Charging System: Maintenance Saab 9-5 I рестайлинг

Battery Maintenance

It is important to check and look after the battery regularly, since its ability to start the engine depends on the state of its charge.

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The load on the starter motor is greater during winter. As the capacity of the battery decreases in cold weather, a battery in good condition is essential. A discharged battery will be damaged if it freezes.

The water level in the battery must be checked at regular intervals.

Keep the battery clean and dry to prevent dirt from entering it while refilling with distilled water and oxide from forming on the terminals.

To avoid oxidation, coat the joint between the battery casing and the terminals with Vaseline.

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Note. If the car is equipped with a radio other than a genuine Saab radio, check that the customer has the radio code before commencing work.

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1. Drape protective covers over the front wings.
2. Lift off the battery cap and disconnect the negative cable.
3. Remove the shield over the intake manifold.
4. Remove the crankcase ventilation solenoid and constant-pressure valves.
5. Relieve the tension on the belt tensioner and remove it. Use special tool «83 95 254 DRAWBAR HANDLE, HYDRAULIC BELT TENSIONER»(ref-212219-S14332940602005122200000) .
6. Remove the generator's upper retaining bolt.
7. Mark and detach the retaining nut on the right-hand engine mounting and lubricate it to give it some mobility.
8. Detach the retaining nut on the rear engine mounting.
9. Remove the front exhaust pipe, see «FRONT EXHAUST SYSTEM WITH THREE-WAY CATALYTIC CONVERTER, 4 CYL.»(ref-212214-S34894270352005122200000) .
10. Remove the hose between the oil trap and the oil sump.
11. Disconnect the terminals B+ and D+ on the generator.
12. Remove the generator's lower retaining bolt.
13. Face the generator and belt pulley downwards between the steering gear and the intermediate shaft.
14. Insert a bar carefully between the gearbox and the subframe.
15. Lower the generator.

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1. To make is easier to refit the generator, tap the bushings until they are level with the mountings.
2. Clean the generator mountings and apply Vaseline to prevent oxidation.
3. Insert a bar carefully between the gearbox and the subframe.
4. Lower the generator.
5. Refit the generator retaining bolts loosely.
6. Clean terminals B+ and D+ and apply Vaseline before connecting them.
7. Refit the hose between the oil trap and the oil sump.
8. Fit the front exhaust pipe, see «FRONT EXHAUST SYSTEM WITH THREE-WAY CATALYTIC CONVERTER, 4 CYL.»(ref-212214-S34894270352005122200000) .
9. Refit the generator's upper retaining bolt.
10. Refit the belt tensioner. Tightening torque: 45 Nm (33 lbf ft)
11. Mount the drive belt. Check the position of the belt on all the pulleys and reapply the tension. Remove the tension reliever.
12. Fit the crankcase ventilation vacuum valve.
13. Adjust the right-hand engine mounting as per the marking. Check that the engine has a neutral position and tighten the retaining nut to the correct torque. Tightening torque: 50 Nm (37 lbf ft).
14. Tighten the retaining nut on the rear engine mounting to the correct torque. Tightening torque: 25 Nm (19 lbf ft).
15. Refit the shield on to the intake manifold.
16. Reconnect the battery's negative cable and refit the cap.
17. Set the clock and reprogram the radio code.
18. Start the engine and let it run at idle speed for a moment. Switch off the engine and check that the belt is correctly positioned.

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Note. If the car is equipped with a radio other than a genuine Saab radio, check that the customer has the radio code before commencing work.

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1. Drape protective covers over the front wings.
2. Lift off the battery cap and disconnect the negative cable.
3. Remove the shield from the intake manifold.
4. Remove the crankcase ventilation solenoid and constant-pressure valves.
5. Relieve the tension on the belt tensioner and remove it. Use special tool «83 95 254 DRAWBAR HANDLE, HYDRAULIC BELT TENSIONER»(ref-212219-S14332940602005122200000) .
6. Remove the generator's upper retaining bolt.
7. Pinch the hoses for the steering servo reservoir inlet and outlet with hose pliers «30 07 739 HOSE PINCH-OFF PLIERS»(ref-212219-S28371521772005122200000) .
8. Mark and detach the retaining nut on the right-hand engine mounting and lubricate it to give it some mobility.
9. Detach the retaining nut on the rear engine mounting.
10. Remove the front exhaust pipe, see «FRONT EXHAUST SYSTEM WITH THREE-WAY CATALYTIC CONVERTER, 4 CYL.»(ref-212214-S34894270352005122200000) .
11. Remove the pipe/hose between the steering gear and the power steering fluid reservoir. Place a collecting vessel under the pipe/hose.
12. Remove the steering gear's two retaining bolts.
13. Remove the hose between the oil trap and the oil sump.
14. Disconnect the terminals B+ and D+ on the generator.
15. Remove the generator's lower retaining bolt.
16. Face the generator and belt pulley downwards between the steering gear and the intermediate shaft.
17. Insert a bar carefully between the gearbox and the subframe.
18. Lower the generator.

