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Home >> Saab >> 2004 >> 9-3 Linear, Standard >> Repair and Diagnosis >> Electrical >> Body Electrical >> Control Module >> Adjustment - Replacement >> Connector PSG16 (595), sleeve replacement >> Sleeve replacement.
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Sleeve replacement.

  1. Remove the cover.
    Fig 1: Illustration For Steps 1-2
    G03719091Courtesy of SAAB-SCANIA OF AMERICA, INC.
  2. Cut off the cable tie.
  3. Remove the secondary catch.
    Fig 2: Illustration For Step 3
    G03719092Courtesy of SAAB-SCANIA OF AMERICA, INC.
  4. Undo the sleeve catch by pressing in the extraction tool (part no. 85 80 151).
    Fig 3: Illustration For Steps 4-5
    G03719093Courtesy of SAAB-SCANIA OF AMERICA, INC.
  5. Pull out the cable with the sleeve.
  6. Cut off the lead at the sleeve.
    Fig 4: Illustration For Steps 6 & 8
    G03719094Courtesy of SAAB-SCANIA OF AMERICA, INC.
    NOTE: For further information on how pins/sleeves are fitted, see WIRING HARNESS REPAIR .
  7. If the lead is not long enough, splice it as follows:
    1. 7.1. Strip the insulation off of the leads.
    2. 7.2. Fit a shrink tube with adhesive on the line.
    3. 7.3. Fit sleeve (0.5-1.0 mm2 ), using the blue pliers from 86 12 939 Toolbox, wiring harness.
      NOTE: Leads with 0.35 mm2 are doubled over and crimped together at both ends.
    4. 7.4. Place the shrink tube over the sleeve.
    5. 7.5. Heat the shrink tube until it is secured.
  8. Strip 4 mm of the lead's insulation.
  9. Search for the connector in the spare parts catalogue/EPC to find the part number of the sleeve (cable terminal) to be used.
  10. Fit a new sleeve on the lead using olive green pliers (0.35-0.75 mm2 ) from 86 12 939 Toolbox, wiring harness.
  11. Check that the stripped lead goes through the entire clamped portion of the sleeve and that the insulation is properly clamped.
    Fig 5: Checking Stripped Lead Goes Entire Clamped Portion
    G03719095Courtesy of SAAB-SCANIA OF AMERICA, INC.
  12. Press the sleeve into the connector through the seal.
  13. Check that the sleeve is properly secured.
  14. Check that the sleeve's depth of engagement is the same as the other sleeves in the connector.
    Fig 6: Pressing Sleeve Into Connector Through Seal
    G03719096Courtesy of SAAB-SCANIA OF AMERICA, INC.
  15. Fit the secondary catch.
    Fig 7: Illustration For Step 15
    G03719097Courtesy of SAAB-SCANIA OF AMERICA, INC.
  16. Secure the leads with a cable tie.
    Fig 8: Illustration For Steps 16-17
    G03719098Courtesy of SAAB-SCANIA OF AMERICA, INC.
  17. Fit the cover.
  18. Use a mirror to check that the engine control module pins are straight.
    IMPORTANT: ESD-SENSITIVE COMPONENT 
    Earth yourself by touching the car body before plugging in/unplugging components. Do not touch the component pins  , see ACTIONS WHEN REPLACING ELECTRICAL COMPONENTS .
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