SAAB WIS ONLINE

(234-2655) Checking/replacement of injectors

MODIFICATION INSTRUCTION
Bulletin Nbr: 234-2655
Date: ........... januari 2007
Market: se separat lista
Checking/replacement of injectors

Service update 157 27

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 with engine alternative Z19DTH with particle filter within Vehicle Identification Number range

4/5D: 71005736 - 71008981

CV: 76001460 - 76002203

Background

Certain cars may be fitted with the incorrect type of injectors, which means that soot forms and then clogs the particle filter. The engine management system cannot then regenerate the particle filter if the car is only driven for short distances.

Parts required

For replacing nozzles:

93 184 794 Injector 1-4 per car

93 178 683 Copper washer 1-4 per car

93 179 045 Fuel pipe cyl 1

93 179 044 Fuel pipe cyl 2

93 179 043 Fuel pipe cyl 3

93 179 042 Fuel pipe cyl 4

93 177 333 Nut M8 1-4 per car

For fitting the modification identity plate:

12 785 148 Modification identity plate

93 160 907 Cleaning agent Motip Dupli, aerosol 400 ml (sufficient for 50-100 cars)

Checking the modification identity plate

Before proceeding, check box XX of the modification identity plate. From and including M04, the car's Warranty and Service Book contains the "Table of Modifications". A modification identity plate must be fitted in accordance with the section "Fitting the modification identity plate" where local directives require the marking of the car. If the box is not marked, continue as follows.

Procedure


1. Remove the upper engine cover.

2. Check the serial numbers on the injectors. Is the number 68 711?

No: The injector is the correct type and must not be replaced. Fit the upper engine cover and proceed to step 4.

Yes: Proceed to step 3.


3. Replace the nozzle in accordance with the method below.

4. Aut: Connect Tech2 and check the engine management system's software number. Is the number 55565574?

Yes: The car has the correct software and does not require updating.

No: Update the software using Tech2.

Man: The software does not need updating.

5. If any injector has been replaced or if new software has been downloaded then run the car to operating temperature and carry out manual regeneration of the particle filter, see WIS - 9-3 - Engine - 4-cylinder diesel - Exhaust emission control system - Adjustment/Replacement - Manual regeneration.


Method for replacing injectors

To remove


1. Unplug the connector (A) from the injector in question.


2. Remove the fuel return hose (B).

3. Cyl 1: Remove the fuel pipe (C) from the injector and fuel rail. Grip the injector with a spanner when undoing the pipe.

Cyl 2-4: Remove the fuel pipe (C) from the injector in question and from the injector in front, as well as from the fuel rail. Grip the injector with a spanner when undoing the pipe.

4. Cyl 1: Remove the cables (D) from the crankcase ventilation pipe.

5. Cyl 1: Undo the crankcase ventilation pipe and lift it up slightly.

6. Remove the nuts and washers from the injectors. Remove the injector with holder (A). If the valves cannot be raised by hand, use 32 025 013 Removal tool, injector with 83 90 270 Sliding hammer and 32 025 012 Sliding hammer adapter (B).


Cyl 2-4: Remove the stud (A) to the injector holder by locking 2 nuts to each other.


7. Clean the injector sealing surfaces (A) in the cylinder head using 32 025 010 Cleaning tool.



To fit


1. Fit the injector with holder (A) and new nuts and seals.

Tightening torque 25 Nm (18 lbf ft)


Cyl 2-4: Fit the stud (A). Remove the counterholding nuts.

Tightening torque 14 Nm (10 lbf ft)


2. Cyl 1: Fit the crankcase ventilation pipe.

3. Cyl 1: Fit the cables (D) to the crankcase ventilation pipe.


4. Fit new delivery pipes (C), without tension, and screw on the nuts by hand. Use new nuts.

Tightening torque 25 Nm (18 lbf ft)

5. Fit the fuel return hose (B).

6. Plug in the connector.

7. Connect the diagnostic tool for programming. Select, Menu - Engine - Engine management system - Adjustment - Injector replaced.

8. Start the engine and check the fuel system for leaks. Connect the diagnostic tool and clear any diagnostic trouble codes.

9. Fit the insulation as well as the upper engine cover.


Marking the modification identity plate

After carrying out the procedure, box xx on the modification identity plate must be marked. From and including M04 the car's Warranty and Service Book contains the "Table of Modifications". Mark the box with the number "7" if the procedure was carried out by the importer or with the number "8" if carried out by the dealer.

Fitting the modification identity plate

Note

A modification identity plate must only be fitted where local directives require the marking of the car.


Fit the modification identity plate as described in WIS.

9-3 (9440) M04 - General - General - Technical data - Plates and labels

Warranty/Time Information

See separate information.