Power Steering System: Removal & Installation Saab 9-5 I рестайлинг

To remove

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1. Place the car on a lift.
2. Remove the mass air flow sensor with hose.
3. Detach the power steering servo hose from the engine mounting bracket.
4. Undo the belt pulley bolts slightly.
5. Detention the multigroove V-belt and lift it off the servo pump pulley.
6. Remove the belt pulley.
7. Remove the upper engine cover.
8. Detach the bypass pipe from the turbo inlet pipe and bend it to one side, retrieve the O-ring. NOTE: Blow clean around the connection first.
9. Remove the exhaust manifold heat shield.
10. Disconnect the crankcase ventilation pipe between the turbo inlet pipe and the cylinder head. Retrieve the sealing washers.
11. Remove the turbo inlet pipe and disconnect the quick-release coupling on the hose to the EVAP canister, use special tool 83 95 261.
12. Pinch the inlet hose to the power steering pump and return hose to the reservoir with pinch-off pliers «30 07 739 HOSE PINCH-OFF PLIERS»(ref-212258-S09300014842005122300000) .
13. Disconnect the inlet hose from the pump. Collect any fluid spill. IMPORTANT: Power steering fluid must not come in contact with belt pulleys or belts.
14. Open the filler cap to the cooling system to release any pressure. Remove the dipstick.
15. Undo the bracket for the fluid level pipe and pull up the pipe to detach it from the engine. Replace the screw loosely to keep the water pipe in place. NOTE: Take care, so that the water pipe does not come away from the thermostat mounting allowing water to run out.
16. Detach the pressure (delivery) pipe from the pump, one bracket and one banjo screw. Collect any fluid spill.
17. Remove the pump bracket, 3 bolts.
18. Unscrew the 2 pump retaining bolts and lift out the pump. It may be necessary to undo the engine coolant hose to the turbo and bend the pipe slightly to one side to access the bottom bolt.

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1. Fit the 2 pump bolts and tighten them. Tightening torque 24 Nm (18 lbf ft)
2. Screw in and tighten the 3 bracket bolts. Tightening torque 24 Nm (18 lbf ft)
3. Connect the pressure (delivery) pipe and tighten the banjo nipple on the pump using new seals. Tightening torque 30 Nm (22 lbf ft) Screw the pipe mounting lug to the bracket.
4. Connect the inlet pipe and tighten the hose clip. Remove the pinch-off pliers.
5. Fit the fluid level pipe. Lubricate the O-rings with petroleum jelly, part no. 30 06 665, and press the pipe in place. Fit the screw for the level pipe bracket. Insert the dipstick.
6. Fit the turbo inlet pipe and tighten the V-clip. Tightening torque 3 Nm (2 lbf ft) Press together the quick-release coupling on the hose to the EVAP canister.
7. Fit the crankcase ventilation pipe to the turbo inlet pipe using new sealing washers. Tightening torque 24 Nm (18 lbf ft)
8. Fit the heat shield to the front exhaust manifold.
9. Connect and tighten the turbo bypass pipe with an O-ring. Tightening torque 8 Nm (6 lbf ft) .
10. Fit the belt pulley. Tightening torque 20 Nm + 30° (15 lbf ft + 30°)
11. Take the strain off the belt tensioner and fit the belt. Ensure the belt is fitted correctly on all the belt pulleys.
12. Fit the power steering servo hose to the engine mounting bracket
13. Fit the mass air flow sensor with hose and plug it in.
14. Fit the engine cover.
15. Top up with fluid and bleed as described under «BLEEDING THE POWER STEERING SYSTEM»(ref-212258-S12646339292005122300000) .
16. Check for leakage around the connectors on the pump. Check also the integrity of the cooling system.
17. Raise the car and wipe off any fluid spill on the right-hand engine cover under the car.
18. Lower the car and road test.

