spray paint.
  12. Remove the support bolts and discard them.
  13. With the aid of an assistant, lower the support from the transmission jack stand.
  14. Remove the stabilizer shaft from the rear support.

Scheme 244

Scheme 244: Installation Procedure
Scheme 244: Installation Procedure
  1. NOTE: When transferring any suspension components, refer to each suspension component replacement procedure for the proper torque specifications. Install the stabilizer shaft assembly on to the support. Refer to «STABILIZER SHAFT REPLACEMENT»(ref-652269-S17875919072014082300000) .
  2. With the aid of an assistant, position the rear support onto the transmission jack and firmly secure the support to the jack with straps.
  3. Refer to «CAUTION: RETAINER»(ref-652229-S20487768742014082300000) . Using the EN-49411 angle meter, install the NEW support bolts and tighten to: First Pass: 100 Nm (74 lb ft) Final Pass: plus 90 degrees
  4. Remove the transmission jack.
  5. Install the rear axle upper control arm inner fasteners. Refer to «REAR AXLE UPPER CONTROL ARM REPLACEMENT»(ref-652268-S01774238572014082300000) .
  6. Install the adjust links to the support. Refer to «ADJUST LINK REPLACEMENT»(ref-652268-S05091175982014082300000) .
  7. Install the rear axle lower control arms. Refer to «REAR AXLE LOWER CONTROL ARM REPLACEMENT»(ref-652268-S28985295812014082300000) .
  8. Install the left park brake cable to the support. Refer to «PARKING BRAKE REAR CABLE REPLACEMENT - LEFT SIDE (FRONT WHEEL DRIVE)»(ref-652264-S34513402752014082300000) or «PARKING BRAKE REAR CABLE REPLACEMENT - LEFT SIDE (ALL WHEEL DRIVE)»(ref-652264-S29904371342014082300000) .
  9. Install the right park brake cable to the support. Refer to «PARKING BRAKE REAR CABLE REPLACEMENT - RIGHT SIDE (FWD)»(ref-652264-S14454950442014082300000) or «PARKING BRAKE REAR CABLE REPLACEMENT - RIGHT SIDE (ALL WHEEL DRIVE)»(ref-652264-S10689707462014082300000) .
  10. Install the rear muffler assembly. Refer to «EXHAUST MUFFLER REPLACEMENT (LAU)»(ref-652240-S40705104932014082300000) or «EXHAUST MUFFLER REPLACEMENT (LF1)»(ref-652240-S40846863702014082300000)
  11. Connect the stabilizer shaft links to the stabilizer shaft. Refer to «STABILIZER SHAFT REPLACEMENT»(ref-652269-S17875919072014082300000) .
  12. Install the rear tire and wheel assemblies. Refer to «TIRE AND WHEEL REMOVAL AND INSTALLATION»(ref-652234-S18162824462014082300000) .
  13. Lower the vehicle.
  14. Realign the rear suspension. Refer to «WHEEL ALIGNMENT MEASUREMENT»(ref-652234-S16703614562014082300000) .

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