Engine Electrical: Removal & Installation Saab 9-7X I

Installation Procedure

1. Squeeze the negative battery cable together. IMPORTANT: Ensure the generator battery current sensor is installed in the correct direction and location on the negative battery cable.
2. Slide the NEW generator battery current sensor (1) up onto the negative battery cable and insert the tab under the negative battery cable terminal cover.
3. Wrap electrical tape around the generator battery current sensor leg in order to secure the sensor to the negative battery cable.
4. Install the negative battery cable clips to the cable to the locations previously marked during removal.
5. Install the negative battery cable. Refer to «Battery Negative Cable Replacement (4.2L Engine)»(ref-268108-S38243103102007101800000) or «Battery Negative Cable Replacement (5.3L Engine)»(ref-268108-S22644214062007101800000) .

Scheme 1

Scheme 2

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Disconnect the engine wiring harness electrical connector (2) from the generator battery control module.
3. Remove the negative battery cable ground terminal bolt (2) at the left wheelhouse panel.
4. Remove the negative battery cable ground terminal (1) from the left wheelhouse panel.
5. Remove the negative battery cable ground terminal bolt (5) from the shock tower.
6. Remove the negative battery cable ground terminal from the shock tower.
7. Remove the negative battery cable clip (3) from the shock tower.
8. Remove the negative battery cable ground terminal bolt (3) from the engine block.
9. Remove the negative battery cable ground from the engine block.
10. Cut the tape wrapped around the conduit and remove the negative battery cable.

Scheme 3

1. Install the negative battery cable and re-tape the conduit.
2. Position the negative battery cable ground to the engine block. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the negative battery cable ground terminal bolt (3) to the engine block. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
4. Install the negative battery cable ground terminal to the shock tower. Ensure that the anti-rotation tab is inserted into the hole in the shock tower.
5. Install the negative battery cable ground terminal bolt (5) to the shock tower. Tighten: Tighten the bolt to 10 N.m (89 lb in).
6. Install the negative battery cable ground terminal (1) to the left wheelhouse panel. Ensure that the anti-rotation tab (6) is inserted into the hole in the wheelhouse panel.
7. Install the negative battery cable ground terminal bolt (2) at the left wheelhouse panel. Tighten: Tighten the bolt to 10 N.m (89 lb in).
8. Install the negative battery cable clip (3) to the shock tower.
9. Connect the engine wiring harness electrical connector (2) to the generator battery control module.
10. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

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Scheme 7

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Disconnect the engine wiring harness electrical connector from the generator battery control module.
3. Remove the negative battery cable ground terminal bolt (2) at the left wheelhouse panel.
4. Remove the negative battery cable ground terminal (1) from the left wheelhouse panel.
5. Remove the battery cable from the battery cable clip attached to the junction block bracket.
6. Remove the negative battery cable ground bolt (7) from the shock tower.
7. Remove the negative battery cable ground terminal (6) from the shock tower.
8. Remove the negative battery cable clip (5) from the shock tower.
9. Remove the negative battery cable terminal bolt (2) from the engine block.
10. Remove the negative battery cable ground (1) from the engine block.
11. Cut the tape wrapped around the conduit and remove the negative battery cable.

1. Install the negative battery cable and re-tape the conduit.
2. Position the negative battery cable ground (1) to the engine block. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the negative battery cable ground terminal bolt (2) to the engine block. Tighten: Tighten the bolt to 50 N.m (37 lb ft).
4. Position the negative battery cable ground terminal (6) to the shock tower.
5. Install the negative battery cable ground bolt (7) to the shock tower. Tighten: Tighten the bolt to 10 N.m (89 lb in).
6. Install the negative battery cable clip (5) to the shock tower.
7. Install the negative battery cable ground terminal (1) to the left wheelhouse panel. Ensure that the anti-rotation tab (3) is inserted into the hole in the wheelhouse panel.
8. Install the negative battery cable ground terminal bolt (2) at the left wheelhouse panel. Tighten: Tighten the bolt to 10 N.m (89 lb in).
9. Install the battery cable to the battery cable clip attached to the junction block bracket.
10. Connect the engine wiring harness electrical connector to the generator battery control module.
11. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

