A/c-Heater System: Removal & Installation Saab 9-5 I

REMOVAL & INSTALLATION

Note. Before working on any ACC component, wait at least 30 seconds after turning ignition off, to give system time to reset valve motors and store any fault codes.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Disconnect compressor clutch electrical connector (located behind right headlight). Relieve tension on drive belt by compressing and locking drive belt tensioner using a 3-mm Allen socket.
2. Remove and set aside intake air duct without disconnecting mass airflow sensor connector. Remove exhaust manifold heat shield. Disconnect by-pass line and valve and set aside.
3. Disconnect radiator/condenser cooling fans connectors located on fan cowl. Release clamps holding hose to top of coolant expansion tank. Release clamps holding A/T cooling hose from bottom of fan cowl. Remove fan cowl, Remove pressure hose from turbo.
4. Disconnect A/C compressor high pressure and low pressure hoses, plug exposed openings and set aside. Remove drive belt. Starting with top bolt, remove 3 A/C compressor mounting bolts and remove compressor.
5. To install, reverse removal procedure. Lubricate "O" rings with synthetic vaseline. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(ref-353-S30900975292000030800000) . Evacuate and charge A/C system. Operate A/C compressor with engine speed at more than 1500 RPM for at least 2 minutes to distribute refrigerant oil throughout system. Check A/C-heater system for proper operation.

Note. Automatic Climate Control (ACC) system will not operate properly until replacement module has been programmed. See PROGRAMMING USING SCAN TOOL under ACC CONTROL MODULE PROGRAMMING.

Disconnect negative battery cable. Remove radio using Removal Handles (84-71-161). Insert each removal handle into holes located in face of radio until handles lock with a clicking sound. Using removal handles, remove radio. Disconnect radio connector and antenna to gain access to ACC control module. Remove ACC control module and disconnect connector. To install, reverse removal procedure.

1. Position a pan under vehicle to collect engine coolant. Disconnect heater hoses at engine and drain engine coolant. Using compressed air, carefully blow into heater hose to remove remaining coolant from heater core.
2. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove instrument panel. See «INSTRUMENT PANEL»(ref-353-S25076532082000030800000) . Remove ground connections from instrument panel support.
3. Remove cable ties holding wiring harness to instrument panel support. Remove middle cable conduit. Remove driver's side and passenger's side knee shields. Remove relay box. Remove steering column-to-steering gear pinch bolt. Press lower steering column shaft upward and remove from steering gear. Remove lower steering column bolt as far as possible. Remove cable ties and move wiring harness away from steering column. Remove 2 upper steering column bolts. Remove steering column as a complete assembly.
4. Remove A/T control module and set aside. Disconnect 4 connectors on passenger's side of A/C-heater unit. In engine compartment, remove line between charge-air cooler and throttle body. Remove charge-air by-pass valve solenoid valve holder cover. Disconnect solenoid valve connector and remove holder from firewall. Disconnect heater hoses to heater core at firewall. Disconnect A/C system lines at expansion valve and plug exposed openings. Remove expansion valve and plug exposed openings.
5. Move front seat to full forward position. If electric seat operation is not functioning, use Emergency Seat Crank (84-71-187) to move seat. Remove 2 rear seat anchor bolts. Move seat to full rear position and remove 2 front seat anchor bolts. Tilt seat assembly back. Remove cable tie and disconnect connector located under seat. Remove seat from vehicle. Fold carpet out of the way, and remove air ducts under front seats.
6. Disconnect evaporator condensation drain hoses on both sides of A/C-heater unit. From engine compartment, remove 3 A/C-heater unit bolts. Lift A/C-heater unit and remove it past gear selector mounting. Ensure any coolant spillage is thoroughly cleaned up.
7. To install, reverse removal procedure. Tighten nuts and bolts to specification. See «TORQUE SPECIFICATIONS»(ref-353-S30900975292000030800000) . Lubricate "O" rings with synthetic vaseline. Evacuate and charge A/C system. Refill and bleed cooling system. See «REFILLING ENGINE COOLING SYSTEM»(ref-353-S17245395042000030800000) under ADJUSTMENTS.

