Parking Heater Accessory 9-3 D223

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19. Saab 9-3 D223 Wiring diagram, MCC, LHD, RHD AB 1 2 36 74 H4-42 Motor, radiator fan, right Relay, water pump Water pump Resistor Motor, cabin fan; in centre between bulkhead wall and partition wall Resistor, cabin fan; under cabin air filter on left-hand side Connection, parking heater; by bulkhead grommet under main fuse box 342a/b in engine bay BN 0.5 BK 0.5 BK 0.5 YE 1.0 BN 1.0 BK 1.0 0.5 BN/RD 1.5 GY 1.5 GN 1.5 BU BN/RD 1.5 BK 0.5 BN 421 H4-42 3 2 1 4 M 1 2 1 A 1 2 3 5 4 2 B 4 OG 86 85 87A 87 30 5 31 1 FL1 2 FL2 4 FL3 74 3 FL4 36 BN 86 85 5 87A 3 87 2 30 1 M496279M 990609

20. Saab 9-3 D223 Wiring diagram, ACC, LHD, RHD B1 H4-42 Relay, water pump Water pump Connection, parking heater; by bulkhead grommet under main fuse box 342a/ b in engine bay 0.5 BK 1.0 BN 1.5 BN/RD 1.0 BK 0.5 BK 1.0 YE BN 86 85 5 87A 3 87 2 30 1 B 4 1 M 1 2 H4-42 421 4 1 2 3 M496279a 990609

2. 2 4962791 Saab 9-3 D223 ACC 1 Engine coolant pump 2 Bracket, coolant pump 3 Nut M6 4 Engine coolant hose (suction hose) 5 Engine coolant hose (delivery hose) 6Hoseclips(2pcs) 7 Main fuse box with wiring harness 8 Mounting, main fuse box 9 Fuse10A 10 Fuse 20 A 11 Label, fuse 12 Label, tank hatch 13 Cableties(5off) D980A067 9 10 11 12 1 3 8 2 4 6 5 7 13

3. 49 62 791 3 Saab 9-3 D223 MCC 1 Engine coolant pump 2 Bracket, coolant pump 3 Nut M6 4 Engine coolant hose (suction hose) 5 Engine coolant hose (delivery hose) 6Hoseclips(2off) 7 Main fuse box with wiring harness 8 Mounting, main fuse box 9 Fuse10A 10 Fuse 20 A 11 Label, fuse 12 Label, tank hatch 13 Cableties(5pcs.) 14 Resistor with mounting 15 Screw M5 16 Washer 17 Nut M5 18 Rubber grommet 19 Connector, straight 20 Connector, angled D980A068 9 10 11 12 1 3 8 2 5 4 6 7 13 17 16 15 14 20 19 18

5. 49 62 791 5 Saab 9-3 D223 LHD 1 Read fully through the installation instructions and check that all the parts are present in the kit. 2 Lay covers on the wings and remove the cap on the coolant system expansions tank. 3 Raise the car. Remove the bottom engine cover. 4 Prepare a receptacle for the engine coolant. Open the drain plug, connect a hose and drain the coolant. WARNING Take care if the car engine is warm. The engine coolant can be hot. There is also a risk of burns from the turbocharger and the exhaust manifold. D980A069 4 3 2

6. 6 4962791 Saab 9-3 D223 5 Lower the car. Apply acid-free vaseline, part no. 30 06 665, on the pump housing and the inside of the bracket. Press the coolant pump into the bracket, making sure the pump outlet is pointing in direction shown in the illustration. 6 Fit the main fuse box mounting to the coolant pump bracket with the M6 nut. 7 MCC: Fit the resistor to its mounting with the screw, washer and nut (M5). 8 Connect the wiring harness cable with the 2-pin connector to the coolant pump. D980A070 5 8 5 6 7

12. 12 49 62 791 Saab 9-3 D223 RHD 1 Read fully through the installation instructions and check that all the parts are present in the kit. 2 Lay covers on the wings and remove the cap on the coolant system expansions tank. 3 Raise the car. Remove the bottom engine cover. 4 Prepare a receptacle for the engine coolant. Open the drain plug, connect a hose and drain the coolant. WARNING Take care if the car engine is warm. The engine coolant can be hot. There is also a risk of burns from the turbocharger and the exhaust manifold. D980A069 4 3 2