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1. Remove the mass air flow sensor with hose.
2. Detach the power steering servo hose from the holder.
3. Undo the belt pulley bolts slightly.
4. Take the strain off the multigroove V-belt and lift it off the servo pump pulley.
5. Remove the belt pulley.

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1. Fit the belt pulley. Tightening torque 20 Nm (15 lbf ft) +(30°) .
2. Take the strain off the belt tensioner and fit the belt. Ensure the belt is fitted correctly on all the belt pulleys.
3. Fit the power steering servo hose to the engine mounting bracket
4. Fit The Mass Air Flow Sensor With Hose And Plug It In.

1. Refill the system with new power steering fluid. NOTE: Always use new fluid. Do not turn the steering wheel, as air can enter the steering gear requiring longer to purge.
2. Run the engine for 5 seconds. IMPORTANT: The pump can be damaged if the engine is run for more than 5 seconds with the fluid level too low.
3. Check the fluid level in the reservoir and top up with 93 160 548 Power steering fluid as necessary. At 20°C it should be between the MAX and MIN markings.
4. Start the engine and let it run until no more bubbles appear in the fluid reservoir. Use a torch to be able to see properly. Abnormal noise from the pump is an indication that there is still air in the system.
5. Switch off the engine and check the fluid level. Top up with 93 160 548 Power steering fluid as necessary.

Removal

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1. Remove the nut from the rear engine mounting.
2. Position the steering wheel in the straight-ahead driving position and fasten it with woven tape to the instrument panel. Remove the bolts that hold the steering shaft to the steering gear, push the steering shaft upwards and withdraw it from the steering gear.
3. Clamp the intake hose of the power steering pump and the return hose to the reservoir with two «30 07 739 HOSE PINCH-OFF PLIERS»(ref-212258-S09300014842005122300000) Pinch-off pliers.
4. 6 cyl. petrol: Remove the battery cover, battery and battery tray.
5. Petrol: Slightly loosen the nuts which attach the exhaust pipe to the turbo so that the pipe can be rotated.
6. Raise the car.
7. Diesel: Remove the lower engine cover.
8. Diesel: Remove the forward exhaust pipe.
9. 4 cyl. petrol: Remove the forward mounting of the exhaust pipe.
10. Detach the exhaust pipe from the catalytic converter.
11. 6 cyl. petrol: Remove the exhaust pipe from the rearward exhaust manifold. Hang up the pipe with a strap.
12. Remove the RH side-cover.
13. Mark the position of the subframe relative to the body.
14. Remove the reinforcement plates.
15. Slowly lower the subframe by undoing the Centre bolts. Use a pillar jack.
16. Undo the rear pipe clamps.
17. Remove the cable tie (LHD) from the rear pipe and the clamp that secures the pipe to the steering gear. RHD
18. Place a bowl under the front pipe union and separate the union.
19. Place a bowl under the banjo nipple and undo the nipple from the steering gear. Remove the pipe. RHD