1. Turn air recirculation control off. see scheme 1 Turn ignition off. Using a 2-jaw puller, remove wiper arms. Remove wiper arm shaft seals. Remove retaining clips from middle portion of rubber molding along edge of firewall. Loosen, but DO NOT remove outer retaining clips.
2. Loosen cover over firewall partition space that is held in place with clips by carefully lifting cover forward until it is released from windshield. Hold hood release cable to one side, lift cover backward, toward windshield and remove cover. Using a screwdriver, release water shield front clips and remove water shield.
3. Remove 4 wiper motor assembly bolts, disconnect wiper motor connector, and remove wiper motor assembly. Remove 2 clips and 2 bolts on front edge of frame, around blower motor, and remove frame. Remove 3 wiper arm bracket bolts and remove bracket.
4. Mark routing of blower motor control module wiring harness and seals. Cut cable ties as necessary and move wiring harness aside. (Scheme 5) Remove blower motor cover. Remove blower motor, cut wiring harness cable tie, and disconnect blower motor.
5. To install, reverse removal procedure. Ensure blower motor fan frame is properly aligned in grooves and fan turns without interference. Check that wiring harness does not touch blower motor or air recirculation flap.
6. After connecting blower motor connector, secure wiring harness using a cable tie. Ensure blower motor cover and gasket do not interfere with air recirculation flap. Ensure blower motor wiring harness is routed and secured properly. Ensure seals are installed in each side of A/C-heater unit.
7. Tighten wiper motor assembly to specification. See «TORQUE SPECIFICATIONS»(ref-353-S30900975292000030800000). Driver's side wiper blade mounting on wiper arm should be installed 1.5" (39 mm) from cover. Passenger's side wiper blade mounting on wiper arm should be installed 2.25" (57 mm) from cover.

Scheme 5

1. Remove driver's side lower instrument panel. Remove Data Link Connector (DLC) and disconnect floor light connector. Disconnect accelerator cable and remove accelerator pedal assembly.
2. Remove glove compartment and passenger's side of center console. Disconnect 2 connectors located above intake air filter in A/C-heater housing. Cut cable ties and remove connectors from mounting plate. (Scheme 6)
3. Remove blower motor assembly. See «BLOWER MOTOR ASSEMBLY»(ref-353-S01175263612000030800000). Mark routing of blower motor control module wiring harness and rubber seals. Cut cable ties as necessary. Remove blower motor control module.
4. To install, reverse removal procedure. Ensure wiring harness, cable ties, rubber seals and connectors are installed in the same positions. Ensure air recirculation flap movement is not obstructed.

Scheme 6

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove grille and headlights. Remove center cover over radiator.
2. Disconnect A/C pressure sensor connector located on right side of condenser. Disconnect condenser refrigerant lines and plug all exposed openings. Remove air filter housing air duct. Remove condenser with A/C pressure sensor and receiver-drier attached. see scheme 4
3. To install, reverse removal procedure. Transfer components as necessary. Lubricate "O" rings with synthetic vaseline. Tighten A/C pressure sensor and refrigerant lines to specification. See «TORQUE SPECIFICATIONS»(ref-353-S30900975292000030800000).
4. If a new condenser is being installed, add one ounce of refrigerant oil to high-pressure side of compressor. Evacuate and charge A/C system. Check A/C-heater system for proper operation.

Remove grille and right side headlight. Disconnect A/C pressure sensor connector located on right side of condenser. see scheme 4 Remove A/C pressure sensor. To install, reverse removal procedure. Lubricate "O" rings with synthetic vaseline. Tighten sensor to specification. See TORQUE SPECIFICATIONS.

Cabin temperature sensor is located in forward part of overhead panel, between rear view mirror and seat belt reminder display. Remove overhead panel light lens and screw. Disconnect sensor connector and remove sensor. To install, reverse removal procedure.

Removal

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove glove box and trim cover on right side right side of A/C-heater unit. Cut cable tie holding wiring harness to A/C-heater unit service cover. Cut cable tie holding cooler duct to glove box. Remove A/C-heater unit service cover and intake air filter(s). see scheme 3and see scheme 6.
2. Remove blower motor. See «BLOWER MOTOR ASSEMBLY»(ref-353-S01175263612000030800000). If evaporator inlet and outlet lines do not have a joint connection, cut lines as close to evaporator as possible. (Scheme 7) If there is a joint connection, remove connection bolt and separate connection. Remove evaporator by sliding it out passenger's side of A/C-heater unit. (Scheme 8)
3. Remove tip of evaporator temperature sensor from evaporator. Remove expansion valve and plug exposed openings. Remove inlet and outlet lines from A/C-heater unit. Using a vacuum cleaner, remove any cuttings, dust, or debris from A/C-heater unit.

