Sports chassis 9-3 CV M04, 4D/5D 8

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5. 12 803 216 5 Saab 9-3 CV M04-, 4D/5D M06- 9 Remove the protective cover from the top of the MacPherson strut. Stop the piston rod from tur- ning 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. F970A025 9 10 11 11 11 10

3. 12 803 216 3 Saab 9-3 CV M04-, 4D/5D M06- 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. F970A023 3 3 3 3 3 4 3 3

4. 4 12 803 216 Saab 9-3 CV M04-, 4D/5D M06- 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 con- nector and the clip for the brake hose. Hook the hose aside. 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. F970A024 2 1 4 2 8 1 6 6

10. 10 12 803 216 Saab 9-3 CV M04-, 4D/5D M06- 10 Remove the bolt which attaches the shock absorber to the steering swivel member. 11 Detach the shock absorber bracket from the body. Lift away the shock absorber. 12 Remove the shock absorber on the other side. 13 Remove the bracket from the shock absorber. 14 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. F970A030 13 10 13 11 11 11

17. 12 803 216 17 Saab 9-3 CV M04-, 4D/5D M06- 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 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.

2. 2 12 803 216 Saab 9-3 CV M04-, 4D/5D M06- 1 Spring, front (x2) 2 MacPherson strut, front (x2) 3 Lock nut, front (x2) 4 Splined bolt (x4) 5 Screw (x6) 6 Nut (x6) 7 Spring, rear (x2) 8 Shock absorber, rear (x2) 9 Nut (x2) 10 Screw (x2) 11 Washer (x4) Contents Preparations, page 3 Front, page 4 Rear, page 8 Finishing steps, page 16 After fitting the sports chassis, page 17 2 1 5 3 4 6 9 11 10 F970A022 8 7

1. Saab 9-3 CV M04-, 4D/5D M06- 900 Installation instructions SCdefault MONTERINGSANVISNING · INSTALLATION INSTRUCTIONS MONTAGEANLEITUNG · INSTRUCTIONS DE MONTAGE SITdefault Saab 9-3 CV M04-, 4D/5D M06- Sports chassis Accessories Part No. Group Date Instruction Part No. Replaces 55 25 472 55 25 480 55 25 498 55 25 506 55 25 514 55 25 522 55 25 530 55 25 548 55 25 555 55 25 563 55 25 571 55 25 589 55 25 597 55 25 605 55 25 613 55 25 621 12 803 088 12 803 089 32 000 525 32 000 526 9:76-06 May 05 12 803 216 12 803 216 Apr 04 F970A021

6. 6 12 803 216 Saab 9-3 CV M04-, 4D/5D M06- 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 symmetrically. F970A026 18 18 12 14 13 13 14 13 13 15

7. 12 803 216 7 Saab 9-3 CV M04-, 4D/5D M06- 20 Raise the steering swivel member and push into place on the MacPherson strut. Fasten the ste- ering 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 Fit the anti-roll bar links on both sides. Use a thin 17 mm open ended spanner. Tightening torque 64 Nm (47 lbf ft) 23 Repeat steps 1-22 on the right-hand side of the car. F970A027 21 20 20 20 22

8. 8 12 803 216 Saab 9-3 CV M04-, 4D/5D M06- Rear In certain cases the description applies to only one side but the work must be carried out on both sides. 1 Raise the car and remove the exhaust system. CV: Remove the tunnel reinforcement. 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. F970A028 1 1 1 1 1 1 1

15. 12 803 216 15 Saab 9-3 CV M04-, 4D/5D M06- 39 Fit the exhaust system. 40 CV: Fit the tunnel reinforcement. 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. F970A035 39 39 39 39 39 39 40

12. 12 12 803 216 Saab 9-3 CV M04-, 4D/5D M06- 20 Fit the spring supports onto the springs. Place the springs on the lower suspension arms. 21 Raise the subframe. Push the subframe slightly forwards. 22 Attach the subframe to the body. Tightening torque 75 Nm +135° (55 lbf ft +135°) 23 Remove the jack. 24 CV: Fit the rear chassis reinforcements. Tightening torque 110 Nm (81 lbf ft) F970A032 24 24 20 22 22

11. 12 803 216 11 Saab 9-3 CV M04-, 4D/5D M06- 15 Fit the brackets to each of the shock absorbers with new nuts. Tightening torque 27 Nm (20 lbf ft) 16 CV: Remove the rear chassis reinforcements. 17 Place a pillar jack centrally under the subframe. 18 Unscrew the subframe bolts from the body. 19 Lower the subframe and lift away the springs. Important The subframe must not be lowered more than 200 mm at the rear edge. F970A031 15 16 16 19 15 18 18

13. 12 803 216 13 Saab 9-3 CV M04-, 4D/5D M06- 25 Attach the shock absorber brackets to the body. Tightening torque 53 Nm (39 lbf ft) 26 Attach the shock absorbers to the steering swi- vel members with new bolts. Tightening torque 150 Nm (111 lbf ft) 27 Remove the inner brake pads and press in the brake pistons using the Resetting tool 89 96 969 together with Adapter 89 96 977. 28 Fit the brake pads. Important Ensure that the springs on the inner pad locate in the groove on the cylinder. F970A033 26 25 25 27,28

9. 12 803 216 9 Saab 9-3 CV M04-, 4D/5D M06- 2 TPM: Remove the screws and nuts which fasten the rear wing liners. 3 TPM: Detach both wing liners from the studs. 4 TPM: Free the wing liners from the wheel arch rim starting at the rear and working forwards. Lift away the wing liners. 5 TPM: Remove the connector from the signal detector, the clips from the wheel housing and fold down the cable harness on both sides. 6 Remove the spring from the brake caliper. 7 Remove the protective covers. 8 Detach the brake caliper and hang it up with a hook from the brake pipe mounting. Remove the outer brake pads. 9 Detach the brake caliper on the other side. Important Be careful so that the brake pipe is not damaged. F970A029 8 2 2 2 5 7 8 7 6 8

14. 14 12 803 216 Saab 9-3 CV M04-, 4D/5D M06- 29 Fit the brake caliper. Tightening torque 28 Nm (21 lbf ft) 30 Fit the protective covers. 31 Fit the spring. 32 Repeat steps 27-31 on the other side. 33 TPM: Plug in the connector to the signal detec- tor and push the clip firmly in place. 34 TPM: Angle each wing liner into position. Mano- euvre the lower edges in against the wheel arch. 35 TPM: Guide each liner onto the upper stud and then onto the remaining studs. 36 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. 37 TPM: Check that the wing liners are correctly fitted. 38 TPM: Fit all the screws and nuts. F970A034 33 38 38 38 34 29 30 31 30 29 29

16. 16 12 803 216 Saab 9-3 CV M04-, 4D/5D M06- Finishing steps 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 Hang the wheels in position. Fit the bolts and screw them in by hand, pro- gressively and sequentially, so that the wheel is centred. 4 Tighten the bolts in sequence twice. Tightening torque 110 Nm (81 lbf ft) 5 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. 6 Lower the car. 7 Push down on the brake pedal a few times to activate the brake pistons and the handbrake self-adjustment. 8 Cars with headlamp washers: Check the func- tion 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. F970A036 1 2 Important After fitting is completed a 4-wheel alignment check must be carried out.

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