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  5. Installation Instructions Manual

Saab 400 106 639 Installation Instructions Manual

Summary of 400 106 639

  • Page 1

    Saab 9-5 b205, b235, b308 9-5 installation instructions scdefault monteringsanvisning · installation instructions montageanleitung · instructions de montage sitdefault saab 9-5 b205, b235, b308 engine/cabin heater accessories part no. Group date instruction part no. Replaces 400 106 639 400 130 217 ...

  • Page 2

    2 47 29 653 saab 9-5 b205, b235, b308 heater kit 400 106 621 contains: 1 petrol heater 2 circulation pump 3 non-return valve 4 fuel pump 5 label vid tankning måste värmaren vara frånkopplad switch off the heater when adding fuel e980a222 1 2 3 4 5.

  • Page 3

    47 29 653 3 saab 9-5 b205, b235, b308 mounting kit 400 106 639 contains: 1 bracket 2 holder 3 coolant hoses (x3) 4 silencer 5 exhaust pipe 90° 6 clip (exhaust hose) (x2) 7 exhaust hose 8 intake hose 9 holder, coolant pump 10 splash guard 11 clips (x4) 12 screw (x3) 13 hose clip (x8) 14 cable tie (x2...

  • Page 4

    4 47 29 653 saab 9-5 b205, b235, b308 mounting kit 400 130 217 contains: 1 bracket 2 holder 3 coolant hoses (x3) 4 silencer 5 exhaust pipe 90° 6 clip (exhaust hose) (x2) 7 exhaust hose 8 intake hose 9 holder, coolant pump 10 splash guard 11 clips (x4) 12 screw (x3) 13 hose clip (x8) 14 cable tie (x2...

  • Page 5

    47 29 653 5 saab 9-5 b205, b235, b308 fuel connection kit 400 126 363 contains: 1 fuel line (x2) 2 junction hose, angled (x2) 3 clamp (x2) 4 junction hose, angled 5 fuel connection kit (tank) 6 bracket, fuel pump 7 clamp 8 rubber spacer 9 cable tie (x10) 10 cable tie 11 screw (x2) 12 hose clip (x4) ...

  • Page 6

    6 47 29 653 saab 9-5 b205, b235, b308 electric connection kit 400 106 654 contains: 1 wiring harness 2 connector 2-pin 3 cable tie (x11) 4 screw (x2) 5 bracket 6 grommet (x2) e980a127 1 2 4 6 5 3.

  • Page 7

    47 29 653 7 saab 9-5 b205, b235, b308 electric connection kit 400 130 225 contains: 1 wiring harness 2 connector 2-pin 3 cable tie (x11) 4 relay 5 fuse 15a 6 grommet (x2) e980a342 1 2 5 6 4 3.

  • Page 8

    8 47 29 653 saab 9-5 b205, b235, b308 additional kit 32 000 515 contains: cable terminal e980a494.

  • Page 9

    47 29 653 9 saab 9-5 b205, b235, b308 safety regulations · assembly of the heater should be performed by qualified staff and in accordance with the instal- lation instructions. · the heater should never be used in an enclosed space, like the garage or workshop, without the exhaust ventilation being ...

  • Page 10

    10 47 29 653 saab 9-5 b205, b235, b308 1 check the radio code and make a note of it if the car is equipped with a radio other than saab audio system. 2 lhd: remove the sound baffle under the left- hand side of the dashboard including the data link connector and floor lighting where appropri- ate. Rh...

  • Page 11

    47 29 653 11 saab 9-5 b205, b235, b308 8 -m01: remove the grille, headlamp surrounds, indicator lights and the headlamps. Undo the left-hand headlamp wiper motor. M02-05: remove both the outer grille seg- ments, indicator lights, headlamps and the headlamp washer covers. 9 using white spirit, clean ...

  • Page 12

    12 47 29 653 saab 9-5 b205, b235, b308 10 raise the car. Remove the front spoiler shield. 11 where fitted, remove the engine-block heater plug from the bumper. 12 -m01: remove the 4 screws which fix the bumper to the bumper beam and the nuts which hold the bumper to the front wing. M02-05: remove th...

  • Page 13

    47 29 653 13 saab 9-5 b205, b235, b308 16 m06-: remove the bumper shell screws to the wing liner on both sides. 17 m06-: detach the shell from the side bracket on the left-hand side. Detach the hook using a screwdriver. 18 m06-, cars with headlamp washers: position a collection container under the c...

