Saab 400 106 639 Installation Instructions Manual

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9-5

MONTERINGSANVISNING · INSTALLATION INSTRUCTIONS

SITdefault

Saab 9-5 B205, B235, B308

Engine/cabin heater

Accessories Part No.

400 106 639

400 130 217

Important

Always check which national requirements and

regulations apply for fitting a fuel driven engine/

passenger compartment heater. Ensure that all

requirements are complied with.

From and including M04 the installation of the

engine/passenger compartment heater fulfils the

requirements in 2001/56/EC (Heating systems).

MONTAGEANLEITUNG · INSTRUCTIONS DE MONTAGE

Group

9:87-7

Nov 05

Saab 9-5 B205, B235, B308

SCdefault

Installation instructions

Date

Instruction Part No.

47 29 653

Replaces

47 29 653 Sep 04

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Summary of Contents for Saab 400 106 639

Page 1 SCdefault Installation instructions 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 9:87-7 Nov 05 47 29 653...
Page 2 2 47 29 653 Vid tankning måste värmaren vara frånkopplad Switch off the heater when adding fuel E980A222 Heater kit 400 106 621 contains: 1 Petrol heater 2 Circulation pump 3 Non-return valve 4 Fuel Pump 5 Label Saab 9-5 B205, B235, B308...
Page 3 47 29 653 3 E980A125 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...
Page 4 14 Cable tie (x2) 15 Screw, M6 16 Screw (x9) 17 Screw M8 (x4) 18 Nut M6 19 Clamp (exhaust pipe) 20 Clamp (intake) 21 Blind rivet (x2) 22 Screw M6 (x2) 23 Clamp (x2) (exhaust pipe) Saab 9-5 B205, B235, B308...
Page 5 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) 13 Clamp (x3) 14 Nut (x3) Saab 9-5 B205, B235, B308...
Page 6 6 47 29 653 E980A127 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) Saab 9-5 B205, B235, B308...
Page 7 47 29 653 7 E980A342 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) Saab 9-5 B205, B235, B308...
Page 8 8 47 29 653 E980A494 Additional kit 32 000 515 contains: Cable terminal Saab 9-5 B205, B235, B308...
Page 9: Safety Regulations
The heater should be activated at least once a month, even during the summer. This will prevent fuel left in the lines from evaporating and leaving deposits that can cause operational problems. Saab 9-5 B205, B235, B308...
Page 10 10 47 29 653 E980A343 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.
Page 11 Peel off the extra label from the heater and affix it to the cleaned area. Important Under no circumstances may this label conceal any part of another label or plate. Saab 9-5 B205, B235, B308...
Page 12 M02-: Disconnect the bumper wiring harness connector. The connector is located under the right-hand headlamp. 15 -M05: First loosen the bumper from the front wings, on both sides, and then pull the bumper forwards. Saab 9-5 B205, B235, B308...
Page 13 Detach the hook using a screwdriver. 20 M06-: Separate the connector for the front bumper harness. 21 M06-: Remove the bumper shell's upper clips. Remove the screws. 22 M06-: With help from an assistant, lift off the bumper shell. Saab 9-5 B205, B235, B308...
Page 14 Punch out the core pin of each rivet and drill out, using first a 4 mm bit and then a 5 mm bit. Remove the washer fluid reservoir. Important This method must be employed to prevent dam- aging the surrounding components. Saab 9-5 B205, B235, B308...
Page 15 The pump is mounted on the bracket at a later stage in the assembly procedure. 33 Connect the two pin connector from the heater to the circulation pump. Saab 9-5 B205, B235, B308...
Page 16 30 07 739 (2), cut and shorten the components. If necessary, fasten the hoses with hose as shown in the illustration. the cable ties supplied. A 140 mm (-M01) 220 mm (M02-) B 90 mm (-M01) 70 mm (M02-) Saab 9-5 B205, B235, B308...
Page 17 52 V6: Unplug the throttle housing's 10 pin connec- tor. 53 V6: Detach the vacuum hose and the connec- tion to the venting line under the limp-home solenoid. 54 V6: Undo the 3 throttle housing mounting screws and remove the throttle housing. Saab 9-5 B205, B235, B308...
Page 18 60 V6: Place a funnel in the marked hose (suction hose), hold up the hoses and fill the heating sys- tem with coolant. Fill also the whole hose. Saab 9-5 B205, B235, B308...
Page 19 67 V6: Connect the 10 pin connector to the throttle housing. 68 V6: Connect the limp-home solenoid's connec- tor. Remove the tongs from the coolant hoses. 69 V6: Attach the throttle cable. 70 V6: Connect the turbo pressure pipe to the throt- tle housing. Saab 9-5 B205, B235, B308...