Installation

1. Using 3/16" (4.5 mm) diameter round-tipped tool, create a hole in fifth cooling fin from passenger's side. (Scheme 8) Install evaporator temperature sensor into hole. Position lower portion of replacement inlet and outlet lines from inside vehicle. Position intake air filter holder with evaporator and push into A/C-heater unit.
2. Remove protective plugs from refrigerant lines. Install expansion valve. Connect joint in inlet and outlet lines between firewall grommet and evaporator. Lubricate "O" rings with synthetic vaseline. Tighten evaporator joint and expansion valve bolts to specification. (Scheme 7) See «TORQUE SPECIFICATIONS»(ref-353-S30900975292000030800000). Evacuate and charge A/C system. Add one ounce of refrigerant oil to high-pressure side of compressor. Check A/C-heater system for proper operation. To complete installation, reverse removal procedure.

Scheme 7

1. Remove glove box and trim cover on right side of A/C-heater unit. Cut cable tie holding wiring harness to A/C-heater unit service cover. Cut cable tie holding cooler duct to glove box. Remove A/C-heater unit service cover and intake air filter(s). see scheme 3
2. Carefully reach into filter holder and remove evaporator temperature sensor. Disconnect sensor connector, lift-up connector plate, and remove sensor connector from plate. (Scheme 8) Carefully install evaporator temperature sensor into existing hole. To complete installation, reverse removal procedure.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. In engine compartment, remove line between charge-air cooler and throttle body. Remove charge-air by-pass valve solenoid valve holder cover. Disconnect solenoid valve connector and remove holder from firewall.
2. Disconnect A/C system refrigerant lines at expansion valve and plug exposed openings. see scheme 4and (Scheme 8). Remove expansion valve and plug exposed openings to evaporator.
3. Lubricate "O" rings with synthetic vaseline and install on evaporator inlet and outlet lines. Press expansion valve onto inlet and outlet lines and tighten screws to specification. See «TORQUE SPECIFICATIONS»(ref-353-S30900975292000030800000). To complete installation, reverse removal procedure. Evacuate and charge A/C system to specifications. See «SPECIFICATIONS»(ref-353-S23394425602000030800000). Ensure A/C system is operating properly.

1. Ensure engine coolant is cold. Position a pan under engine to collect engine coolant. Disconnect heater hoses at engine inlet and outlet. Drain engine coolant. Using compressed air, carefully blow into each heater hose to remove coolant from heater core.
2. Remove glove box and trim cover on right side of A/C-heater unit. Remove tape from air outlet and duct, and remove air outlet. see scheme 15 Disconnect heater core inlet pipe and outlet pipe joint. Remove 4 heater core cover screws and slide heater core out.
3. To install, reverse removal procedure. Lubricate "O" rings with synthetic vaseline. Install air outlet and secure to air duct with tape. Refill and bleed cooling system, and check for leaks. See «REFILLING ENGINE COOLING SYSTEM»(ref-353-S17245395042000030800000) under ADJUSTMENTS.

Scheme 8

1. Disable air bag system. See AIR BAG SYSTEM SAFETY article in GENERAL SERVICING. Position steering wheel in a straight-ahead position. Turn ignition off. Remove instrument panel speakers and covers. Remove center cover with ACC solar sensor and/or alarm sensor. Disconnect ACC solar sensor and/or alarm sensor and push connector into hole.
2. Remove glove box and air duct. Remove 2 driver-side air bag side covers, screws and driver-side air bag. Disconnect driver's side air bag, steering wheel controls, and horn connectors. Remove steering wheel using a steering wheel puller. Tape SRS clockspring (contact roller) to steering column to ensure correct positioning is not lost.
3. Remove Data Link Connector (DLC) located under steering column. Remove driver's side lower instrument panel with air duct and floor light. Lift up manual gear shift lever boot (if equipped). Remove compartment or ashtray with holder and 2 screws. Disconnect central locking switch, lift cover and disconnect seat heater, and cigarette lighter connectors. Release steering wheel adjustment. Remove upper and lower steering column covers. Disconnect connectors for steering column switches and remove switches. Remove steering column dust boot.
4. Remove Saab Information Display (SID), radio, and ACC control modules. Remove side cover on left end of instrument panel, headlight control switch, hazard flasher switch and other switches. Release 4 clips and remove 6 switch panel screws. Remove switch panel. Remove fuse box located at left end of instrument panel. Remove steering column boot. Remove instrument cluster and driver's side air duct. Disconnect passenger's side air bag and remove positioning strap.
5. Remove front sill scuff plates. Fold back carpet and remove protective plate in front of lower instrument panel mounting nuts. Lift rear of center console straight up and remove. Position shift lever to Reverse (M/T) or Park (A/T) position and remove ignition key. Lift theft protection cover from ignition lock, disconnect connector, replace ignition key and move shift lever to Neutral position. Disconnect electric window switches. Remove upper part of center console. Make a match-mark between console and locating pin. Remove lower part of console.
6. Remove 2 bolts at either end of instrument panel, near windshield. Loosen nut located in center of instrument panel, near windshield. Remove 2 nuts lower end of instrument panel and then remove center nut. Lift instrument panel up and pull outward to remove. To install, reverse removal procedure. Ensure there are no wires or connectors trapped between supports and components.

