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(234-2349) Filler cap replacement, 9-3 TiD

Symptom: Fuel leak from tank return line

MODIFICATION INSTRUCTION
Bulletin Nbr: 234-2349
Date: ........... OktoberĀ 2002
Market: enligt separat lista
Filler cap replacement, 9-3 TiD

Service Campaign 157 10

Cars in stock must be rectified before delivery.

Cars already delivered must be rectified in connection with a scheduled visit to the garage for service or repairs.

Cars affected

Saab 9-3 (9400) M98-M02 with engine variant D223L and VIN within the range W2050007-22038723


Background

The pressure when opening the filler cap combined with a clogged roll-over valve can deform the fuel tank due to a vacuum that is created. This results in deformation of the tank sensor armature, which in turn results in higher pressure in the fuel return line so that its snap-on coupling can loosen and fuel leakage can occur. To ensure that there is an adequate air supply, a new filler cap has been produced to change the opening pressure from -8 kPa to -2 kPa.

Symptoms

Fuel leak from tank return line



Parts required

53 36 060 Filler cap (The cap contains the text DIESEL and a label, part no. 51 72 655)

If a new modification identity plate is required

49 00 007 Modification identity plate

79 72 490 Pop rivet

16-30 15 948 Teroson Terotex HV 200 Extra T108

Procedure

Before proceeding, check box C5 (M98), D5 (M99; if necessary, new modification identity plate must be fitted according to the instructions below), A5 (M00) or C5 (M01-M02) on the modification identity plate. If the box is not filled in, continue as follows.


1. Remove the existing filler cap.

2. If the cap has a strap, remove it by pulling it loose from the tank hatch. The new cap does not have a strap.

3. Fit the new filler cap.


Marking the modification identity plate

After completion of the procedure, the modification identity plate must be marked as follows:

Model year

Modification identity plate box

M98

C5

M99

D5 (new modification identity plate)

M00

A5

M01-02

C5



If the procedure has been performed by an importer, mark the box "7". Mark with "8" if the procedure has been performed by a dealer.

Fitting modification identity plate, M99


1. Open the boot lid and fold up the boot mat.


2. Position the modification identity plate as shown in the illustration without removing the protective paper from the back.

3. Mark the drill holes and drill with a 4 mm bit.

4. Apply anti-corrosion treatment to the inside of the holes.

5. Remove the protective paper from the back of the modification identity plate and align the plate with the holes. Fit the modification identity plate with the pop rivets.

6. Apply anti-corrosion treatment to the underside of the floor.

7. Remove burrs from the boot with a vacuum and fold the boot mat back into place. Close the boot lid.


Standard times-/Warranty information

See separate information.