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Home >> Saab >> 2001 >> 9-3 Base, 2D Hatchback, Automatic >> Repair and Diagnosis >> Engine Mechanical >> Blowers, Superchargers & Turbochargers >> Turbocharger System, Petrol >> Adjustment Replacement >> Test pressurization of the charge air cooler and delivery pipes >> To Remove

To Remove

  1. Remove the bypass pipe.
    NOTE: There is an O-ring where the bypass pipe is fastened to the charge air pipe.
    Fig 1: Illustration For Steps 2-3-4-5
    G03504482Courtesy of SAAB-SCANIA OF AMERICA, INC.
  2. Remove the exhaust manifold heat shield. The heat shield is fastened with a nut and two clips underneath.
  3. Disconnect the hose from the turbocharger outlet. Plug the hose with (83 94 595) Plug, turbocharger hose.
  4. Remove the upper engine cover.
  5. Disconnect the charge air pipe from the throttle body.

    Man: Disconnect the venturi hose from the charge air pipe.

  6. Fit 83 95 030 Plug, turbocharger hose to the charge air pipe.
    Fig 2: Illustration For Steps 7-8-9
    G03504483Courtesy of SAAB-SCANIA OF AMERICA, INC.
  7. Connect 83 93 514 Charge pressure gauge.
  8. Connect 30 14 883 Pressure/vacuum pump to the bypass valve. Create a pressure of approx. 1 bar.
    IMPORTANT: Be extremely careful when pressurizing the turbo system. Excessive pressure may damage hoses and connections.
  9. Connect a compressed air gun, 83 93 514 Charge pressure gauge, to the pressure gauge equipment, and carefully create a pressure of approx. 1 bar.
  10. Make sure that the pressure does not drop by more than 0.1 bar in 30 seconds. If the pressure drop is greater than this or if there is an audible hissing sound, check hoses, pipes and connections for leaks.
  11. Check hoses/pipes and the air gun for leaks with fault tracing fluid, part no. 30 20 385, or equivalent.
  12. If a leak is not detected in hoses or pipes, perform a pressure test on the dismantled charge air cooler.
  13. Remove the charge air cooler, refer to CHARGE AIR COOLER (INTERCOOLER) .
    Fig 3: Illustration For Steps 14-15
    G03504484Courtesy of SAAB-SCANIA OF AMERICA, INC.
  14. Fit the inlet and outlet hoses to the charge air cooler and plug one of them. Connect pressure gauge equipment to the other hose.
  15. Connect a compressed air gun to the pressure gauge and carefully build up a pressure of approx. 1 bar.
  16. Make sure that the pressure does not drop by more than 0.1 bar in 30 seconds. If the pressure drop is greater than this or if there is an audible hissing sound, check hoses, pipes and connections for leaks. Use fault tracing fluid, part no. 30 20 385, or equivalent.
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