SAAB WIS ONLINE

(644-2699) Replacement of the power steering system's delivery line

Symptom: Chafing damage to the power steering system's delivery line.

MODIFICATION INSTRUCTION
Bulletin Nbr: 644-2699
Date: ........... April 2008
Market: all
Replacement of the power steering system's delivery line

Customer Satisfaction Program 15456

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.

Cars affected

Saab 9-5 M06-08 with engine alternative B205 and B235 within Vehicle Identification Number range 63520874 - 83506655

Background

The power steering system's delivery line may chafe against the radiator, which in some cases may lead to power steering fluid leakage.

Symptom description

Chafing damage to the power steering system's delivery line.



Parts required

Servo hose 12 784 442

Chafing guard 12 784 443

Power steering fluid 93 160 548 (0.55 l/car)

For fitting the modification identity plate (not US/CA):

12 785 148 Modification identity plate

Checking the modification identity plate (not US/CA)

Before proceeding, check box A5 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

To remove




1. Raise the car.

2. Remove the front spoiler shield (A).


3. Undo the air pipe's hose clip (B) and fold aside the pipe (C).


4. Remove the delivery line's clamps (A).


5. Position a receptacle under the car. Hold with a 21 mm wrench and remove the delivery pipe from the cooling circuit (A).


6. Lower the car.

7. Detach the mass air flow sensor and the hose (A). Move the mass air flow sensor aside.


8. Undo the clamp (A) for the power steering pump's feed hose and move the hose aside.


9. Unload the belt tensioner with the tool 83 95 254 (A).


10. Rotate the power steering pump's belt pulley to a position where it is possible to access the bolt (A) to the bracket. Detach the bracket at the power steering pump for the front delivery line. Remove the pipe (B) from the pump.


11. Raise the car.

12. Route the delivery line down.


To fit




1. Fit the chafing guard by winding it around the new hose.


2. Route up the delivery line with transport protection on. The pipe should be routed up between the radiator member and the radiator, behind the cable for the A/C compressor.


3. Lower the car.

4. Remove the transport protection from the delivery line.

Align the delivery pipe's bracket inside the bolt's washer.

Press the pipe's nut against the pipe's flange.

Fit the delivery pipe's nut (A) enough so that it can be tightened manually.


5. Tighten the delivery pipe (A).

Tightening torque 30 Nm (22 lbf ft)


6. Tighten the bolt for the delivery line's bracket (B).

7. Raise the car.

8. Remove the transport protection from the delivery line.

Press the pipe's nut against the pipe's flange.

Fit the delivery pipe's nut (A) enough so that it can be tightened manually.


9. Fit the delivery line's clamps (B). Make sure that the wide part of the clamp (C) is fitted on the upper pipe.


10. Hold with a 21 mm wrench and tighten the delivery line's connection (A).

Tightening torque 30 Nm (22 lbf ft)


11. Align a 9 mm drill bit between the pipes (A). Adjust the gap to 9 mm by adjusting the position of the lower pipe. Tighten the delivery pipe's clamps (B).

Tightening torque 11 Nm (8 lbf ft)

Note

After fitting the new hose with chafing guard, the hose may now be in contact with the radiator.



12. Fit the air pipe (C) and tighten the hose clip (B).


13. Lower the car.

14. Connect the power steering pump's feed hose and fit the clamp (A).


15. Fit the mass air flow sensor and hose (A).


16. Fill with oil and bleed in accordance with WIS - 6. Steering assembly - Power steering system - Bleeding the power steering system.

17. Check the sealing integrity at the pump's connection.

18. Raise the car.

19. Check the sealing integrity at the cooling circuit's connection.

20. Fit the front spoiler shield (A).


21. Lower the car.


Marking the modification identity plate (not US/CA)

After carrying out the procedure, box A5 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 (not US/CA)

Note

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


Fit the modification identity plate in accordance with WIS

9-5 M04 - General - General - Technical data - Plates and labels

Warranty/Time Information

See separate information.