Sports chassis 9-3 4D 2

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5. 12 788 450 5 Saab 9-3 4D M03- 9 Remove the protective cover from the top of the MacPherson strut. Stop the piston rod from turning and remove the nut using the 89 96 613 Socket, MacPherson strut. 10 Remove the bearing support and the support bearing. 11 Remove the dust excluder, spring, bump stop and the zinc washer. F970A005 9 10 11 11 11 10

8. 8 12 788 450 Saab 9-3 4D M03- 26 Detach the steering column from the steering gear. 27 Remove the heat shield from the steering gear. 28 Detach the track rod from the steering swivel housing on the driver side using Puller, 150 mm 87 91 287. 29 Remove the nuts attaching the engine torque arms to the subframe and detach the torque arms from the subframe. 30 Remove the rear bolts from the subframe. Unscrew the front bolts a few turns. Prise down the subframe with wedges. F970A008 30 30 30 30 28 27 26 29

9. 12 788 450 9 Saab 9-3 4D M03- 31 Detach the anti-roll bar from the subframe. 32 Remove the anti-roll bar via the driver side wheel arch, between the bulkhead and the subframe. 33 Insert the new anti-roll bar via the driver side wheel arch, between the bulkhead and the subframe. 34 Lubricate the rubber bushes with bearing grease (part No. 30 20 476) and fit them onto the new anti-roll bar together with the clamps. Attach the anti-roll bar to the subframe. The opening in the rubber bushes should be facing forwards. Tightening torque 18 Nm (13 lbf ft) F970A009 31 33 34

4. 4 12 788 450 Saab 9-3 4D M03- Front In certain cases the description applies to only one side but the work must be carried out on both sides. 1 Remove the anti-roll bar link from the left-hand side of the car. Use a 17 mm open ended spanner. 2 Remove the holder for the wheel sensor connector and the brake hose clip. Unhook the hose. 3 Support the steering swivel member with a jack. Let the jack remain in place throughout the procedure. 4 Disconnect the steering swivel member from the MacPherson strut. Use a spanner to stop the bolt from rotating. 5 Lower the steering swivel member. 6 Remove the bolts from the MacPherson strut upper mounting. 7 Lift away the MacPherson strut and grip it in a vice. 8 Compress the spring with the 88 18 791 Spring compressor. Important Do not grip too tightly. F970A004 2 1 4 2 8 1 6 6

13. 12 788 450 13 Saab 9-3 4D M03- 9 Remove the bolt which attaches the shock absorber to the steering swivel member. 10 Detach the shock absorber bracket from the body. Lift away the shock absorber. 11 Remove the shock absorber on the other side. 12 Remove the bracket from the shock absorber. 13 Transfer the washers to the new shock absorbers. Note The forward and upper bracket bolts only need to be loosened as they locate in open slots in the bracket. F970A013 9 12 12 10 10 10

16. 16 12 788 450 Saab 9-3 4D M03- 26 Plug in the wiring harness connector and close the lid of the protective box. 27 Fit the spring supports onto the springs. Place the springs on the lower suspension arms. 28 Raise the subframe. Push the subframe slightly forwards. 29 Attach the subframe to the body. Tightening torque 75 Nm +135° (55 lbf ft +135°) 30 Remove the jack. F970A016 29 29 26 27 26 26

19. 12 788 450 19 Saab 9-3 4D M03- 45 Fit the exhaust pipe. Important The flexible dust excluder on the forward section of the exhaust system must not be bent more than 5° from its neutral alignment. Excessive loading of the pipe can lead to residual deformations in the components which can cause noise, leakage and eventually failure. F970A019 45 45 45 45 45 45 45

2. 2 12 788 450 Saab 9-3 4D M03- 1 Spring, front (x2) 2 MacPherson strut, front (x2) 3 Lock nut, front (x2) 4 Splined bolt (x4) 5 Screw (x6) 6 Nut (x9) 7 Anti-roll bar, front 8 Clamp (x2) 9 Rubber bush (x2) 10 Spring, rear (x2) 11 Shock absorber, rear (x2) 12 Nut (x2) 13 Screw (x2) 14 Anti-roll bar, rear 15 Clamp (x2) 16 Rubber bush (x2) 17 Washer (x4) Contents Preparatory work, page 6 Front, page 8 Rear, page 32 Concluding work, page 54 After installation of the sports chassis, page 60 10 2 1 5 3 4 6 7 9 8 14 12 17 13 15 11 F970A002 16

11. 12 788 450 11 Saab 9-3 4D M03- 41 Fit the plastic nut to the rear of the inner wing. 42 Attach the steering column to the steering gear. Ensure that the groove in the steering gear shaft is correctly positioned so that the bolt engages in the groove. Tightening torque 27 Nm (20 lbf ft) 43 Fit the anti-roll bar links on both sides. Use a thin 17 mm open ended spanner. Tightening torque 64 Nm (47 lbf ft) F970A011 41 43 43 42

