Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
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HOMESERVICE MANUALSSAAB20059-3 LINEAR (9440) L4-2.0L TURBO (2.0T)REPAIR AND DIAGNOSISLIGHTING AND HORNSHEADLAMPSERVICE AND REPAIRPROCEDURESHEADLIGHT HOUSING, UPPER MOUNTING
2005 Saab 9-3 Linear (9440) L4-2.0L Turbo (2.0t)
Headlight Housing, Upper Mounting
2005 Saab 9-3 Linear (9440) L4-2.0L Turbo (2.0t)SECTION Headlight Housing, Upper Mounting
Headlight Housing, Upper Mounting
1. Remove the lens as necessary.
2. Protect the reflector from dust and dirt.
3. Identify the type of plastic. See Plastic codes, temperature and welding wire or Plastic code table.
4. Select the correct welding wire and set the welding gun to an operating temperature appropriate for the plastic type.
5. Secure the damaged area and tack with the tacking nozzle of the welding gun.
6. Warm and align the tab. Then tack weld with the welding gun.
7. Check the marking on the headlight housing and find the correct welding wire in the welding wire table. See Plastic code table.
8. Weld the tab in place. Then weld the other joints around the upper mounting.
9. Allow the weld to cool.
10. Grind the weld as necessary.
11. If necessary, remove small plastic burrs from the joints using the welding gun and, if necessary, a screwdriver.
12. Remove grinding scratches by shock heating the damaged area with the welding gun at approx. 25 degrees C above the specified welding temperature.
RENDER: 1.0x
NO RELATED
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.