(644-2652) Replacing the sealing rings on the steering gear
Symptom: Leakage of power steering fluid from the banjo connections on the steering gear.
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MODIFICATION INSTRUCTION
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Bulletin Nbr:
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644-2652
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Date:
...........
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Mars 2007
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Market:
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all
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Replacing the sealing rings on the steering gear
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Customer Satisfaction Program 154 53
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Cars in stock must be rectified before delivery.
A personal communication must be sent to the owners of cars already delivered requesting them to get in touch with the nearest Saab garage as soon as possible to have the fault rectified.
Saab 9-5 M06-M07 within Vehicle Identification Number range 63520874 - 73507946.
The sealing surface on the sealing rings for the banjo connections on the steering gear may have been positioned incorrectly. This could mean that the joint loses clamping force, resulting in the leakage of power steering fluid.
Symptom description
Leakage of power steering fluid from the banjo connections on the steering gear.
48 39 932 Sealing ring (2 per car)
49 05 253 Sealing ring (2 per car)
93 160 548 Power steering fluid (sufficient for 10-13 cars)
55 187 592 Gasket (diesel only)
For fitting the modification identity plate (not US/CA):
12 785 148 Modification identity plate
93 160 907 Cleaning agent Motip Dupli, aerosol 400 ml (sufficient for 50-100 cars).
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Checking the modification identity plate (not US/CA)
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Before proceeding, check box B1 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.
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1.
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RHD with automatic transmission:
Remove the data link connector (A) and the lower panel with air duct (B) on the driver's side.
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2.
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Align the steering wheel and the wheels in the position for driving straight forward and secure the steering wheel to the instrument panel using fabric-backed tape. Remove the screw (A) that holds the steering shaft to the steering gear, press the steering shaft upwards and pull it loose from the steering gear.
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3.
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Check that the cap for the power steering fluid reservoir is tightened. Plug the reservoir's vent hole, use a suitable plug from 82 92 948 Sealing kit.
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Note
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The power steering fluid reservoir is sealed to reduce fluid spill when replacing the sealing rings for the banjo nipples.
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4.
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Remove the nut and the washer (A) from the rear engine mounting.
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6.
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Diesel:
Remove the lower engine cover (A).
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7.
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Diesel:
Lower the exhaust system:
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Loosen the exhaust system's front nuts (A) slightly and remove the rear nut (B).
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Remove the bracket (C) in the oil sump.
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Remove the hose (D) for measuring pressure drop from the particle filter/rear catalytic converter.
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Remove the bracket (E) from the particle filter/rear catalytic converter.
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8.
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Petrol:
Remove the exhaust system's rubber mountings (A).
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9.
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Lower the subframe at the rear edge:
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Mark the position of the subframe against the body.
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Remove the reinforcement plates (A).
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Slowly lower the subframe by removing the screws (B, C). Relieve the load with a column jack.
Petrol:
5-6 cm, measure between the rear mounting of the subframe and the floor of the car.
Diesel:
8-9 cm, measure between the rear mounting of the subframe and the floor of the car.
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10.
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RHD:
Remove the engine pad (A).
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11.
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Replace the sealing rings for the banjo nipples:
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Note
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Use new sealing rings when fitting and replace one side at a time.
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Position a receptacle under the car.
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Wipe clean around the banjo connections and remove the delivery line (A) from the power steering. Remove the old sealing rings.
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Fit the delivery line (A), use new sealing rings (48 39 932).
Tightening torque 30 Nm (22 lbf ft)
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Remove the return line (B) from the power steering. Remove the old sealing rings.
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Fit the return line (B), use new sealing rings (49 05 253).
Tightening torque 30 Nm (22 lbf ft)
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Wipe clean any power steering fluid from the banjo connections.
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12.
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RHD:
Fit the engine pad (A).
Tightening torque 26 Nm (19 lbf ft)
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Raise the subframe with the column jack and insert the screws (C, B, A).
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Tighten the screws (C, B). Check that the subframe is positioned against the body in accordance with the markings.
Tightening torque 100 Nm +45° (74 lbf ft +45°)
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Note
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The screws (C) to the subframe must not be mixed up with the others. The screws have a 20 mm head.
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Tighten the screws (A) for the reinforcement plates.
Tightening torque 65 Nm (50 lbf ft)
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14.
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Petrol:
Fit the exhaust system's rubber mountings (A).
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15.
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Diesel:
Fit the exhaust system:
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Fit the bracket (E) for the particle filter/rear catalytic converter.
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Fit the hose (D) for measuring pressure drop for the particle filter/rear catalytic converter.
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Fit the bracket (C) in the oil sump.
Tightening torque 25 Nm (18 lbf ft)
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Fit the front exhaust pipe (A, B), use a new gasket, 55 187 592.
Tightening torque 25 Nm (18 lbf ft)
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16.
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Diesel:
Fit the lower engine cover (A).
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18.
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Fit the washer and nut (A) for the rear engine mounting.
Tightening torque 47 Nm (35 lbf ft)
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19.
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Fit the screw (A) that holds the steering shaft to the steering gear and remove the tape.
Tightening torque 30 Nm (22 lbf ft)
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20.
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RHD with automatic transmission:
Fit the lower panel with air duct (B) and the data link connector (A).
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21.
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Remove the plug from the cap for the power steering fluid reservoir.
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22.
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Fill with 93 160 548 Power steering fluid, and bleed the power steering system in accordance with WIS - Steering assembly - Power steering system - Adjustment/Replacement.
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23.
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Check that there is no remaining leakage of power steering fluid.
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Marking the modification identity plate (not US/CA)
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After carrying out the procedure, box B1 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.
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Fitting the modification identity plate (not US/CA)
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Note
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A modification identity plate must only be fitted where local directives require the marking of the car.
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Fit the modification identity plate in accordance with WIS
9-5 M04 - General - General - Technical data - Plates and labels
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Warranty/Time Information
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See separate information.
