SAAB WIS ONLINE

Brake servo, RHD

Brake servo, RHD

To remove


1. Put on 82 93 706 Wing cover.

Warning

The cooling system is under pressure. Hot coolant and steam can escape.

- Open the cap slowly to release the pressure.

- Carelessness can cause eye and burn injuries


Warning

The turbocharger can be hot and great care must be observed.


2. Open the expansion tank and release the pressure. Retighten the cap.


3. Remove the battery cover and undo the battery negative cable


4. Raise the car.

5. Use 88 19 096 Bleeding equipment. Connect the brake bleeder to the air nipple on the front left wheel.


6. Open the nipple and draw out brake fluid until one of the reservoir chambers is empty.

7. Remove the brake bleeder and close the nipple.

8. Connect the brake bleeder to the air nipple on the front right wheel.

9. Open the nipple and draw out brake fluid until the other reservoir chamber is empty.

10. Disconnect the brake bleeder and close the nipple.

11. Lower the car.

12. Manual gearbox : Connect the brake bleeder to the clutch bleed nipple.

13. Manual gearbox : Open the nipple and draw out fluid until the level in the reservoir comes below the connection.

14. Manual gearbox : Disconnect the brake bleeder and close the nipple.

15. Manual gearbox : Detach the clutch hose from the brake fluid reservoir. Brake fluid may run out, rag under.

16. Remove Acoustic baffle, driver .

17. Remove brake pedal link bolt.


18. Remove the mass air flow sensor connector.


19. Remove the air cleaner casing cover.

20. Remove the air cleaner. Detach the intake hose and remove the air cleaner casing.


21. Remove the crankcase ventilation pipe and hose from the turbo and camshaft cover.


22. Remove the turbo inlet pipe and hoses.


23. Place a jack underneath the engine. Undo the bolts on the right engine mounting to lower the engine about 30 mm.


24. Remove the turbo heat shield.


25. Remove the bulkhead heat shield.

26. Remove the brake fluid level sensor connector.


27. Remove the brake pipes from the master brake cylinder.

28. Detach the vacuum hose from the brake servo.

29. Remove the brake pipes from the bulkhead bracket. Hold away the brake pipes with a cable tie

30. Remove the master brake cylinder. Use a rag under the cylinder to protect against spillage.


31. Remove the lock clip from the turbo control arm, use 83 94 538 Circlip tool, and remove the diaphragm box from the turbo, laying it to one side.


32. Undo the nut slightly on the turbo coolant pipe

207R : Undo the banjo screw slightly.

33. Undo the coolant pipe bracket from the cylinder head. Press down the pipe about 20 mm.


34. Remove the brake servo bolts.


35. Turn round the brake servo so the pushrod is pointing forwards under the air cleaner casing's rear body bracket. Then turn up the servo and lift it out.

Important

Take care not to damage paintwork during removal.




To fit


1. Change the brake servo gasket.

2. Turn the brake servo so that the pushrod is pointing towards the air cleaner casing's rear body bracket. Press down the brake servo carefully.

Important

Take care when fitting to avoid paint damage.



3. Turn the brake servo, place it on the bulkhead and fit the brake servo bolts. Use 74 96 268 Thread locking adhesive.

Tightening torque: 20 Nm (15 lbf ft)


4. Fit the turbo coolant pipe onto the cylinder head and tighten the nut on the turbo.

Tightening torque: 40 Nm (30 lbf ft)

207R : Tighten the banjo screw.



5. Fit the diaphragm box onto the turbo. Connect the pushrod and fit the clip.

6. Fit the cylinder head. Secure with 74 96 268 Thread locking adhesive. Make sure the pushrod on the master cylinder is positioned on the brake servo pushrod.

Tightening torque: 25 Nm (18 lbf ft)


7. Fit the brake pipes into the brackets on the bulkhead.

8. Fit the vacuum hose on the brake servo.


9. Fit the brake pipes on the master cylinder.

10. Fit the brake fluid level sensor connector.

11. Fit the heat shield onto the bulkhead.


12. Fit the turbo heat shield.

13. Raise the engine with a jack and fit the bolts in the right engine mounting.

Tightening torque: 70 Nm +60° (52 lbf ft + 60°)


14. Fit the turbo inlet pipe and hoses.


15. Fit the crankcase ventilation pipe and hose.


16. Fit the air cleaner casing and air cleaner.


17. Fit the air cleaner cover.


18. Fit the mass air flow sensor connector.

19. Fit the brake pedal link bolt.


20. Fit Acoustic baffle, driver .

21. Fit battery negative cable and battery cover.


22. Fill with brake fluid and bleed the brake system, see Bleeding the brake system .

23. Carry out Procedure after disconnecting the battery .