Saab 2000-06

Alternator

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Alternator

Installation



9-3 (2001-02)
  1. Install or connect the following: AlternatorCatalytic converter mounting boltExhaust manifold to exhaust pipe mounting hardwareAlternator retaining boltsAlternator electrical connectionsBelt drive coverBelt tensionerAir intake hose to throttle bodyAir cleanerRight front wheelNegative battery cable

    Alternator
     
    Catalytic converter mounting bolt
     
    Exhaust manifold to exhaust pipe mounting hardware
     
    Alternator retaining bolts
     
    Alternator electrical connections
     
    Belt drive cover
     
    Belt tensioner
     
    Air intake hose to throttle body
     
    Air cleaner
     
    Right front wheel
     
    Negative battery cable
     

  2.  

9-3 (2003-04)
  1. Install or connect the following: Alternator and retaining boltsTighten bolts to 18 ft. lbs. (24 Nm)Vent hose fastener to camshaft coverVent hose to throttle body air hoseRadiator hoseIntake air pipe to air filter housingPressure sensor connectorAir filter and housing coverSecondary air injection hoseAir hose to air filter housingECM and connectionsUpper engine coverAuxiliary drive belt (through wheel well liner)Plastic nuts on wheel well linerLower vehicle to floorNegative battery cableBattery coverRefill cooling system

    Alternator and retaining bolts
     
    Tighten bolts to 18 ft. lbs. (24 Nm)
     
    Vent hose fastener to camshaft cover
     
    Vent hose to throttle body air hose
     
    Radiator hose
     
    Intake air pipe to air filter housing
     
    Pressure sensor connector
     
    Air filter and housing cover
     
    Secondary air injection hose
     
    Air hose to air filter housing
     
    ECM and connections
     
    Upper engine cover
     
    Auxiliary drive belt (through wheel well liner)
     
    Plastic nuts on wheel well liner
     
    Lower vehicle to floor
     
    Negative battery cable
     
    Battery cover
     
    Refill cooling system
     

  2.  

9-3 2001-02
  1. Install or connect the following: AlternatorCatalytic converter mounting boltExhaust manifold to exhaust pipe mounting hardwareAlternator retaining boltsAlternator electrical connectionsBelt drive coverBelt tensionerAir intake hose to throttle bodyAir cleanerRight front wheelNegative battery cable

    Alternator
     
    Catalytic converter mounting bolt
     
    Exhaust manifold to exhaust pipe mounting hardware
     
    Alternator retaining bolts
     
    Alternator electrical connections
     
    Belt drive cover
     
    Belt tensioner
     
    Air intake hose to throttle body
     
    Air cleaner
     
    Right front wheel
     
    Negative battery cable
     

  2.  

9-3 2003-04
  1. Install or connect the following: Alternator and retaining boltsTighten bolts to 18 ft. lbs. (24 Nm)Vent hose fastener to camshaft coverVent hose to throttle body air hoseRadiator hoseIntake air pipe to air filter housingPressure sensor connectorAir filter and housing coverSecondary air injection hoseAir hose to air filter housingECM and connectionsUpper engine coverAuxiliary drive belt (through wheel well liner)Plastic nuts on wheel well linerLower vehicle to floorNegative battery cableBattery coverRefill cooling system

    Alternator and retaining bolts
     
    Tighten bolts to 18 ft. lbs. (24 Nm)
     
    Vent hose fastener to camshaft cover
     
    Vent hose to throttle body air hose
     
    Radiator hose
     
    Intake air pipe to air filter housing
     
    Pressure sensor connector
     
    Air filter and housing cover
     
    Secondary air injection hose
     
    Air hose to air filter housing
     
    ECM and connections
     
    Upper engine cover
     
    Auxiliary drive belt (through wheel well liner)
     
    Plastic nuts on wheel well liner
     
    Lower vehicle to floor
     
    Negative battery cable
     
    Battery cover
     
    Refill cooling system
     

  2.  

9-5
2.3L Engine
  1. Install or connect the following:
  2.  


NOTE
To make it easier to refit alternator, tap bushings until they are level with the mountings.



Insert bar between gearbox and subframe.
 
