Changing generator, 4-cyl. RHD

Changing generator, 4-cyl. RHD

Note

If the car is equipped with a radio other than a genuine Saab radio, check that the customer has the radio code before commencing work.

1.	Drape protective covers over the front wings.

2.	Lift off the battery cap and disconnect the negative cable.

3.	Remove the shield from the intake manifold.

4.	Remove the crankcase ventilation solenoid and constant-pressure valves.

5.	Relieve the tension on the belt tensioner and remove it. Use special tool 83 95 254.

6.	Remove the generator's upper retaining bolt.

7.	Pinch the hoses for the steering servo reservoir inlet and outlet with hose pliers 30 07 739.

8.	Mark and detach the retaining nut on the right-hand engine mounting and lubricate it to give it some mobility.

9.	Detach the retaining nut on the rear engine mounting.

10.	Remove the front exhaust pipe, see Front exhaust system with three-way catalytic converter, 4 cyl. .

11.	Remove the pipe/hose between the steering gear and the power steering fluid reservoir. Place a collecting vessel under the pipe/hose.

12.	Remove the steering gear's two retaining bolts.

13.	Remove the hose between the oil trap and the oil sump.

14.	Disconnect the terminals B+ and D+ on the generator.

15.	Remove the generator's lower retaining bolt.

16.	Face the generator and belt pulley downwards between the steering gear and the intermediate shaft.

17.	Insert a bar carefully between the gearbox and the subframe.

18.	Lower the generator.

Refitting

1.	To make it easier to fit the generator, tap the bushings until they are level with the mountings.

2.	Clean the generator mountings and apply Vaseline to reduce oxidization.

3.	Insert a bar carefully between the gearbox and the subframe.

4.	Lower the generator.

5.	Refit the generator retaining bolts loosely.

6.	Clean terminals B+ and D+ and apply Vaseline before connecting them.

7.	Refit the hose between the oil trap and the oil sump.

8.	Refit the two retaining bolts on to the steering gear.

9.	Refit the pipe/hose between the steering gear and the power steering fluid reservoir.

10.	Fit the front exhaust pipe, see Front exhaust system with three-way catalytic converter, 4 cyl. .

11.	Refit the generator's upper retaining bolt.

12.	Refit the belt tensioner. Tightening torque: 45 Nm (33 lbf ft)

13.	Mount the drive belt and check its position on all the pulleys. Reapply the tension.

14.	Fit the crankcase ventilation vacuum valve.

15.	Adjust the right-hand engine mounting as per the marking. Check that the engine has a neutral position and tighten the retaining nut to the correct torque. Tightening torque: 50 Nm (37 lbf ft).

16.	Tighten the retaining nut on the rear engine mounting to the correct torque. Tightening torque: 25 Nm (19 lbf ft).

17.	Refit the shield on to the intake manifold.

18.	Reconnect the battery's negative cable and refit the cap.

19.	Release the clamps and fill with power steering fluid.

20.	Set the clock and reprogram the radio code.

21.	Start the engine and let it run at idle speed for a moment. Switch off the engine and check that the belt is correctly positioned.

22.	Bleed the power steering system, see Steering Assembly