  • Page 14

    14 47 29 653 saab 9-5 b205, b235, b308 23 remove the left-hand front wheel and the left- hand wing liner. 24 undo the connections to the pump and the level sensor. Empty the washer fluid reservoir. If the reservoir is fixed with blind rivets they must be drilled out. Punch out the core pin of each r...

  • Page 15

    47 29 653 15 saab 9-5 b205, b235, b308 25 hold the bracket in front of the press fold on the chassis plate, see illustration, so that the protru- sion (x) on the bracket fits into the depression in the chassis plate. Mark the position of the two holes on the underside. 26 drill two 3 mm holes on the...

  • Page 16

    16 47 29 653 saab 9-5 b205, b235, b308 36 hang up the holder, with the heater, on the hook on the front edge of the bracket and screw into position. 37 tighten the 2 screws which retain the heater in the holder. 38 loosen the cap on the expansion tank to release any pressure in it and then tighten i...

  • Page 17

    47 29 653 17 saab 9-5 b205, b235, b308 47 v6: remove the engine cover. 48 v6: undo and set aside the turbo pressure pipe from the throttle housing. 49 v6: clamp the 2 coolant hoses leading to the throttle housing. 50 v6: detach the throttle cable from the throttle arm. 51 v6: unplug the limp-home so...

  • Page 18

    18 47 29 653 saab 9-5 b205, b235, b308 55 v6: cut the pressure hose (46 72 317) which is fixed at the other end to the heater outlet. Cut as shown in the illustration. 56 v6: mark the suction hose (45 77 995) with tape or paint. Cut the end of the hose as illustrated. Then manoeuvre the slightly wid...

  • Page 19

    47 29 653 19 saab 9-5 b205, b235, b308 64 v6: position the throttle housing and screw it down with the 3 mounting screws. If necessary use a new gasket and smear the surfaces with a thin film of vaseline. 65 v6: connect the 2 coolant hoses to the throttle housing. 66 v6: fit the vacuum hose and the ...

  • Page 20

    20 47 29 653 saab 9-5 b205, b235, b308 71 route the long petrol hose inside the engine bay as follows: lhd -m01: from the battery tray - beside the expansion tank (the bend in the hose shall be located in front of the suspension strut turret) - under the brake servo - over the brake pipe to the abs ...

  • Page 21

    47 29 653 21 saab 9-5 b205, b235, b308 74 raise the car, remove the fuel filter cover and position the fuel pump bracket in front of the fuel filter. Drill two 3 mm holes in the floor using the bracket as a template. 75 deburr the holes and remove loose drillings, swarf and flakes of paint. Clean wi...

  • Page 22

    22 47 29 653 saab 9-5 b205, b235, b308 81 lower the car and connect the black cable with the ring cable-shoe to the earth point g2 in front of the battery tray (-m01) or respectively earth point g30 (not the earth point where the battery minus cable is connected) to the left of the bat- tery tray (m...

  • Page 23

    47 29 653 23 saab 9-5 b205, b235, b308 87 remove the windscreen wiper arms. Use puller 85 80 144. 88 remove the bonnet weatherstrip and cover panel over the bulkhead partition space. E980a549 87 88 88 87 87.

  • Page 24

    24 47 29 653 saab 9-5 b205, b235, b308 89 m02-: route the section of cable harness with the most cables alongside the car's ordinary harness towards the engine bay's electrical cen- tre. 90 route the section of harness that shall go to the cabin between the coolant reservoir and the body. Continue a...

  • Page 25

    47 29 653 25 saab 9-5 b205, b235, b308 97 route the fuel pump cables (violet and black) from the bulkhead to the left-hand a-post. From there along the plastic channels in the left-hand sill, under the mat and across to the hole under the back seat. 98 drill a 15 mm hole for the grommet in the cover...

  • Page 26

    26 47 29 653 saab 9-5 b205, b235, b308 104connect the fuel line with junction hose and 2 clips to the suction side of the fuel pump. 105fit the connector to the fuel pump harness (the polarity is not important) and connect it to the pump. 106raise the fuel tank and tighten the screws. Tightening tor...

  • Page 27

    47 29 653 27 saab 9-5 b205, b235, b308 108tighten the cable tie along the brake pipes, but do not tighten so hard that the fuel line is dam- aged. Lower the car and tighten the cable ties along the bulkhead partition as well. 109push the fuel line down to the heater and fit the angled connecting hos...