13. 49 62 791 13 Saab 9-3 D223 5 Lower the car. Apply acid-free vaseline, part no. 30 06 665, on the pump housing and the inside of the bracket. Press the coolant pump into the bracket, making sure the pump outlet is pointing in direction shown in the illustration. 6 Fit the main fuse box mounting to the coolant pump bracket with the M6 nut. 7 MCC: Fit the resistor to its mounting with the screw, washer and nut (M5). 8 Connect the wiring harness cable with the 2-pin connector to the coolant pump. D980A070 5 8 5 6 7

11. 49 62 791 11 Saab 9-3 D223 48 Remove the cover on the main fuse box. 49 Clean the inside of the cover and affix the label marked PARK. HTR 20 A over the marking on position 15. 50 Replace fuse 15 with the 20 A fuse included in the kit. 51 Fit the 10 A fuse included with the kit in position 14 (ADD. HTR./WAT. PUMP). 52 Refit the main fuse box cover. 53 Fit the air cleaner cover with mass air flow sen- sor and turbocharger inlet hose. Fit the hose for the crankcase ventilation. Plug in the mass air flow sensor connector 54 Raise the car. Detach the coolant drain hose and tighten the drain plug. 55 Fit the bottom engine cover. 56 Lower the car. Fill with coolant and check for leaks. 57 Program the parking heater with the diagnostic tool: Diagnosis, model year, car model, Body, SID, Programming, Activating, Parking heater Select: Activate by timer and outdoor temperature. 58 Bleed the cooling system in the following way: Connect an exhaust hose to the auxiliary heater. Start the engine and make sure there is a continuous flow of coolant through the hose from the thermostat housing to the expansion tank. Start the auxiliary heater manually on the SID panel. Run the engine until the thermostat has opened. Then, turn off the engine, carefully open the lid to the expansion tank and top up to MAX level as necessary. Close the lid. 59 Make sure there are no leaks in the coolant system and that the heater is working by starting it manually. 60 Clean the inside of the tank hatch and affix the warning label. 61 Place the installation instructions in the car and draw the customer’s attention to the user instructions at the end of section “Technical data” under the heading “Engine and cabin heater” in the user manual. D980A075 53 51 50 14 15 Note ACC or A/C should be OFF.

18. 18 49 62 791 Saab 9-3 D223 46 Remove the cover on the main fuse box. 47 Clean the inside of the cover and affix the label marked PARK. HTR 20 A over the marking on position 15. 48 Replace fuse 15 with the 20 A fuse included in the kit. 49 Fit the 10 A fuse included with the kit in position 14 (ADD. HTR./WAT. PUMP). 50 Refit the main fuse box cover. 51 Fit the air cleaner cover with mass air flow sen- sor and turbocharger inlet hose. Fit the hose for the crankcase ventilation. Plug in the mass air flow sensor connector 52 Raise the car. Detach the coolant drain hose and tighten the drain plug. 53 Fit the bottom engine cover. 54 Lower the car. Fill with coolant and check for leaks. 55 Program the parking heater with the diagnostic tool: Diagnosis, model year, car model, Body, SID, Programming, Activating, Parking heater Select: Activate by timer and outdoor temperature. 56 Bleed the cooling system in the following way: Connect an exhaust hose to the auxiliary heater. Start the engine and make sure there is a continuous flow of coolant through the hose from the thermostat housing to the expansion tank. Start the auxiliary heater manually on the SID panel. Run the engine until the thermostat has opened. Then, turn off the engine, carefully open the lid to the expansion tank and top up to MAX level as necessary. Close the lid. 57 Make sure there are no leaks in the coolant system and that the heater is working by starting it manually. 58 Clean the inside of the tank hatch and affix the warning label. 59 Place the installation instructions in the car and draw the customer’s attention to the user instructions at the end of section “Technical data” under the heading “Engine and cabin heater” in the user manual. D980A080 51 49 48 14 15 Note ACC or A/C should be OFF.

1. Saab 9-3 D223 900 Monteringsanvisning SCdefault MONTERINGSANVISNING · INSTALLATION INSTRUCTIONS MONTAGEANLEITUNG · INSTALLATIONS DE MONTAGE SITdefault Saab 9-3 D223 Parking Heater Accessory Accessories Part No. Group Date Instruction Part No. Replaces 400 110 482 400 110 839 400 110 821 400 110 847 9:87-13 Aug 98 49 62 791 - D980A066 AC/MCC

