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Home >> Saab >> 2003 >> 9-3 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 20 (Cooling System - Diagnostics) >> Adjustment - Replacement >> Charge air cooler (B235R, B205L/R) >> To Fit

To Fit

WARNING: This page is about a different car, the 2001 Saab 9-3. However, it is still accessible from the selected car via links, so may be relevant.
  1. Lift the charge air cooler into position.
    NOTE: Make sure that the temperature sensor's lead runs clear above the charge air cooler.
    Fig 1: Illustration For Steps 2-3-5-6
    G03504322
  2. Bolt the charge air cooler to the radiator member, 2 bolts.
  3. Connect the charge air cooler outlet hose.
  4. Lower the car to the floor.
  5. Connect the charge air cooler inlet hose and tighten the hose clip.
  6. Tighten the hose clip on the charge air cooler's outlet hose.
  7. Fit the temperature sensor.
    Fig 2: Illustration For Steps 7-8
    G03504323
  8. Position the bumper.
    IMPORTANT: Make sure the mountings on the corners of the bumper are secured tightly to the body brackets.

    Tighten the 2 retaining bolts.

    Tightening torque: 39 N.m (29 lbf ft) 

  9. Fit the wiper arms and secure the washer hose to the bumper.
    Fig 3: Illustration For Steps 9-10-12
    G03504324
  10. Fit the RH and LH headlamps and light clusters.
  11. Lower the headlamp wiper arms.
  12. Fit the front grille.
  13. Raise the car.
  14. Carefully bend the wing liners inside the edge of the bumper and fasten them in place.
    Fig 4: Illustration For Steps 14-15-16
    G03504325
  15. Plug in the fog light connectors.
  16. Make sure that the charge air cooler outlet hose is securely connected.
  17. Fit the two lower air shields.
    Fig 5: Illustration For Step 17
    G03504326
  18. Lower the car to the floor.
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