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Home >> Saab >> 2004 >> 9-3 Linear, Automatic >> Repair and Diagnosis >> Electrical >> Body Electrical >> Control Module >> Adjustment - Replacement >> Diesel pump with control module (595) >> To fit

To fit

  1. Clean the sealing surfaces.
    Fig 1: Illustration For Steps 2-3
    G03719199Courtesy of SAAB-SCANIA OF AMERICA, INC.
  2. Lubricate a new O-ring with acid-free vaseline and fit it to the fuel distribution pump. Fit the pump to the cylinder block. If replacing the pump, transfer the bracket to the new pump.

    Tightening torque 20 Nm (15 lbf ft) 

  3. Insert the screw for the bracket in the cylinder block without tightening it.
  4. Fit 83 95 337 Adjustment tool, fuel pump in the fuel distribution pump socket.
    Fig 2: Illustration For Step 5
    G03719200Courtesy of SAAB-SCANIA OF AMERICA, INC.
  5. Tighten the bolts through the hole in the timing cover. Use 83 95 543 Tool, fuel pump gear.

    Tightening torque 25 Nm (19 lbf ft) 

  6. Tighten the screw securing the bracket to the cylinder block.
    Fig 3: Illustration For Steps 6-7
    G03719201Courtesy of SAAB-SCANIA OF AMERICA, INC.

    Tightening torque 20 Nm (15 lbf ft) 

  7. Fit the engine block drain plug using a new O-ring.
  8. Remove the inspection gauge from the fuel distribution pump.
    Fig 4: Illustration For Steps 13 & 15
    G03719202Courtesy of SAAB-SCANIA OF AMERICA, INC.
  9. Lower the upper timing chain, fit the fuel distribution pump sprocket using a screw, fit the chain and tighten the sprocket screws by hand.
    IMPORTANT: The arrow on the sprocket must be aligned with the recess on the flange and the hole in the pump.
  10. Refit inspection gauge 83 95 337 Adjustment tool, fuel pump in the fuel distribution pump socket.
  11. Fit the camshaft gear to the camshaft.
  12. Raise the car.
  13. Fit the chain tensioner for the lower timing chain using a new gasket.

    Tightening torque 60 Nm (44 lbf ft) 

  14. Lower the car.
  15. Remove the inspection gauge from the fuel distribution pump and tighten the sprocket screws.

    Tightening torque 20 Nm (15 lbf ft) 

  16. Refit the inspection gauge in the fuel distribution pump socket.
    Fig 5: Illustration For Steps 18, 20 & 21
    G03719203Courtesy of SAAB-SCANIA OF AMERICA, INC.
  17. Check that the camshaft gear runs freely on the camshaft and fit a new screw. Tighten by hand.
  18. Fit the adapter for 83 95 394 Adjustment tool, timing chain on the camshaft gear and fit the adjustment tool on the cylinder head.
  19. Secure the position of the adapter on the camshaft gear by gently turning anticlockwise using a lock handle. Tighten the adjuster screw on the tool.
    IMPORTANT: Adjustment tool, fuel pump 83 95 337 must be easy to remove and fit at all times. If not, slacken the adjusting screw on the tool slightly
  20. Tighten the camshaft gear screw. Use an open wrench as counter-stay in the hexagonal socket on the camshaft.

    Tightening torque 90 Nm (67 lbf ft) + 60° 

  21. Fit the chain tensioner for the upper timing chain using a new gasket.

    Tightening torque 60 Nm (44 lbf ft) 

  22. Remove all tools and gauges. Raise the car when removing 83 95 352 Adjustment tool, crankshaft.
    Fig 6: Illustration For Steps 23, 25, 27, 28 & 29
    G03719204Courtesy of SAAB-SCANIA OF AMERICA, INC.
  23. Rotate the crankshaft two revolutions to just before the TDC marking in cylinder 1. Check that both cam lobes for cylinder 1 point upwards on an angle.
  24. Raise the car.
  25. Insert 83 95 352 Adjustment tool, crankshaft in the hole for the crankshaft position sensor. Press the tool in while rotating the crankshaft to its zero mark. The tool will then go into a socket in the crankshaft and lock it.
  26. Lower the car.
  27. Check that the markings on the crankshaft pulley and timing cover line up. The arrow on the single timing chain gear at the fuel distribution pump should line up with the socket in the pump.
  28. Fit 83 95 337 Adjustment tool, fuel pump in the fuel distribution pump socket.
  29. Fit 83 95 386 Adjustment tool, camshaft to the camshaft and cylinder head.
  30. Remove all inspection gauges. Raise the car when removing 83 95 352 Adjustment tool, crankshaft.
  31. Fit the crankshaft position sensor using a new O-ring.
  32. Cover the timing cover opening with a lint-free cloth and clean any gasket residue from the sealing surface. Clean the sealing surface on the lid as well.
  33. Apply a 2 mm thick string of 83 95 691 Flange sealant to the lid, remove the cloth from the timing cover and fit the lid.

    Tightening torque 6 Nm (5 lbf ft) 

  34. Clean any gasket residue from the cylinder head sealing surfaces.
  35. Fit a new gasket on the camshaft cover. The screws have sleeves on which the gasket rests.
    Fig 7: Illustration For Steps 36-37
    G03719205Courtesy of SAAB-SCANIA OF AMERICA, INC.
  36. Apply 83 95 691 Flange sealant to the sealing surface.
  37. Position the camshaft cover on the cylinder head and tighten the screws.