  • Page 28

    28 47 29 653 saab 9-5 b205, b235, b308 113fit the angled exhaust pipe onto the heater's exhaust connector with a clamp. Assemble the silencer (push the ends properly together) together with a clamp. Point the silencer back- wards and angled towards the chassis frame, as illustrated, and tighten the ...

  • Page 29

    47 29 653 29 saab 9-5 b205, b235, b308 121-m05: pull out the radio, the sid-unit and the air conditioning control panel from the dashboard. Unplug the connectors from the air conditioning control panel and the sid. 122-m05: route the blue (bu) and the yellow (ye) cable to the centre console and fast...

  • Page 30

    30 47 29 653 saab 9-5 b205, b235, b308 127m06-: pull the steering wheel out, and down, and then lock it. 128m06-: remove the upper and lower steering col- umn covers, three screws. 129m06-: detach the switches for the indicators and windscreen wipers. 130m06-: remove the covers and audio unit, four ...

  • Page 31

    47 29 653 31 saab 9-5 b205, b235, b308 136m06-: remove the screws for the steering col- umn gaiter. 137m06-: remove the screws for the main instru- ment unit. 138m06-: lift the main instrument unit away. 139m06-: unplug the connectors. E980a557 139 139 137 136 136 137 137 138.

  • Page 32

    32 47 29 653 saab 9-5 b205, b235, b308 140m06-: route the blue (bu) and the yellow (ye) cable to the centre console and fasten them so as to avoid risk of pinching. 141m06-: carefully slide apart the upper and lower sections of the connectors. 142m06-: remove approx. 25 cm of the tape and uncouple b...

  • Page 33

    47 29 653 33 saab 9-5 b205, b235, b308 154lhd: fit the sound baffle under the instrument panel and the sill protection strip. Rhd: fit the glove box and the sill protection strip. All: fit the fuel tank access cover, fold back the mat, fit the back seat cushions and hinge them back. 155fasten the he...

  • Page 34

    34 47 29 653 saab 9-5 b205, b235, b308 161bleed the cooling system: 4-cyl: start the engine and let it run until the thermostat opens. V6: fill up the system to the max level. Screw the cap on the expansion tank, start the engine and warm it up at varying rpm until the radiator fan starts. Carefully...

  • Page 35

    47 29 653 35 saab 9-5 b205, b235, b308 167-m05: check that none of the metal tabs is dam- aged or bent down. 168fit the wing liner and check that the heater exhaust hose is not touching the liner. 169fit the bumper to the bumper beam. -m01: ensure that the wiper blade stop and the wiper motor shaft ...

  • Page 36

    36 47 29 653 saab 9-5 b205, b235, b308 173m06-: with help from an assistant, lift the bumper shell on. 174m06-: fit the bumper shell's upper clips. Fit the screws. 175m06-: plug in the connector for the front bumper harness on the right-hand side. 176m06-: press the shell back and press it into the ...

  • Page 37

    47 29 653 37 saab 9-5 b205, b235, b308 185where applicable refit the engine block-heater plug to the bumper. 186-m05: fit the front spoiler shield. 187-m01: fit the left-hand headlamp wiper motor, headlamps, any spacer washer, indicator lights, the grille and the headlamp surrounds. Ensure that the ...

  • Page 38

    38 47 29 653 saab 9-5 b205, b235, b308 193clean all dirt and rust from the contact surfaces of the wheel and brake disc. 194apply white high-pressure grease (part no. 30 06 442) to the hub. 195aluminium wheels: oil the screw threads and the conical surface of the screws. 196position the wheel, fit t...

  • Page 39

    47 29 653 39 saab 9-5 b205, b235, b308 electrical circuit diagram (-m01) 3 1 4 compact bk 0.5 rd/wh 1.0 bn 0.5 3 3 rd 2.5 0.5 bu mcc 19 sid bk 1.0 vt 1.0 ye 0.5 acc rd/gy 1.0 1.0 rd/bu 2 saab heater 85 87 30 86 a a4 a1 a2 a5 15 a 1 + battery g2 m 1 2 7 comhtry 990917.

  • Page 40

    40 47 29 653 saab 9-5 b205, b235, b308 electrical circuit diagram (m02-) sid bk 2. 5 vt 1.0 bn 0. 5 rd /gy 1. 5 g30 acc 3 rd /wh 1. 0 1 2 bk 1. 0 +30 5 rd /wh 1. 0 3 1 7 4 2 ye 0.5 (1) 84 (3) 80 (5) 81 (2) 82 sid 18 sid 19 bu 0.5 e64729653 051007 m saab compact heater 85 87 30 86 409a 342a 323a (342...