Scheme 8

Scheme 9

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Loosen the battery positive cable bolt.
3. Remove the positive battery cable (1) from the battery.
4. Loosen the positive battery cable terminal bolt (1) at the junction block.
5. Remove the positive battery cable terminal (2) from the junction block.
6. Disconnect the battery cable conduit from the conduit retaining clip.
7. Remove the battery positive cable from the conduit.
8. Remove the battery positive cable harness from the fir-tree retainer on the powertrain control module (PCM) bracket.
9. Remove the positive battery cable nut (1) from the starter.
10. Remove the positive battery cable terminal (2) from the starter.
11. Reposition the positive battery cable boot (3).
12. Remove the positive battery cable terminal nut (1).
13. Remove the positive battery cable from the generator.
14. Remove the battery positive cable from the vehicle.

1. Position the battery positive cable in the engine compartment.
2. Install the positive battery cable to the generator. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the positive battery cable terminal nut (1). Tighten: Tighten the nut to 9 N.m (80 lb in).
4. Position the positive battery cable boot (3).
5. Install the positive battery cable terminal (2) to the starter.
6. Install the positive battery cable nut (1) to the starter. Tighten: Tighten the nut to 9 N.m (80 lb in).
7. Install the battery positive cable harness to the fir-tree retainer on the PCM bracket.
8. Install the battery positive cable into the conduit.
9. Connect the battery cable conduit to the conduit retaining clip.
10. Install the positive battery cable terminal (2) to the junction block.
11. Tighten the positive battery cable terminal bolt (1) at the junction block. Tighten: Tighten the bolt to 10 N.m (89 lb in).
12. Install the positive battery cable (1) to the battery.
13. Tighten the battery positive cable bolt. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
14. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

Scheme 10

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Loosen the battery positive cable bolt.
3. Remove the positive battery cable (1) from the battery.
4. Loosen the positive battery cable terminal bolt (1) at the junction block.
5. Remove the positive battery cable terminal (2) from the junction block.
6. Reposition the positive battery cable boot (2).
7. Remove the positive battery cable nut (1).
8. Remove the positive battery cable terminal (3) from the generator.
9. Open the clips (4) on the retaining brackets.
10. Remove the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
11. Remove the positive battery cable channel bolt (3).
12. Remove the positive battery cable channel locating pin (4) from the oil pan.
13. Remove the positive battery cable terminal nut (2) from the starter.
14. Remove the positive battery cable terminal (3).
15. Remove the positive battery cable clip (1) from the bracket.
16. Remove the positive battery cable from the conduit.

1. Install the positive battery cable to the conduit.
2. Install the positive battery cable terminal (3). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the positive battery cable terminal nut (2) to the starter. Tighten: Tighten the nut to 9 N.m (80 lb in).
4. Install the positive battery cable clip (1) to the bracket.
5. Install the positive battery cable channel locating pin (4) to the oil pan.
6. Install the positive battery cable channel bolt (3). Tighten: Tighten the bolt to 12 N.m (106 lb in).
7. Install the engine protection shield. Refer to «Engine Protection Shield Replacement»(ref-268103-S05084402582007101800000) .
8. Install the positive battery cable terminal (3) to the generator.
9. Install the positive battery cable nut (1). Tighten: Tighten the nut to 9 N.m (80 lb in).
10. Position the positive battery cable boot (2).
11. Close the clips (4) on the retaining brackets.
12. Install the positive battery cable terminal (2) to the junction block.
13. Tighten the positive battery cable terminal bolt (1) at the junction block. Tighten: Tighten the bolt to 10 N.m (89 lb in).
14. Position the positive battery cable (1) to the battery.
15. Tighten the battery positive cable bolt. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
16. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

Scheme 11

Scheme 12

Scheme 13

Scheme 14

Scheme 15

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Loosen the positive battery cable bolt.
3. Remove the positive battery cable (1) from the battery.
4. Remove the coolant heater cord retainers (1) from the battery cover, if equipped.
5. Remove the battery air duct from the battery cover.
6. Remove the battery tray brace bolts/nut.
7. Remove the battery cover.
8. Remove the battery hold down nut (3), retainer (1), and washer.
9. Remove the battery.

