Saab 2000-06

Fuel Injectors

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Removal & Installation



9-3

CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Detach the crankcase vent hoses.
  8.  
  9. Remove or disconnect the following: Fuel line connections from fuel railDipstick and filler pipe (plug pipe opening)Cover over throttle valveAccelerator wire from throttle spindleAccelerator wire with holder (bend it to one side)Cable channel (put it to one side)Cable tie securing check valve to camshaft coverInjector connectors

    Fuel line connections from fuel rail
     
    Dipstick and filler pipe (plug pipe opening)
     
    Cover over throttle valve
     
    Accelerator wire from throttle spindle
     
    Accelerator wire with holder (bend it to one side)
     
    Cable channel (put it to one side)
     
    Cable tie securing check valve to camshaft cover
     
    Injector connectors
     

  10.  


WARNING
Secure each injector clip with a narrow cable tie. Make sure they are positioned correctly and tighten them. Otherwise, the injectors may come loose from the fuel rail while being removed.


CAUTION
To prevent entry of foreign matter, regularly blow around the injectors with compressed air.

  1. Undo both rail retaining screws.
  2.  
  3. Detach the pressure regulator vacuum hose.
  4.  
  5. Carefully pry off the rail using 2 crowbars or similar tool and lift out the rail.
  6.  
  7. Plug the nozzle holes.
  8.  

To install:

  1. Remove the plugs in the nozzle holes and lubricate the injector O-rings.
  2.  
  3. Carefully lift the rail into position and attach with 2 screws.
  4.  
  5. Install or connect the following: Pressure regulator vacuum hoseRemove the cable ties round the injectors.Plug in injector connectorsCable channel and fit the 3 screwsCheck valve to camshaft cover with cable tieThrottle cable and bracket (adjust the throttle cable)Throttle valve coverDipstick and filler pipeCrankcase ventilation hosesFuel connections to fuel railUpper engine coverNegative battery cable

    Pressure regulator vacuum hose
     
    Remove the cable ties round the injectors.
     
    Plug in injector connectors
     
    Cable channel and fit the 3 screws
     
    Check valve to camshaft cover with cable tie
     
    Throttle cable and bracket (adjust the throttle cable)
     
    Throttle valve cover
     
    Dipstick and filler pipe
     
    Crankcase ventilation hoses
     
    Fuel connections to fuel rail
     
    Upper engine cover
     
    Negative battery cable
     

  6.  

9-5
2.3L Engine

CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following: Negative battery cableUpper engine coverCrankcase ventilation hosesDipstick with the oil filler pipeCover and detach the throttle cable from the spindleTurbocharger delivery pipeFuel injector connectorsIgnition discharge moduleManifold Absolute Pressure (MAP) sensorBoost pressure control valveTurbocharger pressure sensor and slacken the upper bolt on the wiring holderFuel rail retaining bolts and cable tiesFuel linesPressure regulator vacuum hoseFuel rail with the injectorsFuel injector locking clipsFuel injectors

    Negative battery cable
     
    Upper engine cover
     
    Crankcase ventilation hoses
     
    Dipstick with the oil filler pipe
     
    Cover and detach the throttle cable from the spindle
     
    Turbocharger delivery pipe
     
    Fuel injector connectors
     
    Ignition discharge module
     
    Manifold Absolute Pressure (MAP) sensor
     
    Boost pressure control valve
     
    Turbocharger pressure sensor and slacken the upper bolt on the wiring holder
     
    Fuel rail retaining bolts and cable ties
     
    Fuel lines
     
    Pressure regulator vacuum hose
     
    Fuel rail with the injectors
     
    Fuel injector locking clips
     
    Fuel injectors
     

  6.  


    Click image to see an enlarged view

    Fig. Remove the fuel rail and injectors as an assembly


To install:

  1. Lubricate the O-rings on the fuel injectors
  2.  
  3. Install or connect the following: Fuel injectors to the fuel rail and make certain that the injectors are fitted to the proper cablesFuel rail and torque the bolts to 6 ft. lbs. (8 Nm)Vacuum hose to the pressure regulatorFuel injector hosesScrews for the wiring holderThrottle cable and cover and adjust if necessaryDipstick and filler pipeCrankcase ventilation hosesUpper engine coverNegative battery cable

    Fuel injectors to the fuel rail and make certain that the injectors are fitted to the proper cables
     
    Fuel rail and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Vacuum hose to the pressure regulator
     
    Fuel injector hoses
     
    Screws for the wiring holder
     
    Throttle cable and cover and adjust if necessary
     
    Dipstick and filler pipe
     
    Crankcase ventilation hoses
     
    Upper engine cover
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

3.0L Engine

CAUTION
The fuel injection system remains under pressure, even after the engine has been tuned OFF . The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following: Negative battery cableEngine coverTurbocharger delivery hose from the throttle bodyThrottle body from the intake manifoldUpper intake manifoldFuel rail wiringVacuum hose from the fuel pressure regulatorFuel rail and injectors as an assembly

    Negative battery cable
     
    Engine cover
     
    Turbocharger delivery hose from the throttle body
     
    Throttle body from the intake manifold
     
    Upper intake manifold
     
    Fuel rail wiring
     
    Vacuum hose from the fuel pressure regulator
     
    Fuel rail and injectors as an assembly
     

  6.  

