Page 721
DOOR HANDLE
Dismantling
There are two types of door handles, an earlier and a
later version. The later version was introduced in early
cars of model 1976.
Knock out the pin in the handle and remove the lever.
Save the dust cover, return spring and the four balls.
Assembly
Removal and installation
1. Remove the door trim.
2. Remove the front screw of the door handle inside the
door. Back off the rear screw of the door handle (in
door edge) about four turns.
3. Separate the handle from the door using tool 8995607
to draw the door lock lever to the side. Turn the handle
and withdraw it diagonally upwards and towards the
rear.
~
~.~-~-
'!"'I;.
--
1. Mount the lever, return spring, balls and pin in the
door handle.
Before assembly, grease all springs and moving parts
with chassis grease.
2. Fit the dust cover in the handle.
I
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S4809
DUSTCOVER
Dismantling and assembly, later design
The manouvre part of the handle is kept in position by
means of a plastic retainer, which is fixed to the handle
by peening.
REMOVING DOOR HANDLE
2
3
Installation is carried out in the reverse order.
Dismantling and assembly, earlier design
S 5537
3
1
5
DOOR HANDLE, LATER DESIGN
1. Bearing
2. Slide pad
3. Guide
4. Spring
5. Spring guide
DOOR HANDLE, EARLIER DESIGN
1. Manouvre part
2. Spring
3. Lock pin
SAAS
L
830-5
I
Page 722
DOOR LOCK CYLINDER
Removing
1. Crank the window all the way up.
2. Remove the inside door trim.
3. Unhook the link rod from the plastic arm of the lock
cylinder.
4. Remove the lock clip using polygrip pliers and remove
the entire lock cylinder.
10
DOOR LOCK
1. Lock ring
2. Driver
3. Plastic arm
4. Spring
5. Lock clip
6. Gasket
7. Locking sleeve
8. O-ring
9. Lock cylinder
10. Key
KEYS
Two keys are supplied with the car. Both fit the ignition
switch and all locks.
THE LOCK CLIP 1S REMOVED
SPARE PARTS
1. Pry off the driver and remove its lock ring.
2. Remove the plastic arm and the spring.
3. Withdraw the lock cylinder from the lock sleeve. Leave
If the lock cylinder in the ignition switch, the trunk lock
or any door is damaged, a replacement cylinder can be
ordered by quoting the serial number of the key and the
spare part number (see Spare Parts Catalogue). The system of master keys fitting all locks can thus be maintained without the need to fit a complete new set of
locks to the car.
the key in the lock cylinder as long as it is withdrawn
from the lock sleeve or the lock cylinder may fall apart.
4. Remove the O-ring.
TRUNK LID, SAAB 99 (99 L), 99 L (99 GL, 99 GLE
AND 99 EMS
Disassemblyand assembly
Removal and installation
NOTE
The key in the new lock cylinder must not be withdrawn before the lock cylinder is fitted in the lock
sleeve.
The lock ring should be changed after having been
removed.
Open the lid and undo the four screws by which the lid
is fastened to its hinges. The lid can then be lifted up.
Re-assemble in reverse order.
830-6
SAAB
Page 723
Adjustment
The position of the trunk lid can be adjusted upward
and downward or forward and backward by loosening
and retightening the hinge screws in the oversized
holes.
3. Remove the side padding guards and remove lock pins
and washers from the hinge pins. The hinges can now
be removed.
REMOVAL OF LOCK PINS
ADJUSTING THE TRUNK LID
Adjusting the striker plate
The striker plate is secured by screws in oversized holes
and can be adjusted when the screws are loosened.
Changing the hinges
1. Remove the trunk lid.
2. Remove the hinge springs by means of tool 8291577.
As from model 1976, the side trim must first be removed.
4. Fit the new hinges with new plastic bushings on the
pins.
5. Install the springs at the hinges with the aid of tool
8291577.
6. Install and adjust the trunk lid.
7. As from model 1976, refit the side trim in the luggage
compartment.
Changing the lock cylinder
1. Open the trunk lid and remove the lock mechanism
by undoing the two retaining screws.