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1. To make it easier to fit the generator, tap the bushings until they are level with the mountings.
2. Clean the generator mountings and apply Vaseline to reduce oxidation.
3. Insert a bar carefully between the gearbox and the subframe.
4. Lower the generator.
5. Refit the generator retaining bolts loosely.
6. Clean terminals B+ and D+ and apply Vaseline before connecting them.
7. Refit the hose between the oil trap and the oil sump.
8. Refit the two retaining bolts on to the steering gear.
9. Refit the pipe/hose between the steering gear and the power steering fluid reservoir.
10. Fit the front exhaust pipe, see «FRONT EXHAUST SYSTEM WITH THREE-WAY CATALYTIC CONVERTER, 4 CYL.»(ref-212214-S34894270352005122200000) .
11. Refit the generator's upper retaining bolt.
12. Refit the belt tensioner. Tightening torque: 45 Nm (33 lbf ft)
13. Mount the drive belt and check its position on all the pulleys. Reapply the tension.
14. Fit the crankcase ventilation vacuum valve.
15. Adjust the right-hand engine mounting as per the marking. Check that the engine has a neutral position and tighten the retaining nut to the correct torque. Tightening torque: 50 Nm (37 lbf ft).
16. Tighten the retaining nut on the rear engine mounting to the correct torque. Tightening torque: 25 Nm (19 lbf ft).
17. Refit the shield on to the intake manifold.
18. Reconnect the battery's negative cable and refit the cap.
19. Release the clamps and fill with power steering fluid.
20. Set the clock and reprogram the radio code.
21. Start the engine and let it run at idle speed for a moment. Switch off the engine and check that the belt is correctly positioned.
22. Bleed the power steering system, see «STEERING LINKAGE»(ref-212254)

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1. Remove the negative battery cable. IMPORTANT: Make a note of the belt's direction of rotation. The belt must be refitted for the same direction of rotation as previously.
2. Relieve the tension on the belt tensioner and unhook the multigroove V-belt.
3. Remove the generator air intake by pulling it straight up.
4. Remove the belt tensioner.
5. Raise the car.
6. Remove the front right wheel.
7. Remove the drive belt cover.
8. Remove the engine oil pressure sensor and plug the hole.
9. Remove the wiring harness clip on the generator.
10. Remove the right outboard drive shaft, see «DRIVE SHAFT»(ref-168017-S00640987562004110300000) .
11. Raise the car.
12. Remove the generator connectors.
13. Press the engine forward and fit two «83 95 238 WEDGE»(ref-212219-S29676107322005122200000) (x 5) between the engine and the engine frame.
14. Remove the two generator retaining bolts and lift out the generator through the right wheel housing.

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1. Clean the generator securing points and electrical connections and apply them with Vaseline to prevent oxidation.
2. Insert the generator through the right wheel housing.
3. Fit the generator with the two bolts.
4. Reconnect the cables to the generator.
5. Remove the wedges between the assembly and subframe.
6. Fit the oil pressure sensor.
7. Fit the right outboard drive shaft, see «DRIVE SHAFT»(ref-168017-S00640987562004110300000) .
8. Fit the drive belt cover.
9. Fit the front right wheel.
10. Lower the car.
11. Refit the belt tensioner. Tightening torque: 40 Nm (30 lbf ft).
12. Fit the generator air intake. IMPORTANT: Make a note of the belt's direction of rotation. The belt must be refitted for the same direction of rotation as previously.
13. Refit the multigroove V-belt. NOTE: Make sure that the belt is correctly positioned on all the pulleys.
14. Reconnect the negative cable to the battery.
15. Set the clock.

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In the method described below, the generator has already been removed.

1. Unscrew the three screws and remove the generator's protective housing.
2. Unscrew the two screws that hold the regulator in place and pull it upwards.

The generator brushes are fixed to the regulator. The whole unit must be replaced with a new one.

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1. Carefully straighten the spring tab so that it is in contact with the regulator. Clean and apply a thin layer of Vaseline to prevent oxidation.
2. Clean the ground connection on the regulator and apply Vaseline.
3. Refit the regulator.
4. Refit the protective housing on to the generator.

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1. Take the weight of the engine with a jack.
2. Remove the power steering hose from the clip under the engine mounting.
3. Remove the engine mounting.
4. Relieve the tension of the belt tensioner with «83 95 254 DRAWBAR HANDLE, HYDRAULIC BELT TENSIONER»(ref-212219-S14332940602005122200000) and lift off the belt. IMPORTANT: Be careful not to damage the belt tensioner at its end position!
5. Remove the belt tensioner using an 8 mm Allen key.

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1. Refit the belt tensioner. Tightening torque: 45 Nm (33 lbf ft).
2. Relieve the tension of the belt tensioner with «83 95 254 DRAWBAR HANDLE, HYDRAULIC BELT TENSIONER»(ref-212219-S14332940602005122200000) and insert a 3 mm drill bit, for example, into the hole.
3. Fit the belt, check its position on all pulleys and remove the drill bit to release the belt tensioner.
4. Fit the engine mounting. Tightening torque 47 Nm (36 lbf ft)
5. Attach the power steering hose with the clip.
6. Remove the jack.
7. Rock the engine from side to side until it is in a balanced, neutral position.
8. Fit the nut to the engine bracket. Tightening torque 105 Nm (78 lbf ft)
9. Start the engine and let it run at idle speed for a moment. Switch off the engine and check that the belt is correctly positioned.

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1. Remove the left-hand direction indicator and headlamp, see «MAIN LIGHTING»(ref-212222-S28680571302005122200000) and «DIRECTION INDICATORS»(ref-212222-S34961348982005122200000) .
2. Detach the drain hose from the battery.
3. Unplug the 6-pin connector to the front bumper wiring harness.
4. Insert the wiring harness towards the LH fog light/corner light.
5. Raise the car.
6. Carefully cut the hose away from the wiring harness.

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1. Secure the new hose to the wiring harness with adhesive tape as illustrated. Check the measurement.
2. Insert the wiring harness up to the engine bay
3. Plug in the 6-pin connector on the wiring harness to the front harness.
4. Attach the hose to the battery.
5. Fit the left-hand direction indicator and headlamp, see «MAIN LIGHTING»(ref-212222-S28680571302005122200000) and «DIRECTION INDICATORS»(ref-212222-S34961348982005122200000)
6. Adjust the lights.

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Location: On the left-hand structural member behind the headlamp (battery ground).