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Home >> Saab >> 2004 >> 9-3 Linear, Automatic >> Repair and Diagnosis >> Electrical >> Body Electrical >> Control Module >> Adjustment - Replacement >> Diesel pump with control module (595) >> To remove
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To remove

IMPORTANT: ESD-SENSITIVE COMPONENT 
Earth yourself by touching the car body before plugging in / unplugging components. Do not touch the component pins  . Read Before removing a control module before changing a control module. See PROCEDURES BEFORE DISMANTLING CONTROL MODULE  .
  1. Loosen the expansion tank cap and release any excess pressure.
    Fig 1: Illustration For Step 4
    G03719182Courtesy of SAAB-SCANIA OF AMERICA, INC.
  2. Raise the car.
  3. Remove the front right wheel.
  4. Remove the right-hand wheel arch liner.
  5. Raise the car.
  6. Remove the front spoiler shield. Detach the headlamp washer hose and unplug and remove the connector.
    Fig 2: Illustration For Step 6
    G03719183Courtesy of SAAB-SCANIA OF AMERICA, INC.
  7. Remove the lower engine cover.
  8. Mark the direction of rotation. Then unload and remove the Poly-V belt.
    Fig 3: Illustration For Steps 8-9
    G03719184Courtesy of SAAB-SCANIA OF AMERICA, INC.
  9. Remove the belt tensioner. Store the belt tensioner upright. See .
  10. Place a receptacle under the car, connect a hose and drain the cooling system.
    Fig 4: Illustration For Step 11
    G03719185Courtesy of SAAB-SCANIA OF AMERICA, INC.
  11. Loosen the coolant pipe screws.
  12. Lower the car.
  13. Remove the upper engine cover.
    Fig 5: Illustration For Steps 14-17, 19-21
    G03719186Courtesy of SAAB-SCANIA OF AMERICA, INC.
  14. Unplug the connector from the mass air flow sensor.
  15. Detach the hose from the crankcase ventilation.
  16. Detach the inlet hose from the turbocharger. Cover the turbocharger inlet.
  17. Remove the cover of the air filter housing.
  18. Remove the air filter.
  19. Detach the intake air hose from the air filter housing.
  20. Remove the air filter housing. Be careful so as not to damage the A/C pressure sensor.
  21. Remove the charge air hose with charge air pipe from the turbocharger and the charge air pipe on the fan cowling. Plug the connections.
  22. Detach the fuel lines using 83 95 261 Fuel line tool and seal them. Have a cloth or the like on hand to catch any fuel spill.
    Fig 6: Illustration For Step 22
    G03719187Courtesy of SAAB-SCANIA OF AMERICA, INC.
  23. Detach the boost pressure hose from the throttle body and put it to the side.
    Fig 7: Illustration For Steps 23-26
    G03719188Courtesy of SAAB-SCANIA OF AMERICA, INC.
  24. Detach the vacuum hose from the throttle body.
  25. Remove the throttle body.
  26. Detach the EGR valve connector and coolant hoses. Remove the EGR valve from the intake manifold.
  27. Place a receptacle under the car to catch fuel spill. Detach the fuel return hoses from the fuel bridges.
    Fig 8: Illustration For Steps 27-29
    G03719189Courtesy of SAAB-SCANIA OF AMERICA, INC.
  28. Mark the position of the fuel rails with clamps and remove them.
  29. Remove the upper section of the intake manifold.
  30. Detach the hoses from the thermostat housing.
    Fig 9: Illustration For Steps 30-31
    G03719190Courtesy of SAAB-SCANIA OF AMERICA, INC.
    IMPORTANT: Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to CONNECTORS, HANDLING AND INSPECTION  .
  31. Unplug the connectors of the A/C pressure sensor, coolant temperature sensor and the engine control module.
  32. Cut off the cable tie securing the coolant pipe. Move aside the wiring from the engine control module.
  33. Detach the supply and return fuel leads from the fuel distribution pump.
    Fig 10: Illustration For Steps 33-34
    G03719191Courtesy of SAAB-SCANIA OF AMERICA, INC.
  34. Detach the coolant pipe with hose and move it aside.
  35. Detach and move aside the cable guides.
    Fig 11: Illustration For Steps 35-37
    G03719192Courtesy of SAAB-SCANIA OF AMERICA, INC.
  36. Detach the vacuum hose of the brake servo and the vacuum hose connected to the bottom of the vacuum pump.
  37. Remove the four retaining bolts of the vacuum pump and carefully lift out the pump and its adapter. Have a cloth or the like on hand to catch any oil spill.
  38. Loosen the rear mounting of the wiring harness from the camshaft cover.
    Fig 12: Illustration For Step 38
    G03719193Courtesy of SAAB-SCANIA OF AMERICA, INC.
  39. Remove the camshaft cover.
    Fig 13: Illustration For Step 39
    G03719194Courtesy of SAAB-SCANIA OF AMERICA, INC.
  40. Rotate the crankshaft to just before the TDC marking in cylinder 1. Check that both cam lobes for cylinder 1 point upwards on an angle.
    Fig 14: Illustration For Steps 40, 43 & 45
    G03719195Courtesy of SAAB-SCANIA OF AMERICA, INC.
  41. Raise the car.
  42. Remove the crankshaft position sensor.
  43. Insert 83 95 352 Adjustment tool, crankshaft in the hole for the crankshaft position sensor. Press the tool in while rotating the crankshaft to its zero mark. The tool will then go into a socket in the crankshaft and lock it.
  44. Lower the car.
  45. Fit inspection gauge 83 95 386 Adjustment tool, camshaft to the camshaft and cylinder head.
  46. Remove the screws of the timing cover lid, carefully insert a putty knife behind the lid and carefully prying it loose.
    Fig 15: Illustration For Steps 46-50
    G03719196Courtesy of SAAB-SCANIA OF AMERICA, INC.
    IMPORTANT: Take care, otherwise the cover can be distorted and cause leaks.
  47. Fit 83 95 337 Adjustment tool, fuel pump in the fuel distribution pump socket.
  48. Remove the upper timing chain tensioner.
  49. Raise the car.
  50. Remove the lower timing chain tensioner.
  51. Lower the car.
  52. Remove inspection gauge 83 95 337 Adjustment tool, fuel pump from the fuel pump socket.
    Fig 16: Illustration For Steps 53, 55 & 57
    G03719197Courtesy of SAAB-SCANIA OF AMERICA, INC.
  53. Secure the upper timing chain to the camshaft gear with a cable tie.
  54. Remove the camshaft gear using an open wrench as counter-stay in the hexagonal socket on the camshaft.
  55. Loosen the screws of the fuel distribution pump sprocket and remove the sprocket.
    IMPORTANT: The center nut must absolutely not  be undone.
  56. Pull the chain up and remove it.
  57. Remove the fuel distribution pump retaining bolts, accessible through a hole in the timing cover. Use 83 95 543 Tool, fuel pump gear.
    Fig 17: Illustration For Steps 58 & 60
    G03719198Courtesy of SAAB-SCANIA OF AMERICA, INC.
  58. Place a receptacle under the car. Loosen the drain nipple, 8 mm socket. Connect a hose to the engine block drain nipple. Drain the coolant.
  59. Remove the drain nipple.
  60. Remove the bracket screw from the cylinder block and remove the fuel pump.
    IMPORTANT: ESD-SENSITIVE COMPONENT 
    Earth yourself by touching the car body before plugging in / unplugging components. Do not touch the component pins  . Read Before removing a control module before changing a control module.
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