1. Saab 9-3 4D M03- 900 Installation instructions SCdefault MONTERINGSANVISNING · INSTALLATION INSTRUCTIONS MONTAGEANLEITUNG · INSTRUCTIONS DE MONTAGE SITdefault Saab 9-3 4D M03- Sports chassis Accessories Part No. Group Date Instruction Part No. Replaces 12 787 892 12 799 202 12 799 203 32 000 521 32 000 522 32 000 523 32 000 524 9:76-05 May 04 12 788 450 May 02 F970A001

3. 12 788 450 3 Saab 9-3 4D M03- Preparations 1 Raise the car. 2 Remove all the wheels. 3 Remove the spoiler shield, unplug the bumper connector and remove it from the holder on the spoiler shield. Cars with headlamp washers: Unhook the hose from the spoiler shield. 4 Vehicles with diesel engine: Remove the sound insulation from under the engine. F970A003 3 3 3 3 3 4 3 3

6. 6 12 788 450 Saab 9-3 4D M03- 12 Compress the new spring with the 88 18 791 Spring compressor. 13 Assemble the zinc washer, bump stop, spring and the dust excluder. Make sure that the spring's lower end lies against the stop lug in the lower spring seat. 14 Fit the support bearing and the bearing support. 15 Fit a new nut. Tightening torque 105 Nm (78 lbf ft) 16 Fit the protective cover. 17 Release the spring compressor and adjust the dust excluder so that it fits over the end of the shock absorber. 18 Position the MacPherson strut in place on the car and fit new bolts to the upper mounting. 19 Tighten the bolts by hand to begin with and thereafter with a torque wrench to the correct torque. Tightening torque 19 Nm (14 lbf ft) Note The mounting holes are not positioned symmetri- cally. F970A006 18 18 12 14 13 13 14 13 13 15

7. 12 788 450 7 Saab 9-3 4D M03- 20 Raise the steering swivel member and push into place on the MacPherson strut. Fasten the steering swivel member to the MacPherson strut with new bolts, nuts and washers (the washers must be fitted on the same side as the nuts). Stop the bolt from turning with a spanner. Tightening torque 80 Nm +135° (59 lbf ft +135°) Lower and remove the jack. 21 Fit the mounting for the wheel sensor cable and fit the brake hose and clip. 22 Repeat steps1-21 on the right-hand side of the vehicle. 23 Remove the rear nut from the inner wing on the driver side. 24 Lower the vehicle and secure the steering wheel in the straight ahead position using for example fibre tape attached to the instrument panel. 25 Raise the vehicle and remove the exhaust pipe. Important The flexible dust excluder on the forward section of the exhaust system must not be bent more than 5° from its neutral alignment. Excessive loading of the pipe can lead to residual deformations in the components which can cause noise, leakage and eventually failure. F970A007 21 20 23 25 25 25 25 25 25 20

14. 14 12 788 450 Saab 9-3 4D M03- 14 Fit the brackets to each of the shock absorbers with new nuts. Tightening torque 27 Nm (20 lbf ft) 15 Open the protective box and unplug the wiring harness connectors. 16 Place a pillar jack centrally under the subframe. 17 Unscrew the subframe bolts from the body. 18 Lower the subframe and lift away the springs. Important The subframe must not be lowered more than 200 mm at the rear edge. F970A014 14 18 14 17 17 15 15 15

15. 12 788 450 15 Saab 9-3 4D M03- 19 Detach the anti-roll bar from the axle carrier. 20 Remove the anti-roll bar clamps from the subframe. 21 Lift out the anti-roll bar backwards between the subframe and the body. 22 Manoeuvre in the new anti-roll bar between the subframe and the body. Lubricate the rubber bushes with bearing grease (part No. 30 20 476) and fit them onto the new anti-roll bar together with the clamps. Locate the anti-roll bar against the subframe. 23 Insert and loosely screw in all of the anti-roll bar mounting bolts. 24 Tighten the bolts holding the anti-roll bar to the subframe. Tightening torque 18 Nm (13 lbf ft) 25 Attach the anti-roll bar to the axle carrier on each side. Tightening torque 53 Nm (39 lbf ft) WARNING Check that the wiring harness is not pinched. Incorrect fitting can damage the wiring harness and cause a short-circuit/fire. F970A015 21 20 19 22 23,24 23,25

21. 12 788 450 21 Saab 9-3 4D M03- After fitting the sports chassis: 1 Carry out a 4-wheel alignment check and adjust if necessary. (See WIS 6. Steering assembly - Steering linkage - Adjustment, replacement - Four wheel alignment.) 2 Vehicles with ESP: Connect the diagnostic tool, select model and year, select “All”, select “Add/Remove”, select the accessory and select “Add”. 3 Cars with conventional headlights: Check headlight alignment and adjust if necessary. Cars with xenon headlights: Calibrate AHL as follows: – The car must be standing level. – The car must be unladen. – Rock the car to ensure that all dampers are freed up. – The handbrake must be released. – The xenon headlights must be on. – Connect the diagnostic tool and calibrate both AHL control modules. Check the func- tion of the headlights and erase any DTCs. – Check headlight alignment and adjust if necessary.