14. 14 49 62 791 Saab 9-3 D223 9 Undo the lid to the air cleaner, which also con- tains the mass air flow sensor. Detach the turbo- charger inlet hose and the crankcase ventila- tion. Unplug the mass air flow filter connector. 10 Undo the coolant hose from the generator bracket and heater. Cut the cable ties on the hoses to the vacuum box and vacuum pump and remove the hose. 11 Remove the left-hand and centre screws securing the stay between the suspension struts in the bulkhead. 12 Fit the coolant pump bracket (with the main fuse box mounting) with the screws on the stay. Make sure there is sufficient room between the brake pipes and the coolant pump. If necessary, push aside the brake pipes with the shaft of a hammer or similar. Tighten the nut on the main fuse box mounting. MCC: Fit the resistor with its mounting using the centre screw on the stay. Connect the main fuse box cables to the resistor. Tightening torque 8 Nm (6 lbf ft) 13 Lay the main fuse box cables behind the coolant pump bracket. 14 Make sure the drainage from the bulkhead par- tition is free and not pinched, preventing any water from running out. 15 Fit the coolant hose (suction hose) to the gene- rator bracket and to the coolant pump inlet with hose clips. 16 Connect the coolant hose (delivery hose) bet- ween the coolant pump outlet and the heater inlet. Make sure the resistor is not touching the coolant hoses. 17 Secure the hoses with cable ties, see illustra- tion. 18 Hook the main fuse box to the mounting on the coolant pump bracket. Make sure the cables are not pinched. Note Cover the generator to prevent it from being damaged if coolant should run out. D980A076 12 11 10 10 9 12 17 17 14

7. 49 62 791 7 Saab 9-3 D223 9 Undo the lid to the air cleaner, which also con- tains the mass air flow sensor. Detach the turbo- charger inlet hose and the crankcase ventila- tion. Unplug the mass air flow filter connector. 10 Undo the coolant hose from the generator bracket and heater. Cut the cable tie and remo- ve the hose. 11 Remove the left-hand and centre screws securing the stay between the suspension struts in the bulkhead. 12 Fit the coolant pump bracket (with the main fuse box mounting) with the screws on the stay. Tigh- ten the nut on the main fuse box mounting. MCC: Fit the resistor with its mounting using the centre screw on the stay. Connect the main fuse box cables to the resistor. Tightening torque 8 Nm (6 lbf ft) 13 Lay the main fuse box cables behind the coolant pump bracket. 14 Make sure the drainage from the bulkhead par- tition is free and not pinched, preventing any water from running out. 15 Fit the coolant hose (suction hose) to the gene- rator bracket and to the coolant pump inlet with hose clips. 16 Connect the coolant hose (delivery hose) bet- ween the coolant pump outlet and the heater inlet. 17 Secure the hoses with cable ties, see illustra- tion. 18 Hook the main fuse box to the mounting on the coolant pump bracket. Make sure the cables are not pinched. Note Cover the generator to prevent it from being damaged if coolant should run out. 9 11 10 D980A071 15 17 12 12 16 14

4. 4 4962791 Saab 9-3 D223 Introduction The parking heater accessory is available in differ- ent versions for left-hand drive (LHD) cars and right- hand drive (RHD) cars as well as for cars with ACC (automatic climate control) or MCC (manual climate control with or without A/C). The installation instructions are separate for left and right-hand drive cars. See the heading LHD on page 8 for left-hand drive cars. See the heading RHD on page 28 for right-hand drive cars. Safety regulations • The heater must not be used in confined spaces such as garages or workshops unless apparatus for exhaust extraction is used. • Always turn off the heater in service stations and similar premises.

17. 49 62 791 17 Saab 9-3 D223 41 MCC: Fit the cabin air filter. 42 MCC: Fit the wiper motor cover. 43 MCC: Fit the windscreen cover. 44 MCC: Fit the wiper arms. 45 MCC: Fit the rubber strip. D980A079 41 44 45 43

10. 10 49 62 791 Saab 9-3 D223 42 MCC: Fit the cabin air filter. 43 MCC: Fit the wiper unit, four screws and plug in the connector. 44 MCC: Fit the wiper motor cover. 45 MCC: Fit the windscreen cover. 46 MCC: Fit the wiper arms. 47 MCC: Fit the rubber strip. D980A074 43 44 46 47 46 45 42

15. 49 62 791 15 Saab 9-3 D223 19 ACC: Undo the sealing strip and nut securing the main fuse box. Lift up the main fuse box. 20 MCC: Remove the wiper arms, sealing strip and windscreen cover. 21 MCC: Remove the cover over the wiper motor. 22 MCC: Remove the cabin air filter. 23 MCC: Unplug the connector and lift away the existing cable grommet in the fan housing. 24 MCC: Put aside the cables and drill a 15 mm hole in the fan housing as illustrated. Remove the protection against cuttings. 25 MCC: Replace the rubber grommet and plug in the connector. Note Make sure the sealing strip is not damaged and that no cuttings fall into the fan housing. 19 D980A077 23 22 23,25 23 24 20 20 19