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1. Position the pipe, starting from the rear. 6 cyl. petrol: Transfer the heat shield from the old pressure hose to the new hose.
2. Remove the rear transit protection and screw by hand the banjo nipple into place with new seals.
3. Remove the front transport protection and lightly screw together the front pipe union. NOTE: Be careful with the O ring.
4. Fit the rear clamp to the steering gear. RHD
5. LHD: Fit the return hose with two cable ties.
6. Tighten the banjo nipple. Tightening torque 30 Nm (22 lbf ft) LHD 6 cyl. diesel: Restrain the pipe so that it is not twisted when the nipple is tightened. Twisting will affect the clearance between the pressure pipe and the alternator.
7. Check that the seal between the steering gear and the body is correctly positioned.
8. Raise the subframe with a pillar jack and screw in the Centre bolts finger tight. NOTE: M02-: The Centre subframe bolts must not be confused with the other bolts. The Centre bolts have a smaller washer and a 20 mm head.
9. Fit the reinforcement plates. Tightening torque 65 Nm (48 lbf ft)
10. Adjust the subframe so as to align with the previously made marks on the body. Tighten the subframe mounting bolts. Tightening torque 100 Nm +45°(74 lbf ft +45°)
11. 6 cyl. diesel: Check that the clearance between the pressure hose and the generator fastening heel is at least 15 mm. If YES . Go to item 16 . If NO . Go to item 12.
12. Remove the push nut for upholding the bulkhead insulation.
13. Fit a cable tie mounting.
14. Fit the short cable tie loosely around the delivery line to the right of the existing cable tie.
15. Insert the long cable tie through the short one and the cable tie mounting. Tighten the short cable tie around the line. Adjust the distance between the delivery line and the generator mounting heel to 15 mm using the long cable tie.
16. Diesel: Fit the forward exhaust pipe. NOTE: Apply a thin layer of 90 513 210 Universal paste to the studs. Tightening torque 6 cyl. diesel against the forward joint: 40 Nm (29 lbf ft) Tightening torque 4 cyl. diesel against the turbo: 25 Nm (18 lbf ft)
17. 4 cyl. petrol and 6 cyl. diesel: Fit the mounting.
18. Assemble the exhaust pipe to the catalytic converter. Tightening torque 22 Nm (16 lbf ft)
19. 6-cyl petrol: Assemble the exhaust pipe to the rearward exhaust manifold. Tightening torque 40 Nm (30 lbf ft)
20. Fit the pipe into the clamps.
21. Fit a new tie with holder to the pressure hose. Fit the return hose to the holder.
22. Tighten the front pipe union. Check that the rear pressure line hose connection is at least 5 mm from the subframe.
23. Fit the RH side-cover.
24. Diesel: Fit the lower engine cover.
25. Lower the car.
26. Remove the pinch-off pliers.
27. Fit the nut to the rear engine mount. Tightening torque 50 Nm (37 lbf ft)
28. Petrol: Tighten the bolts securing the exhaust pipe to the turbo. Tightening torque 25 Nm (18 lbf ft)
29. 6 cyl.: Fit the battery shelf, battery and battery cover.
30. Check that the wheels and steering wheel are in the straight-ahead position and attach the steering shaft to the steering gear. Remove the tape from the steering wheel. Tightening torque 30 Nm (22 lbf ft)
31. Fill the system with fluid and bleed as described in «BLEEDING THE POWER STEERING SYSTEM»(ref-212258-S12646339292005122300000) .
32. Check for any leakage at the hose connections.
33. Check the steering wheel position when driving straight ahead on a level road. Adjust if necessary.

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1. Cars without water separator: Remove the grille.
2. Cars without water separator: Undo the air intake bolt and lift the air intake out from its mounting.
3. Raise the car.
4. Remove the forward engine cover. Diesel: Remove the lower engine cover.
5. Remove the RH engine cover.
6. 4 cyl. petrol: Undo the 2 engine oil cooler bolts and let the cooler hang by its hoses.
7. Cars without water separator: Loosen the clamp holding the air intake hose to the air filter housing and remove the air intake.
8. Undo the nuts which hold the cooling loop to the radiator mount.
9. Remove the clamp from the front delivery line.
10. Place a bowl under the car to collect the power steering fluid. Separate the front and rear delivery pipes at the joint.
11. Lower the car.
12. 4 cyl. petrol: Undo the hose clip which retains the intake hose with the mass air flow sensor and bend the hose to one side.
13. 4 cyl petrol: Relieve the tension in the belt tensioner with tool «83 95 254 DRAWBAR HANDLE, HYDRAULIC BELT TENSIONER»(ref-212258-S23662076722005122300000) . Rotate the power steering pump pulley to gain access to the bolt and detach the front delivery line bracket. Remove the pipe from the pump.
14. 6 cyl. diesel: Undo the bolt which retains the delivery line bracket. Undo the clamp band from the bracket and undo the banjo nipple.
15. 4 cyl. diesel: Undo the banjo nipple on the delivery line from the power steering pump.
16. Raise the car.
17. Angle the cooling loop downward on the front delivery line so that all of the front delivery line can be removed. IMPORTANT: Scrupulous cleanliness must always be observed during all work with hydraulic components.