Alternator and loosely install the lower retaining bolt
 
Alternator electrical connectors
 
Hose between the oil trap and oil pan
 
Front exhaust pipe
 
Upper retaining bolts and torque the bolts to 33 ft. lbs. (45 Nm)
 
Auxiliary drive belt and tensioner
 
Crankcase ventilation solenoid and constant pressure valves
 
Right side engine mount and torque the nut to 37 ft. lbs. (50 Nm)
 
Rear engine mount and torque the nut to 19 ft. lbs. (25 Nm)
 
Intake manifold shield
 
Negative battery cable
 

  1. Install or connect the following:
  2.  


NOTE
To make it easier to refit alternator, tap bushings until they are level with the mountings.



Insert bar between gearbox and subframe.
 
Alternator and loosely install the lower retaining bolt
 
Alternator electrical connectors
 
Hose between the oil trap and oil pan
 
Front exhaust pipe
 
Upper retaining bolts and torque the bolts to 33 ft. lbs. (45 Nm)
 
Auxiliary drive belt and tensioner
 
Crankcase ventilation solenoid and constant pressure valves
 
Right side engine mount and torque the nut to 37 ft. lbs. (50 Nm)
 
Rear engine mount and torque the nut to 19 ft. lbs. (25 Nm)
 
Intake manifold shield
 
Negative battery cable
 

3.0L Engine
  1. Install or connect the following: Position alternator and boltsAlternator electrical connectorsWedges between engine and frame (remove)Engine oil pressure sensorRight front halfshaftWheel housing drive belt coverRight front wheelBelt tensioner and torque the bolt to 30 ft. lbs. (40 Nm)Alternator air intakeV-beltNegative battery cableReset clock and radio

    Position alternator and bolts
     
    Alternator electrical connectors
     
    Wedges between engine and frame (remove)
     
    Engine oil pressure sensor
     
    Right front halfshaft
     
    Wheel housing drive belt cover
     
    Right front wheel
     
    Belt tensioner and torque the bolt to 30 ft. lbs. (40 Nm)
     
    Alternator air intake
     
    V-belt
     
    Negative battery cable
     
    Reset clock and radio
     

  2.  

  1. Install or connect the following: Position alternator and boltsAlternator electrical connectorsWedges between engine and frame (remove)Engine oil pressure sensorRight front halfshaftWheel housing drive belt coverRight front wheelBelt tensioner and torque the bolt to 30 ft. lbs. (40 Nm)Alternator air intakeV-beltNegative battery cableReset clock and radio

    Position alternator and bolts
     
    Alternator electrical connectors
     
    Wedges between engine and frame (remove)
     
    Engine oil pressure sensor
     
    Right front halfshaft
     
    Wheel housing drive belt cover
     
    Right front wheel
     
    Belt tensioner and torque the bolt to 30 ft. lbs. (40 Nm)
     
    Alternator air intake
     
    V-belt
     
    Negative battery cable
     
    Reset clock and radio
     

  2.  

9-5 Models
2.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

    Alternator and loosely install the lower retaining bolt
     
    Alternator electrical connectors
     
    Hose between the oil trap and oil sump
     
    Front exhaust pipe
     
    Upper retaining bolts and torque the bolts to 33 ft. lbs. (45 Nm)
     
    Belt tensioner and belt
     
    Crankcase ventilation solenoid and constant pressure valves
     
    Right side engine mount and torque the nut to 37 ft. lbs. (50 Nm)
     
    Rear engine mount and torque the nut to 19 ft. lbs. (25 Nm)
     
    Intake manifold shield
     
    Negative battery cable
     

  2.  

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

    Alternator and torque the bolts to 33 ft. lbs. (45 Nm)
     
    Alternator electrical connectors
     
    Alternator air intake
     
    Engine oil pressure sensor
     
    Right front halfshaft
     
    Belt pulley and torque the six bolts to 15 ft. lbs. (20 Nm)
     
    Wheel housing cover
     
    Right front wheel
     
    Belt tensioner and V belt. Torque the bolt to 30 ft. lbs. (40 Nm).
     
    Negative battery cable
     

  2.  

900 And 9-3 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Install or connect the following:

    Alternator
     
    Catalytic converter mounting bolt
     
    Exhaust manifold to exhaust pipe mounting hardware
     
    Alternator retaining bolts and torque them to 15 ft. lbs. (20 Nm)
     
    Alternator electrical connections
     
    Belt drive cover
     
    Belt tensioner
     
    Drive belt
     
    Air intake hose to throttle body
     
    Air cleaner
     
    Right front wheel
     
    Negative battery cable
     

  4.  