8. 8 4962791 Saab 9-3 D223 19 ACC: Undo the sealing strip and nut securing the main fuse box. Lift up the main fuse box. 20 MCC: Remove the wiper arms, sealing strip and windscreen cover. 21 MCC: Remove the cover over the wiper motor and unplug the connector. 22 MCC: Remove the wiper unit, 4 bolts. 23 MCC: Remove the cabin air filter. 24 MCC: Unplug the connector and lift away the existing cable grommet in the fan housing. 25 MCC: Put aside the cables and drill a 15 mm hole in the fan housing as illustrated. Remove the protection against cuttings. 26 MCC: Replace the rubber grommet and plug in the connector. 27 MCC: Undo the nut securing the main fuse box. Lift up the main fuse box. Note Make sure the sealing strip is not damaged and that no cuttings fall into the fan housing. D980A072 21 21 22 20 20 19 19,27 23 23 24,26 24 25

9. 49 62 791 9 Saab 9-3 D223 28 Lift up the SID connector. Remove the seal on the connector and spray Kontakt 61, part no. 30 04 520, on the pins. 29 ACC: Run the main fuse box cable with the 4- pin connector behind the brake servo and plug it into the connector on the cable from SID. Secu- re with cable ties. 30 ACC: Fit the main fuse box and sealing strip. 31 MCC: Carefully make a hole in the existing rub- ber grommet, see illustration. 32 MCC: Runtheremainingtwomainfusebox cables (with uninsulated cable lugs) behind the brake servo and in through the wall to the bulk- head partition space. 33 MCC: Thread the rubber grommet included in the kit onto the cables and insert them through the drilled hole in the fan housing. 34 MCC: Detach the pin with the orange cable in the fan housing and fit the angled connector to the pin. 35 MCC: Fit the straight connector to the pin on the blue cable. 36 MCC: Couple together the orange and blue cables. 37 MCC: Plug the green cable (with angled pin) to the fan connector pin. 38 MCC: Secure the cables to the existing wiring harness in the fan housing. 39 MCC: Seal both grommets with Teroson T242, part no. 30 15 781, or equivalent sealant. 40 MCC: Plug in the 4-pin connector to the connec- tor on the cable coming from SID. Secure both cables with cable ties. 41 MCC: Fit the main fuse box. WARNING Make sure the cables are not lying against sharp edges or warm surfaces. Wear and heat damage can cause short circuits. D980A073 30 28,30,41 33 32 38 31 28,29,40 35 37 34 WARNING Make sure the cables are not lying against sharp edges or warm surfaces. Wear and heat damage can cause short circuits.

16. 16 49 62 791 Saab 9-3 D223 26 MCC: Undo the nut securing the main fuse box. Lift up the main fuse box. 27 Lift up the SID connector. Remove the seal on the connector and spray Kontakt 61, part no. 30 04 520, on the pins. 28 ACC: Run the main fuse box cable with the 4- pin connector behind the brake servo and plug it into the connector on the cable from SID. Secu- re with cable ties. 29 ACC: Fit the main fuse box and sealing strip. 30 MCC: Carefully make a hole in the existing rub- ber grommet, see illustration. 31 MCC: Runtheremainingtwomainfusebox cables (with uninsulated cable lugs) behind the brake servo and in through the wall to the bulk- head partition space. 32 MCC: Thread the rubber grommet included in the kit onto the cables and insert them through the drilled hole in the fan housing. 33 MCC: Detach the pin with the orange cable in the fan housing and fit the angled connector to the pin. 34 MCC: Fit the straight connector to the pin on the blue cable. 35 MCC: Couple together the orange and blue cables. 36 MCC: Plug the green cable (with angled pin) to the fan connector pin. 37 MCC: Secure the cables to the existing wiring harness in the fan housing. 38 MCC: Seal both grommets with Teroson T242, part no. 30 15 781, or equivalent sealant. 39 MCC: Plug in the 4-pin connector to the connec- tor on the cable coming from SID. Secure both cables with cable ties. 40 MCC: Fit the main fuse box. WARNING Make sure the cables are not lying against sharp edges or warm surfaces. Wear and heat damage can cause short circuits. 27,29,40 26,29 27,28,39 D980A078 30 33 35 34 37 32 31 WARNING Make sure the cables are not lying against sharp edges or warm surfaces. Wear and heat damage can cause short circuits.

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