1. Install the battery. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the battery hold down retainer (1), nut (3), and washer. Tighten: Tighten the nut to 15 N.m (11 lb ft).
3. Install the battery cover.
4. Install the battery tray brace bolts/nut. Tighten: Tighten the bolts/nut to 10 N.m (89 lb in).
5. Install the battery air duct to the battery cover.
6. Install the coolant heater cord retainers (1) to the battery cover, if equipped.
7. Position the positive battery cable (1) to the battery.
8. Tighten the positive battery cable bolt. Tighten: Tighten the bolt to 15 N.m (11 lb ft).
9. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

Scheme 16

1. Remove the battery. Refer to «Battery Replacement»(ref-268108-S02806396732007101800000) .
2. Loosen and remove the 5 bolts that secure the battery tray to the wheelhouse.
3. Remove the battery tray.

1. Install the battery tray.
2. Install the 5 bolts to the battery tray. Tighten: Tighten the bolts to 20 N.m (15 lb ft). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
3. Install the battery.

Scheme 17

Scheme 18

Scheme 19

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Remove the vacuum brake booster hose. Refer to «Vacuum Brake Booster Check Valve and/or Hose Replacement»(ref-268124-S15196332952007101800000) .
3. Remove the battery positive lead from the solenoid (1).
4. Remove the starter solenoid S-terminal lead nut (1) from the solenoid.
5. Remove the starter solenoid S-terminal lead (2) from the solenoid.
6. Remove the starter mount bolt and nut (1, 2).
7. Remove the starter motor.

1. Install the starter motor. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the starter motor mount bolt (2) and nut (1). Tighten: Tighten the starter mount bolt and nut to 50 N.m (37 lb ft).
3. Connect the positive battery cable to the starter solenoid and secure the cable with a nut (1). Tighten: Tighten the positive cable nut to 9 N.m (80 lb in).
4. Install the starter solenoid S-terminal lead (2) to the solenoid and secure the lead with a nut (1). Tighten: Tighten the S-terminal nut to 2.3 N.m (20 lb in).
5. Install the vacuum brake booster hose. Refer to «Vacuum Brake Booster Check Valve and/or Hose Replacement»(ref-268124-S15196332952007101800000) .
6. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

Scheme 20

Scheme 21

Scheme 22

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Scheme 25

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-268088-S13434065972007101800000) .
3. Remove the rear steering gear crossmember. Refer to «Crossmember Replacement - Rear Steering Gear»(ref-268103-S17092021262007101800000) .
4. Remove the wire harness from the wire harness retaining clips on the transmission oil cooler line bracket.
5. Remove the transmission oil cooler line bracket bolt.
6. Remove the right transmission cover bolt.
7. Remove the starter bolts.
8. Move the starter toward the front of the vehicle, and remove the transmission cover.
9. Remove the starter solenoid heat shield.
10. Tilt and rotate the starter in order to pass the starter between the transmission oil cooler lines and the engine oil pan.
11. Remove the starter solenoid nut (2).
12. Remove the starter lead (1) from the solenoid stud.
13. Remove the battery positive cable nut (2).
14. Remove the battery positive cable (1) from the starter solenoid.
15. Finish removing the starter from the vehicle.

1. Begin installing the starter between the transmission oil cooler lines and the engine oil pan. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the battery positive cable (1) to the starter stud.
3. Install the battery positive cable nut (2). Tighten: Tighten the nut to 9 N.m (80 lb in).
4. Install the starter solenoid lead (1) to the solenoid stud.
5. Install the starter solenoid nut (2). Tighten: Tighten the nut to 3.4 N.m (30 lb in).
6. Install the starter solenoid heat shield.
7. Slide the starter toward the front of the vehicle. Position the transmission cover to the transmission.
8. Position the starter to the engine.
9. Install the starter bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
10. Install the right transmission cover bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
11. Install the transmission oil cooler line bracket bolt. Tighten: Tighten the bolt to 9 N.m (80 lb in).
12. Attach the wire harness to the wire harness retaining clips on the transmission oil cooler line bracket.
13. Install the rear steering gear crossmember. Refer to «Crossmember Replacement - Rear Steering Gear»(ref-268103-S17092021262007101800000) .
14. Lower the vehicle.
15. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