9000 Models
2.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Install or connect the following:

    Alternator electrical connections
     
    Power steering pump bracket
     
    Top alternator bolt. Do not tighten.
     

  4.  
  5. Align alternator, then tighten bolts to 19 ft. lbs. (25 Nm)

    Power steering pump
     
    Wheel arch to subframe support bar
     
    Belt
     
    Inner wheel well
     
    Wheel
     
    Negative battery cable
     

  6.  

Removal



9-5 Models
2.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold shield
     
    Crankcase ventilation solenoid and constant pressure valves
     
    Drive belt
     
    Belt tensioner with Tool 83-95-254
     
    Alternator upper mounting bolt
     
    Right side engine mount nut
     
    Rear engine mount nut
     
    Front exhaust pipe
     
    Hose between the oil trap and the oil sump
     
    Alternator electrical connectors
     
    Alternator lower bolt and insert a pry bar between the gearbox and subframe
     
    Alternator
     

  4.  

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    V belt and tensioner
     
    Right front wheel and housing cover
     
    6 outside hex screws from the pulley
     
    Engine oil pressure sensor
     
    Right front halfshaft
     
    Alternator electrical connectors
     
    Alternator air intake
     
    Alternator through the right side wheel well opening

    Click image to see an enlarged view

    Fig. Remove the alternator through the right front wheel well opening-3.0L Engine

     

  4.  

900 And 9-3 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner
     
    Air intake hose to throttle body
     
    Drive belt
     
    Drive belt tensioner
     
    Right front wheel
     
    Belt drive cover
     
    Alternator electrical connections
     
    Alternator retaining bolts
     
    Exhaust manifold-to-exhaust pipe mounting hardware
     
    Catalytic converter mounting bolt. Push catalytic converter aside.
     
    Alternator
     

  4.  

9000 Models
2.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Right front wheel
     
    Inner wheel well
     
    Drive belt
     
    Wheel arch to subframe support bar
     
    Power steering pump
     
    Alternator mounting bolts
     
    Pump bracket
     
    Alternator electrical connections
     
    Alternator
     

  4.  

Removal & Installation



9-3
2.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the battery cover.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Raise and safely support the front of the vehicle.
  8.  
  9. Remove the front right wheel.
  10.  
  11. Remove the right wheel well liner.
  12.  
  13. Relieve the belt tensioner and unhook the belt. Use a ½ inch drawbar handle.
  14.  
  15. Remove the bolt from the steering swivel member, lower the suspension arm and place a 83 95 238 Wedge between the suspension arm and the anti-roll bar.
  16.  
  17. Tap the drive shaft out of the intermediate shaft with a brass drift and large hammer. Move aside the drive shaft. Use protective goggles to protect against flying splinters of metal.
  18.  
  19. Remove the alternator electrical connections.
  20.  
  21. Remove the alternator retaining bolts.
  22.  
  23. Remove the alternator.
  24.  

To install:

  1. Install the alternator. Torque the retaining bolts to 18 ft. lbs. (24 Nm).
  2.  
  3. Connect the alternator electrical connections.
  4.  
  5. Grease the drive shaft splines and make sure the rubber seal is mounted on the shaft.
  6.  
  7. Fit the drive shaft to the intermediate shaft. Make sure the lock ring clicks into place.
  8.  
  9. Remove the wedge and connect the ball joint to the steering swivel member with a nut and bolt. The pin must be visible above the steering swivel member before the bolt is fitted. Tighten the nut to 37 ft. lbs. (50 Nm).
    NOTE
    Press up the pin carefully. The groove in the pin must be visible in the screw hole in the spindle housing. If the rubber gaiter is pressed down, it will not seal properly to the swivel pin.

  10.  
  11. Relieve the belt tensioner, use a ½ inch drawbar handle and mount the belt.
  12.  
  13. Install the right wheel well liner.
  14.  
  15. Install the front wheel.
  16.  
  17. Lower the vehicle.
  18.  
  19. Connect the negative battery cable.
  20.  
  21. Fit the battery cover.

    Reset clock and radio
     

  22.  

2000-2002 Model
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Air cleaner
     
    Air intake hose to throttle body
     
    Drive belt tensioner
     
    Right front wheel
     
    Belt drive cover from under vehicle
     
    Alternator electrical connections
     
    Alternator retaining bolts
     
    Exhaust manifold to exhaust pipe nuts and rubber hanger on front pipe
     
    Push catalytic converter carefully aside.
     
