LEMON Manuals: Even more car manuals for everyone
Home >> Saab >> 2003 >> 9-3 Vector, Standard >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Hydraulic Brake System - FOOTBRAKE System (Late; 9440) >> Adjustment - Replacement >> Brake servo, RHD >> To fit

To fit

  1. Change the brake servo gasket.
  2. Turn the brake servo so that the pushrod is pointing towards the air cleaner casing's rear body bracket. Press down the brake servo carefully.
    IMPORTANT: Take care when fitting to avoid paint damage.
    Fig 1: Illustration For Step 2
    G03619426Courtesy of SAAB-SCANIA OF AMERICA, INC.
  3. Turn the brake servo, place it on the bulkhead and fit the brake servo bolts. Use 74 96 268 Thread locking adhesive.

    Tightening torque: 20 Nm (15 lbf ft) 

    Fig 2: Illustration For Step 3
    G03619427Courtesy of SAAB-SCANIA OF AMERICA, INC.
  4. Fit the turbo coolant pipe onto the cylinder head and tighten the nut on the turbo.

    Tightening torque: 40 Nm (30 lbf ft) 

    207R:  Tighten the banjo screw.

    Fig 3: Illustration For Step 4
    G03619428Courtesy of SAAB-SCANIA OF AMERICA, INC.
    Fig 4: Illustration For Step 4-5
    G03619429Courtesy of SAAB-SCANIA OF AMERICA, INC.
  5. Fit the diaphragm box onto the turbo. Connect the pushrod and fit the clip.
  6. Fit the cylinder head. Secure with 74 96 268 Thread locking adhesive. Make sure the pushrod on the master cylinder is positioned on the brake servo pushrod.

    Tightening torque: 25 Nm (18 lbf ft) 

    Fig 5: Illustration For Step 6
    G03619430Courtesy of SAAB-SCANIA OF AMERICA, INC.
  7. Fit the brake pipes into the brackets on the bulkhead.
  8. Fit the vacuum hose on the brake servo.
    Fig 6: Illustration For Step 7-10
    G03619431Courtesy of SAAB-SCANIA OF AMERICA, INC.
  9. Fit the brake pipes on the master cylinder.
  10. Fit the brake fluid level sensor connector.
  11. Fit the heat shield onto the bulkhead.
    Fig 7: Illustration For Step 11-12
    G03619432Courtesy of SAAB-SCANIA OF AMERICA, INC.
  12. Fit the turbo heat shield.
  13. Raise the engine with a jack and fit the bolts in the right engine mounting.

    Tightening torque: 70 Nm +60° (52 lbf ft + 60°) 

    Fig 8: Illustration For Step 13
    G03619433Courtesy of SAAB-SCANIA OF AMERICA, INC.
  14. Fit the turbo inlet pipe and hoses.
    Fig 9: Illustration For Step 14
    G03619434Courtesy of SAAB-SCANIA OF AMERICA, INC.
  15. Fit the crankcase ventilation pipe and hose.
    Fig 10: Illustration For Step 15
    G03619435Courtesy of SAAB-SCANIA OF AMERICA, INC.
  16. Fit the air cleaner casing and air cleaner.
    Fig 11: Illustration For Step 16
    G03619436Courtesy of SAAB-SCANIA OF AMERICA, INC.
  17. Fit the air cleaner cover.
    Fig 12: Illustration For Step 17-18
    G03619437Courtesy of SAAB-SCANIA OF AMERICA, INC.
  18. Fit the mass air flow sensor connector.
  19. Fit the brake pedal link bolt.
    Fig 13: Illustration For Step 19
    G03619438Courtesy of SAAB-SCANIA OF AMERICA, INC.
  20. Fit Acoustic baffle, driver.
  21. Fit battery negative cable and battery cover.
    Fig 14: Illustration For Step 21
    G03619439Courtesy of SAAB-SCANIA OF AMERICA, INC.
  22. Fill with brake fluid and bleed the brake system, see BLEEDING THE BRAKE SYSTEM  .
  23. Carry out Procedure after disconnecting the battery.