Saab 400 106 639 Installation Instructions Manual Download Page 2

Page: 2 / 40

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

Summary of Contents for 400 106 639

Page 1: ...Group Date Instruction Part No Replaces 400 106 639 400 130 217 9 87 7 Nov 05 47 29 653 47 29 653 Sep 04 Important Always check which national requirements and regulations apply for fitting a fuel dr...

Page 2: ...05 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 m ste v rmaren vara fr nkopplad Switch off the heater when adding fu...

Page 3: ...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 15 Screw M6 16 Screw x9 17 Screw M8 x4 18 Nut M6 19 Cla...

Page 4: ...t 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 15 Screw M6 16 Screw x9 17 Screw M8 x4 18 Nut M6 19 Clamp exhaust p...

Page 5: ...ins 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 c...

Page 6: ...6 4729653 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: ...4729653 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 4729653 Saab 9 5 B205 B235 B308 Additional kit 32 000 515 contains Cable terminal E980A494...

Page 9: ...BE fire extinguisher near at hand Be mindful of the danger of sparks occurring when making and breaking electric circuits in the event of a short circuit etc Smoking is prohibited Important All ends...

Page 10: ...ctor housing of the left hand back seat cush ion heater if fitted and lift out the left hand sec tion of the back seat Fold back the mat and remove the tank access cover 4 Remove the battery cover bat...

Page 11: ...9 Using white spirit clean an area on the left hand front wing level with the cooling system s expansion tank Peel off the extra label from the heater and affix it to the cleaned area Important If a...

Page 12: ...the bumper is attached to the wing liners 14 M98 Where fog lights or a temperature sensor have been fitted disconnect their respective cables M99 01 Disconnect the bumper wiring harness connector The...

Page 13: ...tainer under the car Remove the hose s quick release coupling for the headlamp washers Plug the hole for the washer fluid res ervoir connection 19 M06 Detach the shell from the side bracket on the rig...

Page 14: ...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 rivet and drill out using first a 4 mm bit and then a 5 mm bit Rem...

Page 15: ...30 Position the heater in the holder so that the retaining lugs engage properly 31 Fit the two screws that secure the heater in the holder 32 Connect the circulation pump to the heater inlet with the...

Page 16: ...eturn valve with 2 hose clips into the cut hose The connections to the heater should be point ing upwards 42 4 CYL Connect the unmarked hose pressure hose from the heater to the non return valve 43 4...

Page 17: ...e housing 50 V6 Detach the throttle cable from the throttle arm 51 V6 Unplug the limp home solenoid connector 52 V6 Unplug the throttle housing s 10 pin connec tor 53 V6 Detach the vacuum hose and the...

Page 18: ...r connections must be aligned as in the illustration 59 V6 Connect the unmarked hose pressure hose from the heater to the non return valve see illustration 60 V6 Place a funnel in the marked hose suct...

Page 19: ...2 coolant hoses to the throttle housing 66 V6 Fit the vacuum hose and the connection to the venting line under the limp home solenoid 67 V6 Connect the 10 pin connector to the throttle housing 68 V6...

Page 20: ...e located in front of the suspension strut turret over the brake pipe to the ABS unit over the hoses to the cabin heat exchanger between the rear engine mount and the steering box valve block and behi...

Page 21: ...et must be mounted so that the pump s delivery connection the smaller one points upwards 78 Using 8 cable ties do not tighten excessively fasten the fuel line under the car parallel with the existing...

Page 22: ...ing the bracket as a template 84 M01 Deburr the holes and remove loose swarf and flakes of paint Clean with Teroson FL Cleaner Apply Standox 1K Primer Filler Apply finish paint 85 M01 Hold the bracket...

Page 23: ...4729653 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: ...94 M02 Connect the cables to relay position FR5 as follows 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 c...

Page 25: ...uel connection kit and discard the installation instructions found in the bag Couple the larger end of the connection hose onto the tank connection with a clip and fit the other clip onto the connecti...

Page 26: ...e heater s fuel pump Fit the fuel filter cover as fitted previously use the heavy duty cable tie from the kit Important Form the end of the fuel pipe leading to the pump inlet suction side with the fi...

Page 27: ...th the narrow part facing the heater Cars with electric vacuum pump The fuel lines must run between the pump and the bracket and be fastened to the bracket see illustration so that the fuel line canno...

Page 28: ...ustration and bend the ends of the hose downwards and outwards towards the wheel hub Make sure the exhaust hose will not rattle or make a noise and that there is at least 10 mm clearance between the h...

Page 29: ...Connect the blue BU cable to position 18 in the SID unit connector and the yellow YE cable to position 3 in the connector for the air conditioning control panel Plug in the connec tor 125 M05 Plug in...

Page 30: ...r screws 131M06 Remove the heating and ventilation panel and unplug the connector 132M06 Remove the cover over the fuse holder on the side of the panel Detach the light switch and other switches and u...

Page 31: ...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 13...

Page 32: ...46M06 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 148M06 Fi...

Page 33: ...the relay plate and the cover Fit the cable tie to the elec trical centre mounting bracket 157M02 Fit the battery tray All Fit and connect the battery 158V6 Refit the engine cover 159Fit the washer re...

Page 34: ...fan has started three more times 162Switch off the engine and allow it to cool down Check the coolant level and top up as necessary to the MAX level 163Programme the SID unit as follows connect the d...

Page 35: ...Position the steel bumper reinforcement so that it is located between the wing and the wing liner 171 M05 Fit the 6 screws 3 on each side where the bumper is attached to the wing liners 172 M01 Insta...

Page 36: ...ght hand side 178M06 cars with headlamp washers Remove the plug and connect hose s quick release cou pling to the washer fluid reservoir 179M06 Press the shell back and press it into the bracket on th...

Page 37: ...that the headlamp washers are function ing correctly 189M02 Mark out the splash guard as illustrated and drill a 10 mm hole 190Fit a clip nut on the heater bracket s mounting and three clip nuts on th...

Page 38: ...r hatch with white spirit Take out the warning label from the kit adapt the size of the label and affix it to the cleaned area 202Place the installation instructions in the car and inform the customer...

Page 39: ...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 BA TT...

Page 40: ...uit 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...

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Saab 400 106 639, Installation Instructions Manual

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