    Tightening torque 8 Nm (6 lbf ft) 

  38. Fit the rear mounting of the wiring harness to the camshaft cover.
    Fig 8: Illustration For Step 38
    G03719206Courtesy of SAAB-SCANIA OF AMERICA, INC.
  39. Clean the sealing surfaces of the vacuum pump and the cylinder head.
    Fig 9: Illustration For Step 40
    G03719207Courtesy of SAAB-SCANIA OF AMERICA, INC.
  40. Fit a new gasket to the vacuum pump, apply 83 95 691 Flange sealant as illustrated and fit the pump together with the adapter.

    Tightening torque 8 Nm (6 lbf ft) 

  41. Fit the cable guides.
    Fig 10: Illustration For Steps 41-42
    G03719208Courtesy of SAAB-SCANIA OF AMERICA, INC.
  42. Connect the vacuum hoses to the vacuum pump.
  43. Connect the coolant pipe with hose.
    Fig 11: Illustration For Steps 43-44
    G03719209Courtesy of SAAB-SCANIA OF AMERICA, INC.
  44. Fit a new fuel return hose to the supply lead. Fit the supply and return fuel leads to the fuel pump using new sealing washers. Do not completely tighten the connections.

    Connect the fuel leads to the leads from the tank, adjust the leads to the socket in the camshaft cover and completely tighten the connections to the fuel pump.

    Hold the fuel leads so that they do not rotate when tightened.

    Tightening torque 25 Nm (19 lbf ft) 

    IMPORTANT: Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to CONNECTORS, HANDLING AND INSPECTION  .
  45. Plug in the connectors to the fuel pump control module, coolant temperature sensor and AC pressure sensor.
    Fig 12: Illustration For Steps 45-46
    G03719210Courtesy of SAAB-SCANIA OF AMERICA, INC.
    IMPORTANT: ESD-SENSITIVE COMPONENT 
    Earth yourself by touching the car body before plugging in / unplugging components. Do not touch the component pins  . Read Before removing a control module before changing a control module.
  46. Fit the coolant hoses to the thermostat housing.
    Fig 13: Illustration For Steps 48, 50 & 51
    G03719211Courtesy of SAAB-SCANIA OF AMERICA, INC.
  47. Secure the wiring to the coolant pipe with a cable tie.
  48. Clean the sealing surfaces of the upper section of the intake manifold. Fit the upper section using a new gasket.

    Tightening torque 10 Nm (7 lbf ft) 

  49. Check the connecting cones of the fuel rails. If they are damaged, the rail must be replaced.
  50. Fit the fuel rails.

    Tightening torque 25 Nm (19 lbf ft) 

  51. Fit new fuel return hoses to the fuel bridges and connect the fuel return hose fitted earlier.
  52. Fit the EGR valve using a new O-ring.
    Fig 14: Illustration For Steps 52-55
    G03719212Courtesy of SAAB-SCANIA OF AMERICA, INC.

    Tightening torque 10 Nm (7 lbf ft) 

  53. Plug in the EGR valve connector and attach its coolant hoses.
  54. Fit the throttle body using a new gasket.

    Tightening torque 10 Nm (7 lbf ft) 

  55. Fit the connector and vacuum hose to the throttle body.
  56. Fit the turbo pressure hose to the throttle body.
  57. Remove the plugs, fit the charge air hose with charge air pipe to the turbocharger and the charge air pipe to the fan cowling.
    Fig 15: Illustration For Steps 58-61
    G03719213Courtesy of SAAB-SCANIA OF AMERICA, INC.
  58. Fit the inlet hose for the air filter housing. Fit the air filter housing.
  59. Fit the air filter.
  60. Fit the cover of the air filter housing.
  61. Fit the inlet hose from the mass air flow sensor to the turbocharger and the hose for crankcase ventilation.
  62. Raise the car.
  63. Fit the coolant pipe screws.
    Fig 16: Illustration For Step 63
    G03719214Courtesy of SAAB-SCANIA OF AMERICA, INC.
  64. Check that the coolant drain cock is closed.
  65. Fit the belt tensioner, tightening the upper screw first.

    Tightening torque 42 Nm (31 lbf ft) 

  66. Tighten the lower screw.

    Tightening torque 23 Nm (17 lbf ft) 

  67. Check that the pulleys are clean and dry.
  68. Fit the Poly-V belt matching the mark made previously and check that it sits correctly over the pulleys.
  69. Fit the lower engine cover.
    Fig 17: Illustration For Steps 69-70
    G03719215Courtesy of SAAB-SCANIA OF AMERICA, INC.
  70. Fit the front spoiler shield. Fit and plug in the connector. Connect the headlamp washer hose.
  71. Fit the right-hand wheel arch liner.
    Fig 18: Illustration For Step 71
    G03719216Courtesy of SAAB-SCANIA OF AMERICA, INC.
  72. Fit the wheel. See WHEEL & TIRES .
  73. Lower the car.
  74. Bleed the fuel system.
    Fig 19: Illustration For Steps 75 & 77
    G03719217Courtesy of SAAB-SCANIA OF AMERICA, INC.
  75. Fill with 40 - 400 131 389 Coolant to about 20 mm above the expansion tank mark.
  76. Fit the upper engine cover.
  77. Carry out Procedure after replacement of control module. See PROCEDURE AFTER CHANGING CONTROL MODULE  .
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