10. 10 12 788 450 Saab 9-3 4D M03- 35 Raise the subframe up against the body and loosely screw into place the bolts on both sides. 36 Position and raise a trolley jack with fixture underneath and tighten all of the subframe bolts. Tightening torque 75 Nm +135° (55 lbf ft +135°) 37 Lower and remove the trolley jack. 38 Fit the heat shield to the steering gear. 39 Fit the engine torque arms. Tightening torque 70 Nm +90° (52 lbf ft +90°) 40 Attach the driver side track rod to the steering swivel housing with a new nut. Stop the ball joint rotating with an 8 mm spanner. Tightening torque 35 Nm (26 lbf ft) F970A010 36 38 35 40 36 36 36 39

17. 12 788 450 17 Saab 9-3 4D M03- 31 Attach the shock absorber brackets to the body. Tightening torque 53 Nm (39 lbf ft) 32 Attach the shock absorbers to the steering swivel members with new bolts. Tightening torque 150 Nm (111 lbf ft) 33 Remove the inner brake pads and press in the brake pistons using the Resetting tool 89 96 969 together with Adapter 89 96 977. 34 Fit the brake pads. Important Ensure that the springs on the inner pad locate in the groove on the cylinder. F970A017 32 31 31 33,34

12. 12 12 788 450 Saab 9-3 4D M03- Rear In certain cases the description applies to only one side but the work must be carried out on both sides. 1 TPM: Remove the screws and nuts which fasten the rear wing liners. 2 TPM: Detach both wing liners from the studs. 3 TPM: Free the wing liners from the wheel arch rim starting at the rear and working forwards. Lift away the wing liners. 4 TPM: Unplug the connector from the signal detector. Undo the clips in the wheel arch and fold down the wiring harness on both sides. 5 Remove the spring from the brake caliper. 6 Remove the protective covers. 7 Detach the brake caliper and hang it up with a hook from the brake pipe mounting. Remove the outer brake pads. 8 Detach the brake caliper on the other side. Important Be careful so that the brake pipe is not damaged. F970A012 7 1 1 1 4 6 7 6 5 7

18. 18 12 788 450 Saab 9-3 4D M03- 35 Fit the brake caliper. Tightening torque 28 Nm (21 lbf ft) 36 Fit the protective covers. 37 Fit the spring. 38 Repeat steps 33-37 on the other side. 39 TPM: Plug in the connector to the signal detector and push the clip firmly in place. 40 TPM: Angle each wing liner into position. Manoeuvre the lower edges in against the wheel arch. 41 TPM: Guide each liner onto the upper stud and then onto the remaining studs. 42 TPM: Fit each wing liner in against the wheel arch rim and the bumper cover. The wing liner should be located behind the bumper cover. 43 TPM: Check that the wing liners are correctly fitted. 44 TPM: Fit all the screws and nuts. F970A018 39 44 44 44 40 35 36 37 36 35 35

20. 20 12 788 450 Saab 9-3 4D M03- Concluding work 1 Clean all dirt and rust from the contact surfaces of the wheel and brake disc. 2 Brush White high-pressure grease paste 30 06 442 onto the hub. 3 Aluminium wheels: Oil the bolt threads and the conical surface of the bolts. 4 Hang the wheels in position. Fit the bolts and screw them in by hand, progressively and sequentially, so that the wheel is centred. 5 Tighten the bolts in sequence twice. Tightening torque 110 Nm (81 lbf ft) 6 Vehicles with diesel engine: Fit the sound insulation under the engine. 7 Lift up the spoiler shield, fit the bumper connec- tor into the holder and plug in the connector. Cars with headlamp washers: Hook the hose to the spoiler shield. All: Fit the spoiler shield. 8 Lower the car. 9 Remove the steering wheel restraint. 10 Push down on the brake pedal a few times to activate the brake pistons and the handbrake self-adjustment. 11 Cars with headlamp washers: Check the function of the headlamp washers. Important Make sure that no grease gets onto the contact surfaces of the wheel and brake disc. Important When tightening the wheel bolts the wheel must be hanging freely. F970A020 1 2 Important After fitting is completed a 4-wheel alignment check must be carried out.

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