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1. Fit the front delivery line. The pipe must be inserted between the radiator member and the radiator, behind the cable for the A/C compressor. IMPORTANT: The AC compressor cable can easily catch in the delivery pipe bracket
2. Remove the protection from the front pipe, join the pipes and tighten the coupling as much as possible by hand.
3. Check that the cooling loop is horizontal and tighten the coupling between the front and rear pipes.
4. Fit the rubber suspension onto the radiator unit mounting and then fit the delivery line onto the rubber suspension.
5. Fit the pipe to the clamp.
6. 4 cyl. petrol: Attach the engine oil cooler with 2 bolts.
7. Cars without water separator: Replace the air intake in the air filter housing and bend up the air intake in front of the radiator.
8. Cars without water separator: Tighten the hose clip on the lower air intake mounting on the air filter housing.
9. Wipe of any oil that has spilled onto the subframe.
10. Wipe off any oil from the air deflectors and fit the deflectors.
11. Lower the car.
12. Cars without water separator: Lift up and fit the air intake and tighten the bolt.
13. 4-cylinder petrol: IMPORTANT: Make sure that the O-ring is fitted correctly. ? Insert the delivery line into the power steering pump as far as possible by hand to give it some support. ? Mount the bolt in the bracket. ? Tighten the delivery line. ? Tighten the bolt on the bracket.
14. 6 cyl. diesel: Screw into place the banjo nipple using new seals. Assemble the bolts and clamp band to the bracket. Tighten the banjo nipple. Tightening torque 30 Nm (22 lbf ft)
15. 4 cyl. diesel, 6 cyl. petrol: Fit the banjo nipple using new seals. Tightening torque 30 Nm (22 lbf ft)
16. 4 cyl. petrol: Fit the intake hose onto the intake pipe of the turbo unit.
17. Cars without water separator: Fit the grille.
18. Fill the system with fluid. Refer to «BLEEDING THE POWER STEERING SYSTEM»(ref-212258-S12646339292005122300000) .
19. Make sure that there are no leaks in the system.

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1. Drain the power steering fluid reservoir, using oil suction equipment.
2. Undo and lift aside the reservoir.
3. Clean carefully around the return hose connection to the power steering fluid reservoir.
4. Remove the return hose from the power steering fluid reservoir.
5. Raise the car.
6. Diesel: Remove the lower engine cover.
7. LHD: Cut off the cable tie holding the return line to the steering gear.
8. Place a receptacle under the car and remove the return hose from the steering servo.

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1. Connect the line to the steering gear. NOTE: Use new seals with the banjo connector. Tightening torque 30 Nm (22 lbf ft)
2. LHD: Fasten the return line to the delivery line with two cable ties.
3. Fit the clamp holding the line to the steering gear.
4. Diesel: Refit the lower engine cover.
5. Lower the car and fit a cable tie around the line and the air-conditioning low pressure pipe.
6. Connect and fasten the line to the power steering fluid reservoir. Ensure that the white line on the line is aligned with the arrow on the reservoir.
7. Fit the steering servo reservoir.
8. Fasten the return line to the suspension strut tower with a cable tie.
9. Bleed the power steering system.

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For unloading the belt tensioner

86 12 798 Toolboard T1 Service

Group: Engine

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (HYDRAULIC BELT TENSIONER DRAWBAR HANDLE)

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86 11 600 Toolboard T2

Group: Chassis

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (SERVO PUMP PULLEY FITTING TOOL)

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86 11 600 Toolboard T2

Group: Chassis

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (SERVO PUMP PULLEY PULLER)

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Prevents runoff from cooling system hoses

86 12 798 Toolboard T1 Service

Group: Engine

SPECIAL TOOL COMPATIBILITY DESCRIPTIONS (HOSE PINCH-OFF PLIERS)