To install:

  1. Install or connect the following: New O-rings on the injectorsFuel rail and injectors as an assembly and torque the bolts to 6 ft. lbs. (8 Nm)Fuel pressure regulator vacuum hoseFuel lines and wiringUpper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)Throttle bodyThrottle cable and adjust if neededTurbocharger delivery hoseEngine coverNegative battery cable

    New O-rings on the injectors
     
    Fuel rail and injectors as an assembly and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Fuel pressure regulator vacuum hose
     
    Fuel lines and wiring
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Throttle body
     
    Throttle cable and adjust if needed
     
    Turbocharger delivery hose
     
    Engine cover
     
    Negative battery cable
     

  2.  
  3. Start the vehicle, check for leaks and repair if necessary.
  4.  

9-5 Models
2.3L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Upper engine cover
     
    Crankcase ventilation hoses
     
    Dipstick with the oil filler pipe
     
    Cover and detach the throttle cable from the spindle
     
    Turbocharger delivery pipe
     
    Fuel injector connectors
     
    Ignition discharge module
     
    Manifold Absolute Pressure (MAP) sensor
     
    Boost pressure control valve
     
    Turbocharger pressure sensor and slacken the upper bolt on the wiring holder
     
    Fuel rail retaining bolts and cable ties
     
    Fuel lines
     
    Pressure regulator vacuum hose
     
    Fuel rail with the injectors
     
    Fuel injector locking clips
     
    Fuel injectors

    Click image to see an enlarged view

    Fig. Remove the fuel rail and injectors as an assembly

     

  6.  

To install:

  1. Lubricate the O-rings on the fuel injectors
  2.  
  3. Install or connect the following:

    Fuel injectors to the fuel rail and make certain that the injectors are fitted to the proper cables
     
    Fuel rail and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Vacuum hose to the pressure regulator
     
    Fuel injector hoses
     
    Screws for the wiring holder
     
    Throttle cable and cover and adjust if necessary
     
    Dipstick and filler pipe
     
    Crankcase ventilation hoses
     
    Upper engine cover
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

3.0L Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Engine cover
     
    Turbocharger delivery hose from the throttle body
     
    Throttle body from the intake manifold
     
    Upper intake manifold
     
    Fuel rail wiring
     
    Fuel connectors
     
    Vacuum hose from the fuel pressure regulator
     
    Fuel rail and injectors as an assembly
     

  6.  

To install:

  1. Lubricate the new O-rings with vaseline.
  2.  
  3. Install or connect the following:

    New O-rings on the injectors
     
    Fuel rail and injectors as an assembly and torque the bolts to 6 ft. lbs. (8 Nm)
     
    Fuel pressure regulator vacuum hose
     
    Fuel lines and wiring
     
    Upper intake manifold with a new gasket and torque the bolts to 15 ft. lbs. (20 Nm)
     
    Throttle body
     
    Throttle cable and adjust if needed
     
    Turbocharger delivery hose
     
    Engine cover
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

900 And 9-3 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Resonator
     
    Cowl on turbo engines only
     
    Crankcase breather hose
     
    Idle adjusting valve
     
    Dipstick holder bracket
     
    Throttle and cruise control cable bracket
     
    Fuel pressure and return lines
     
    Four retaining bolts and 2 covers on the fuel rail
     
    Electrical connectors to fuel rail
     
    Fuel rail
     
    Injector locking clips
     
    Injectors
     

  6.  

To install:

  1. Lubricate injector O-rings with petroleum jelly
  2.  
  3. Install or connect the following:

    Injectors and clips to fuel rail and place the fuel rail into position
     
    Electrical connections to fuel rail. Press the fuel rail into place.
     
    Two covers and 4 bolts
     
    Fuel pressure and return lines
     
    Throttle and cruise control cable bracket
     
    Dipstick holder bracket
     
    Idle adjusting valve
     
    Crankcase breather hose
     
    Resonator
     
    Cowl on turbo engines only
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

9000 Models
  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Remove or disconnect the following:

    Negative battery cable
     
    Plastic pipe between throttle body and resonator
     
    Idle Air Control (IAC) valve from throttle body
     
    Cruise control cable
     
    Throttle body
     
    Vacuum hoses to intake manifold. Label prior to removal
     
    Upper half of intake manifold bracket retaining screws. There are 4 on each side. Remove the top screws and loosen the bottom.
     
    Oil fill pipe bracket
     
    Remaining screws on upper half of the intake manifold
     
    Upper half of the intake manifold
     
    IAC connector
     
    Two injector support rails
     
    Fuel injector connectors
     
    Fuel rail with injectors
     
    Injector retaining clips
     
    Injectors
     

  6.  

To install:

  1. Lubricate injector O-rings with petroleum jelly
  2.  
  3. Install or connect the following:

    Injectors and clips to fuel rail
     
    Fuel rail and torque the bolts to 13 ft. lbs. (18 Nm)
     
    Electrical connections to fuel rail
     
    Two injector support rails
     
    IAC connector
     
    Upper half of intake manifold
     
    Upper half of intake manifold retaining screws
     
    Oil fill pipe bracket
     
    Remaining screws to upper intake manifold bracket
     
    Vacuum hoses to intake manifold
     
    Throttle body
     
    Cruise control cable
     
    IAC to throttle body
     
    Plastic pipe between throttle body and resonator
     
    Negative battery cable
     

  4.  
  5. Start the vehicle, check for leaks and repair if necessary.
  6.  

 
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