    Alternator
     

  4.  

To install:

  1. Install or connect the following:

    Alternator
     
    Catalytic converter mounting bolt
     
    Exhaust manifold to exhaust pipe mounting hardware
     
    Alternator retaining bolts
     
    Alternator electrical connections
     
    Belt drive cover
     
    Belt tensioner
     
    Air intake hose to throttle body
     
    Air cleaner
     
    Right front wheel
     
    Negative battery cable
     

  2.  

2003-06 Model (Except 2.8L Engine)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Lower engine cover
     
    Drain coolant
     
    Plastic nuts from wheel well liner
     
    Drive belt (through wheel well liner)
     
    Upper engine cover
     
    Connector(s) from ECM
     
    ECM from mounting
     
    Air hose from air filter housing
     
    Secondary air injection hose
     
    Air filter housing cover and air filter
     
    Pressure sensor connector
     
    Air filter housing
     
    Radiator hose
     
    Vent hose from air hose to throttle body
     
    Loosen fastener in camshaft cover
     
    Bend vent hose aside
     
    Alternator electrical connections
     
    Alternator retaining bolts
     
    Alternator (lift upward)

    Click image to see an enlarged view

    Fig. Showing location of ECM connectors-9-3 2003-06

     

  4.  

To install:

  1. Install or connect the following:

    Alternator and retaining bolts
     
    Tighten bolts to 18 ft. lbs. (24 Nm)
     
    Vent hose fastener to camshaft cover
     
    Vent hose to throttle body air hose
     
    Radiator hose
     
    Intake air pipe to air filter housing
     
    Pressure sensor connector
     
    Air filter and housing cover
     
    Secondary air injection hose
     
    Air hose to air filter housing
     
    ECM and connections
     
    Upper engine cover
     
    Auxiliary drive belt (through wheel well liner)
     
    Plastic nuts on wheel well liner
     
    Lower vehicle to floor
     
    Negative battery cable
     
    Battery cover
     
    Refill cooling system
     

  2.  
  3. Reset the clock and radio, if necessary.
  4.  

9-3 (2001-02)
  1. Remove or disconnect the following: Negative battery cableAir cleanerAir intake hose to throttle bodyDrive belt tensionerRight front wheelBelt drive cover from under vehicleAlternator electrical connectionsAlternator retaining boltsExhaust manifold to exhaust pipe nuts and rubber hanger on front pipePush catalytic converter carefully aside.Alternator

    Negative battery cable
     
    Air cleaner
     
    Air intake hose to throttle body
     
    Drive belt tensioner
     
    Right front wheel
     
    Belt drive cover from under vehicle
     
    Alternator electrical connections
     
    Alternator retaining bolts
     
    Exhaust manifold to exhaust pipe nuts and rubber hanger on front pipe
     
    Push catalytic converter carefully aside.
     
    Alternator
     

  2.  

9-3 (2003-04)
  1. Remove or disconnect the following: Negative battery cableLower engine coverDrain coolantPlastic nuts from wheel well linerDrive belt (through wheel well liner)Upper engine coverConnector(s) from ECMECM from mountingAir hose from air filter housingSecondary air injection hoseAir filter housing cover and air filterPressure sensor connectorAir filter housingRadiator hoseVent hose from air hose to throttle bodyLoosen fastener in camshaft coverBend vent hose asideAlternator electrical connectionsAlternator retaining boltsAlternator (lift upward)

    Negative battery cable
     
    Lower engine cover
     
    Drain coolant
     
    Plastic nuts from wheel well liner
     
    Drive belt (through wheel well liner)
     
    Upper engine cover
     
    Connector(s) from ECM
     
    ECM from mounting
     
    Air hose from air filter housing
     
    Secondary air injection hose
     
    Air filter housing cover and air filter
     
    Pressure sensor connector
     
    Air filter housing
     
    Radiator hose
     
    Vent hose from air hose to throttle body
     
    Loosen fastener in camshaft cover
     
    Bend vent hose aside
     
    Alternator electrical connections
     
    Alternator retaining bolts
     
    Alternator (lift upward)
     

  2.  