1. Remove glove box and trim cover on right side of A/C-heater unit. Remove air distribution flap stepping motor bolts. see scheme 6 Disconnect stepping motor connector and remove stepping motor.
2. To install, reverse removal procedure. Ensure both air distribution flaps are closed when installing stepping motor. Perform ACC system calibration. See «ACC CONTROL MODULE CALIBRATION»(ref-353-S08362475352000030800000) under PROGRAMMING.

1. Remove glove box and trim cover on right side of A/C-heater unit. Remove air recirculation motor bolts. see scheme 6 Disconnect motor connector. Disengage motor arm from slot in air recirculation flap linkage, and remove motor. Cut cable tie securing wiring harness, and remove harness connector from connector mounting plate.
2. To install, reverse removal procedure. Ensure air recirculation flap moves freely between open and closed positions. Ensure motor arm is properly inserted into air recirculation flap linkage. Perform ACC system calibration. See «ACC CONTROL MODULE CALIBRATION»(ref-353-S08362475352000030800000) under PROGRAMMING.

Remove left lower instrument panel under steering column. Remove DLC and floor light. Disconnect left side mixed-air flap stepping motor connector. Remove stepping motor. (Scheme 6) To install, reverse removal procedure. Perform ACC system calibration. See ACC CONTROL MODULE CALIBRATION under PROGRAMMING.

1. Using ACC control panel, set mixed-air temperature to either maximum cold or maximum hot position. Remove glove box and trim cover on right side of A/C-heater unit. Remove right side mixed-air flap stepping motor. Disconnect stepping motor connector. see scheme 6
2. To install, reverse removal procedure. Ensure lower flap is positioned similarly as top flap. Ensure both flaps move simultaneously and without restrictions. Perform ACC system calibration. See «ACC CONTROL MODULE CALIBRATION»(ref-353-S08362475352000030800000) under PROGRAMMING.

1. Disconnect negative battery cable. Remove left lower instrument panel under steering column. Remove DLC and floor light. Remove left side mixed-air temperature sensor from air duct. (Scheme 6)
2. Remove radio using Removal Handles (84-71-161). Insert each removal handle into holes located in face of radio, until handles lock with a clicking sound. Using removal handles, remove radio. Disconnect radio connector and antenna to gain access to ACC control module. Remove ACC control module and disconnect connector.
3. Disconnect Black 10-pin connector mounted on cabin side of A/C-heater unit. see scheme 9 Remove temperature sensor terminals from Black 10-pin connector. Procedure can be simplified by cutting old sensor leads in an appropriate location and replacing sensor leads. To install, reverse removal procedure. Ensure sensor leads are secured to wiring harness.

1. Remove glove box and trim cover on right side of A/C-heater unit. Remove right side mixed-air temperature sensor from air duct. (Scheme 6)
2. Remove radio using Removal Handles (84-71-161). Insert each removal handle into holes located in face of radio, until handles lock with a clicking sound. Using removal handles, remove radio. Disconnect radio connector and antenna to gain access to ACC control module. Remove ACC control module and disconnect connector.
3. Disconnect Gray 10-pin connector mounted on cabin side of A/C-heater unit. see scheme 9 Remove temperature sensor terminals from Gray 10-pin connector. Procedure can be simplified by cutting old sensor leads in an appropriate location and replacing sensor leads. To install, reverse removal procedure. Ensure sensor leads are secured to wiring harness.

1. Discharge A/C system, using approved refrigerant recovery/recycling equipment. Remove grille and left side headlight. Raise and support vehicle. Remove center cover under radiator/condenser. Disconnect refrigerant lines from receiver-drier and plug exposed openings. see scheme 4 Remove receiver-drier.
2. To install, reverse removal procedure. Lubricate "O" rings with synthetic vaseline. Tighten refrigerant line connections to specification. See «TORQUE SPECIFICATIONS»(ref-353-S30900975292000030800000). Evacuate and charge A/C system to specifications. See «SPECIFICATIONS»(ref-353-S23394425602000030800000). Add one ounce of refrigerant oil to high-pressure side of compressor. Check A/C-heater system for proper operation.