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Just did this yesterday on my 2002 9-3, so I thought I would share my wisdom!
1. Jack up drivers side front, support using axle stand and remove wheel.
2. Remove the wheel well liner - this comes in two parts. You only need to remove the small approx 6" x 6" cover that is located forwards of the shock. Simply undo the trim bolts using a socket (9 or 10mm).
3. Remove the air filter assembly. This is held on by 3-4 bolts which are easily accessed using a socket. I removed the air filter first (as per Haynes), but this probably isn't necessary. Also detach the 3-4" dia. rubber hose at the front of the air filter assembly (undo two hose clips).
4. To loosen the serp belt you need to insert a lever in the tensioner socket. Look to the left hand side of the serp belt and you will see a square shaped socket approx 10mm x 10mm. The idea is that you insert a lever in that and then rotate it towards the front of the car. Down on the side of the tensioner you will notice a small 3-4mm hole. The idea is that once the tensioner is pivoted forwards, you insert a suitable pin (e.g. drill bit) through the hole and into a similar hole in the body of the tensioner to hold the tensioner in the retracted position. I didn't have a suitable lever, so ended up using a large carriage bolt (head chopped off) which I inserted into the recess. I then used the handle of the jack which I slipped over the bolt to get better leverage.
5. Once the tensioner is retracted it is a simple job to remove the old serp belt AFTER you have made a sketch of how it is routed.
6. There are two idler pulleys: i) one held on with a 15mm bolt - easy to undo using a socket. ii) a second one held on with a #40 torx bolt. Unfortunately there isn't enough room to get a socket or torx wrench in there (wonderful bit of Saab design!). I ended up cutting the end of a torx socket off so that it would fit in the limited space. To undo the bolt I taped the hex shank of the torx socket into the end of a wrench (think it was 4 or 5 mm). Holding this in position with the help of a large screwdriver to lever it against the bolt I then gave the end of the wrench a gentle tap with a heavy hammer which was sufficient to loosen the bolt (phehttp://wwwww! - did try using a vice wrench to hold onto the torx shank, but this kept slipping off).
7. Replacing the torx nut pulley is a bit of a pain, as it is difficult to align the bolt and get it started. Persevere you will get there!
8. Using the sketch you made it is then pretty simple to thread on the new serp belt.
9. Put everything back together and that's it (took me around 3 hrs to do).
posted by 99.232.103...
, Thu, 8 May 2008 09:40:00
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