Scheme 26

1. Remove the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-268108-S11577458102007101800000) or «Generator Replacement (5.3L Engine)»(ref-268108-S14779794212007101800000) .
2. Remove the power steering pump. Refer to «Power Steering Pump Replacement (4.2L)»(ref-268130-S06939904192007101800000) or «Power Steering Pump Replacement (Except 4.2L)»(ref-268130-S22765424012007101800000) .
3. Remove the generator bracket bolts.
4. Remove the generator bracket.

1. Install the generator bracket. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the generator bracket bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the power steering pump. Refer to «Power Steering Pump Replacement (4.2L)»(ref-268130-S06939904192007101800000) or «Power Steering Pump Replacement (Except 4.2L)»(ref-268130-S22765424012007101800000) .
4. Install the generator. Refer to «Generator Replacement (4.2L Engine)»(ref-268108-S11577458102007101800000) or «Generator Replacement (5.3L Engine)»(ref-268108-S14779794212007101800000) .

Scheme 27

Scheme 28

Scheme 29

Scheme 30

1. Disconnect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Remove the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .
3. Remove the A/C line mounting bracket bolt at the engine life hook.
4. Remove the right engine lift hook bolts and remove the lift hook.
5. Remove the 3 generator mounting bolts and remove the generator.
6. Disconnect the battery positive cable nut (1) on the generator.

1. Install the battery positive cable to the generator and secure the positive cable with the nut (1). Tighten: Tighten the generator positive cable nut to 9 N.m (80 lb in). NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the generator and secure the generator with 3 bolts. Tighten: Tighten the generator bolts to 50 N.m (37 lb ft).
3. Install the engine lift hook and secure the lift hook with 2 bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
4. Install the A/C line bracket to the lift hook and secure the bracket with the bolt. Tighten: Tighten the A/C line bracket bolt to 10 N.m (89 lb in).
5. Install the drive belt. Refer to «Drive Belt Replacement»(ref-268132-S04886974512007101800000) .
6. Connect the battery negative cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

Scheme 31

Scheme 32

Scheme 33

1. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .
2. Remove the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-268156-S14863840422007101800000) .
3. Disconnect the generator electrical connector.
4. Remove the generator cable (3) from the generator, perform the following: Slide the boot (1) down revealing the terminal stud. Remove the generator cable nut (2) from the terminal stud. Remove the generator cable (3).
5. Remove the generator bolts.
6. Remove the generator.

1. Install the generator. NOTE: Refer to «Fastener Notice»(ref-268087-S07010920292007101800000) .
2. Install the generator bolts. Tighten: Tighten the bolts to 50 N.m (37 lb ft).
3. Install the generator cable (3) to the generator, perform the following: Install the generator cable (3). Install the generator cable nut (2) to the terminal stud. Tighten: Tighten the nut to 9 N.m (80 lb in). Slide the boot (1) over the terminal stud.
4. Connect the generator electrical connector.
5. Install the accessory drive belt. Refer to «Drive Belt Replacement - Accessory»(ref-268156-S14863840422007101800000) .
6. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-268108-S09012939602007101800000) .

Scheme 34

Batteries that are no longer wanted must be disposed of by an approved battery recycler and must never be thrown in the trash or sent to a landfill.

Batteries that are not part of the vehicle itself, not the battery under the hood, must only be transported on public streets for business purposes via approved hazardous material transportation procedures.

Battery storage, charging, and testing facilities in repair shops must meet various requirements for ventilation, safety equipment, material segregation, etc.

The maintenance-free battery is standard. There are no vent plugs in the cover. The battery is completely sealed except for 2 small vent holes in the side. These vent holes allow the small amount of gas that is produced in the battery to escape.

The battery has 3 functions as a major source of energy

1. Engine cranking
2. Voltage stabilizer
3. Alternate source of energy with generator overload

The battery specification label, example below, contains information about the following

1. The test ratings
2. The original equipment catalog number
3. The recommended replacement model number

Scheme 35