Tests W/ Codes 2.5L V6: Removal & Installation Saab 900 II

To Remove

1. Disconnect the negative battery cable.
2. Remove the glove box. On RH drive cars: remove the lower part of the dashboard.
3. Fold the carpet out of the way and remove the central locking system relay.
4. Unplug the connector and remove the control module.

1. Open the expansion tank cap to release the pressure in the cooling system. Screw the cap back in place.
2. Remove both engine covers.
3. Unplug the connector.
4. Remove the sensor.

1. Remove the right-hand part of the engine cover.
2. Unplug the connector.
3. Undo the retaining bolt and remove the sensor.

1. Remove the engine covers.
2. Unplug the sensor's connector (by the left-hand side of the intake manifold).
3. Note how the wiring is run and the locations of the fastening points for the cable ties. Then remove the wiring.
4. Raise the car.

Undo the sensor retaining bolt and remove the sensor. Note how the sealing ring is positioned.

1. Remove the two engine covers.
2. Remove the rubber duct in front of the throttle body.
3. Disconnect the crankcase breather hose.
4. Unplug the connector, undo the two retaining screws and remove the sensor.

Note the position of the O-ring.

1. Remove the engine covers.
2. Remove the rubber duct in front of the throttle body.
3. Unplug the connector. NOTE: Make a note of the position of the valve.
4. Disconnect the hoses.
5. Remove the valve from the holder.

Scheme 72

1. Remove the engine covers.
2. Undo the hose clips on the rubber duct. Disconnect the IAC valve's hose and unplug the rear knock sensor's connector from the duct. Remove the rubber duct. Undo the intake manifold's retaining stay and cable conduits.
3. Disconnect the throttle and Cruise Control cables from the throttle lever and bracket. Also disconnect the crankcase ventilation and brake servo vacuum hoses.
4. Remove the seven nuts securing the upper half of the intake manifold.
5. Raise the upper half of the intake manifold and support it by means of a rubber mallet or the like. Plug the intake manifolds with paper or rags to prevent screws and the like from falling down into the cylinders. WARNING: Since replacement of the injectors entails working on the car's fuel system, the following points should be observed in connection with installation: Work only in a well-ventilated area. If approved equipment for the extraction of fuel vapor is available, be sure to use it. Wear suitable gloves. Prolonged contact with fuel may give rise to skin irritation. Keep a class BE fire extinguisher near at hand. Be mindful of the danger of sparks caused by short-circuits and when connecting and disconnecting leads, etc. in electrical circuits. No smoking anywhere in the vicinity.
6. Unplug the connectors from all injectors.
7. Undo the fuel rail's seven retaining bolts. Using a screwdriver, ease the fuel rail loose.
8. Remove the retaining clip from the injector or injectors that are to be inspected or replaced. Wrap the injector in a cloth to catch any dripping fuel and then withdraw the injector from the fuel rail.

Scheme 73

Scheme 74

1. Inspect the O-rings at both ends of the injector. Smear them with a little petroleum jelly (Vaseline) to facilitate fitting.
2. Fit the injector or injectors in the fuel rail and refit the retaining clip.
3. Fit the fuel rail in place and tighten it.
4. Plug in the injector connectors.
5. If necessary, clean the mating surface of the intake manifold. Remove the paper or rags from the intake manifold and fit a new gasket. Position the upper half of the intake manifold correctly.
6. Tighten all the nuts securing the upper half of the intake manifold. Start with the nuts in the middle and continue alternately towards the outer ends of the manifold. Tightening torque: 20 Nm (15 lbf ft).
7. Tighten the retaining stay at the rear of the intake manifold. Tightening torque: 20 Nm (15 lbf ft). Refit the cable conduits.
8. Make sure that the pressure regulator's vacuum hose is connected to the front nipple on the throttle body (in front of the butterfly).
9. Reconnect the vacuum hoses for the brake servo and crankcase ventilation. Refit the throttle and Cruise Control cables to the throttle lever and mounting bracket.
10. Fit the rubber duct and tighten the hose clip. Connect the IAC hose and plug the rear knock sensor's connector into the duct.
11. Fit the engine covers back in place.

Scheme 75

1. Remove the fuel rail with injectors as described on the previous pages.
2. Start the fuel pump by connecting a jumper lead across fuses 4 and 32. Check that the injectors do not leak.
3. Place the injectors in turn over a measuring flask and connect battery voltage to the injector to be checked, using cables 86 11 410 and 86 11 345. Activate the injector for exactly 30 seconds and then check whether the quantity of fuel in the measuring glass is at least 107 and at most 115 milliliters.
4. Change any defective injectors.
5. Refit the fuel rail and injectors. Be careful to fit the right connectors to the right injectors.

1. Unplug the connector of the sensor that is to be removed.
2. Note how the wiring is run and the locations of any cable ties before removing the wiring.

1. Unplug the connector of the sensor that is to be removed.
2. Note how the cable is run and the locations of any cable ties before removing the cable.
3. Remove both the front and rear sensors from underneath the car.

Removal Of Pump And Filter

1. Remove the lower section and the lower half on the left-hand side of the spoiler.
2. Remove the three retaining bolts, unplug the connector and disconnect the hoses.
3. Lift the pump away.
4. Remove the filter retaining bolt and remove the filter with hose.

Removal Of Vacuum Valve

1. Undo the hose clips and remove the hoses.
2. Disconnect the vacuum hose and remove the valve.

Removal Of Control Valve

1. Lift up the engine bay sealing strip on the top of the bulkhead partition.
2. Undo the retaining clip and lift up the valve.
3. Unplug the connector and disconnect the valve's two hoses.
4. Remove the valve.

Removal Of Non-Return Valve

1. Disconnect the hoses.
2. Remove the valve.