    Click image to see an enlarged view

    Fig. Showing location of ECM connectors-9-3 2003-04


9-5
2.3L Engine
  1. Remove or disconnect the following: Negative battery cableIntake manifold shieldCrankcase ventilation solenoid and constant pressure valvesBelt tensioner with special tool 83 9-5 254Alternator upper mounting boltRight side engine mount nutRear engine mount nutFront exhaust pipeHose between the oil trap and the oil panAlternator electrical connectorsAlternator lower bolt and insert a bar between the gearbox and subframeAlternator (tip and lower downward)

    Negative battery cable
     
    Intake manifold shield
     
    Crankcase ventilation solenoid and constant pressure valves
     
    Belt tensioner with special tool 83 9-5 254
     
    Alternator upper mounting bolt
     
    Right side engine mount nut
     
    Rear engine mount nut
     
    Front exhaust pipe
     
    Hose between the oil trap and the oil pan
     
    Alternator electrical connectors
     
    Alternator lower bolt and insert a bar between the gearbox and subframe
     
    Alternator (tip and lower downward)
     

  2.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Intake manifold shield
     
    Crankcase ventilation solenoid and constant pressure valves
     
    Belt tensioner with special tool 83 95 254
     
    Alternator upper mounting bolt
     
    Right side engine mount nut
     
    Rear engine mount nut
     
    Front exhaust pipe
     
    Hose between the oil trap and the oil pan
     
    Alternator electrical connectors
     
    Alternator lower bolt and insert a bar between the gearbox and subframe
     
    Alternator (tip and lower downward)
     

  4.  

To install:

  1. Install or connect the following:
    NOTE
    To make it easier to refit alternator, tap bushings until they are level with the mountings.






    Insert bar between gearbox and subframe.
     
    Alternator and loosely install the lower retaining bolt
     
    Alternator electrical connectors
     
    Hose between the oil trap and oil pan
     
    Front exhaust pipe
     
    Upper retaining bolts and torque the bolts to 33 ft. lbs. (45 Nm)
     
    Auxiliary drive belt and tensioner
     
    Crankcase ventilation solenoid and constant pressure valves
     
    Right side engine mount and torque the nut to 37 ft. lbs. (50 Nm)
     
    Rear engine mount and torque the nut to 19 ft. lbs. (25 Nm)
     
    Intake manifold shield
     
    Negative battery cable
     

  2.  

3.0L Engine
  1. Remove or disconnect the following: Negative battery cableBelt tensioner and auxiliary drive belt (note direction of belt rotation)Alternator air intake (pull straight up)Right front wheel and drive belt coverEngine oil pressure sensor (plug hole)Right front halfshaftAlternator electrical connectorsRaise vehicle insert 2 wedges between engine and frameAlternator through the right side wheel well opening

    Negative battery cable
     
    Belt tensioner and auxiliary drive belt (note direction of belt rotation)
     
    Alternator air intake (pull straight up)
     
    Right front wheel and drive belt cover
     
    Engine oil pressure sensor (plug hole)
     
    Right front halfshaft
     
    Alternator electrical connectors
     
    Raise vehicle insert 2 wedges between engine and frame
     
    Alternator through the right side wheel well opening
     

  2.  


    Click image to see an enlarged view

    Fig. Remove the alternator through the right front wheel well opening-3.0L Engine


  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove or disconnect the following:

    Negative battery cable
     
    Belt tensioner and auxiliary drive belt (note direction of belt rotation)
     
    Alternator air intake (pull straight up)
     
    Right front wheel and drive belt cover
     
    Engine oil pressure sensor (plug hole)
     
    Right front halfshaft
     
    Alternator electrical connectors
     
    Raise vehicle insert 2 wedges between engine and frame
     
    Alternator through the right side wheel well opening

    Click image to see an enlarged view

    Fig. Remove the alternator through the right front wheel well opening-3.0L Engine

     

  4.  

To install:

  1. Install or connect the following:

    Position alternator and bolts
     
    Alternator electrical connectors
     
    Wedges between engine and frame (remove)
     
    Engine oil pressure sensor
     
    Right front halfshaft
     
    Wheel housing drive belt cover
     
    Right front wheel
     
    Belt tensioner and torque the bolt to 30 ft. lbs. (40 Nm)
     
    Alternator air intake
     
    V-belt
     
    Negative battery cable
     
    Reset clock and radio
     

  2.  

 
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