Page 20 Important Do not tighten the cable ties just yet in order to facilitate adjustment of the fuel hose. Saab 9-5 B205, B235, B308...
Page 21 77 Fit the holder on the fuel pump and mount it on the bracket with the delivery side (the smaller connection) facing the left-hand side of the car, see illustration. The bracket must be mounted so that the pump's delivery connection (the smaller one) points upwards. Saab 9-5 B205, B235, B308...
Page 22 5.5 mm holes using the bracket as a template. Important Be careful not to damage the bonnet catch cable or the vent pipe from the radiator to the expansion tank. Saab 9-5 B205, B235, B308...
Page 23 47 29 653 23 E980A549 87 Remove the windscreen wiper arms. Use puller 85 80 144. 88 Remove the bonnet weatherstrip and cover panel over the bulkhead partition space. Saab 9-5 B205, B235, B308...
Page 24 (the marking on the top in brackets): Red/white cable to position 84 (1) Two red/white cables to position 80(3) Blue cable to position 82 (2) Brown cable to position 81(5) 95 Fit a grommet on the wiring harness. Saab 9-5 B205, B235, B308...
Page 25 102Manoeuvre a welding rod (about 1.5 m) into position alongside the fuel lines down towards the fuel filter and then on to the front of the top of the fuel tank. Saab 9-5 B205, B235, B308...
Page 26 Check that the pipes and cables are not caught 107Fasten the fuel line and harness in abutment to the heater's fuel pump. Fit the fuel filter cover as fitted previously (use the heavy duty cable tie from the kit). Saab 9-5 B205, B235, B308...
Page 27 111 Adjust the line so that it does not come into con- tact with hot or sharp components. 112 Adjust the fuel pipe in the engine bay and fasten it with a rubber covered clip to the earthing point by the battery. Saab 9-5 B205, B235, B308...
Page 28 If it is not, it must be reposi- hose. tioned. 120Drill a 3 mm drain hole in the intake hose at its Tightening torque 25 Nm (18 lbf ft) lowest point adjacent to the heater connection. Saab 9-5 B205, B235, B308...
Page 29 SID unit and the air conditioning con- trol panel. 126-M05: Fasten the cables in place under the dashboard so that they run clear of moving parts and cannot give rise to rattling or other unwanted noise. Saab 9-5 B205, B235, B308...
Page 30 133M06-: Detach the switch for the hazard warning lights and unplug the connector. 134M06-: Remove the instrument plate, secured with six screws and four clips. 135M06-: Lift the instrument plate away. Saab 9-5 B205, B235, B308...
Page 31 47 29 653 31 E980A557 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. Saab 9-5 B205, B235, B308...
Page 32 146M06-: Fit the instrument plate, secured with six screws and four clips. 147M06-: Connect and fit the light switch and other switches. Refit the cover over the fuse holder on the side of the panel. Saab 9-5 B205, B235, B308...
Page 33 -M01: Fasten the heater's 8-pin connector behind the heater, towards the front wheel. M02-: Fasten the heater's 8-pin connector to the underside of the pump. Saab 9-5 B205, B235, B308...
Page 34 – select Parking Heater Activation and Activa- tion By Timer – select Parking Heater Type and Fuel Pow- ered 164First start the heater and then the engine. Keep them both running until there is no more air in the system. Saab 9-5 B205, B235, B308...
Page 35 M02-05: Install the 6 screws which hold the bumper to the bumper beam and the 5 clips which are located over the grille. Saab 9-5 B205, B235, B308...
Page 36 182M06-: Fit the front spoiler shield. 183M06-: Lower the car. 184M98: If a temperature sensor or fog lights are fit- ted they should be connected. M99-: Connect the bumper wiring harness and fit the battery cover. Saab 9-5 B205, B235, B308...
Page 37 (A= -M01. B=M02-05, C=M06-). Adjust the posi- tioning against the bumper shell or alternatively the bottom spoiler flange. Mark the position of the holes, remove the splash guard and drill with a 4 mm bit. Saab 9-5 B205, B235, B308...
Page 38 Tightening torque 110 Nm (81 lbf ft) 198Lower the car. 199Where applicable programme the radio code and the clock, including the date. ACC: Calibrate the ACC system also. 200Fill up with washer fluid. Saab 9-5 B205, B235, B308...
Page 39 47 29 653 39 Electrical circuit diagram (-M01) BA TTERY 15 A RD/BU RD/WH RD/GY BN 0.5 VT 1.0 SAAB COMPACT HEATER COMHTRY 990917 Saab 9-5 B205, B235, B308...
Page 40 40 47 29 653 Electrical circuit diagram (M02-) 342a 409a (342b:FR5) (M06-) (M02-03) (M04-05) BU 0.5 YE 0.5 323a SAAB COMPACT HEATER E64729653 051007 Saab 9-5 B205, B235, B308...

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