2. Undo the two screws securing the handle to the lid.
3. a. Pry the plastic disc loose with a suitable tool and
remove the compression spring and push button
from the handle.
b. The driver and the torsion spring can be removed
after the lock ring has been taken off.
w
REMOVAL OF SPRING, TRUNK LID
Tool 8291577
TRUNK LOCK
1. Plastic disc
2. Compression spring
3. Lock ring
4. Driver
5. Torsion spring
6. Push button sleeve with lock cylinder
7. Handle, up to and incl. model 1976
8. Handle, as from model 1977
9. O-ring
830-7
Page 724
LUGGAGE COMPARTMENT DOOR, SAAB 99 COMBI
COUPE
c. If the lock cylinder is withdrawn from the push
button sleeve, the key must first be inserted in the
lock cylinder so the cylinder does not fall apart.
Reassemble in reverse order.
Dismantling
1. Remove the cable clip and cut off the cable between
the body and the door, and disconnect the main connection from the body.
NOTE
If the lock cylinder is to be removed from the push
button sleeve, the key should first be inserted in the
lock cylinder to prevent the latter from falling apart.
DISCONNECTING THE MAIN CONNECTION
2. Mark the position of the door at the hinge mounting
if the door is to be refitted, and back off the insex
screws slightly.
3. Remove the two pneumatic springs and place a suitable support at the rear edge of the door.
4. Remove the insex screws and lift away the door with
the aid of an assistant.
REMOVING THE LOCK FROM THE TRUNK LID
ADJUSTING THE STRIKER PLATE
LIFTING OFF THE LUGGAGE COMPARTMENT DOOR
830-8
5'1i\EI
L
Page 725
NOTE
The pneumatic springs must not be dismantled.
The pressure in the spring is more than 60 bar
(kp/cm2, 850 psi.),which means that in the event
of the lock ring being removed, the internal components will be forced out at a force sufficient to
cause injury.
3. Remove the two lock cylinder retaining screws from
the inside of the trunk door and remove the complete
cylinder.
Install in the reverse order.
Dismantling and assembly
Fitting
1. Insert the key in the lock cylinder.
2. Pry off the driver and remove the circlip.
3. Remove the control arm and spring.
4. Withdraw the lock cylinder from the sleeve. Ensure
that the key remains in the lock cylinder for as long
as the latter is withdrawn from the sleeve. There will
otherwise be a danger of the cylinder coming apart.
1. Place suitable spacers under the hinge plates.
Assemble in the reverse order.
CAUTION
Do not withdraw the key from the new lock cylinder
until the cylinder has been inserted in the lock sleeve.
CAUTION
Once the circlip has been removed it should be exchanged for a new one.
SPACERS UNDER THE HINGE PLATES
2. With the help of an assistant, lift the door and secure
it to the hinges. Simplify the lift by placing a suitable
support at the rear edge of the door.
3. Remove the spacers under the hinges before lowering
the door.
NOTE
The pneumatic springs can be damaged if they remain fitted to the body and if the door is closed
without the springs being secured to the door.
4. Adjust the fit of the door at the hinges, and if necessary, adjust the lock mechanism.
5. Fit the pneumatic springs.
6. Connect the electric cable by means of joint sleeves
and insulate the joint with black insulating tape.
Clamp the table to the body. Connect the main connection.
S 5185
DOOR LOCK CYLINDER
LOCK CYLINDER
Removal
1. Remove the trim from the inside of the door.
2. Unhook the link rod from the arm of the lock cylinder.
SA.4'EI
1. Key
2. Lock cylinder
3. Lock cylinder bracket
4. Gasket
5. Spring
6. Control arm
7. Driver
830-9
Page 726
SUNROOF
Sunroofs are available in two different versions:
A. Earlier versions have a movable windbreak fitted at
the front edge of the openinlJ. The windbreak is raised
as the sunroof is opened. This version is only fitted to
cars manufactured in Belgium (and, as from model
1978, only to Saab 99 GL and 99 EMS).
1
WINDBREAK,
SUNROOF
1. Roof plate
2. Sunroof plate
3. Panel with locking device and guides
4. Cover plate
5. Roof lining
6. Windbreak
7. Toothed guide rails
8. Fastening irons with Plastic wedges
9. Drainage hoses
10. Guides
830-10
EARLIER
VERSION
Page 727
8. Later versions are equipped with a windbreak in the
form of a raised section in the roof plate at the front
edge of the opening. The later version is fitted to Saab
99 Combi Coupe cars as from model 1978.
WINDBREAK,
LATER VERSION
9
The sunroof is opened and closed by sliding the handle
backwards or forwards. Once the handle is released, it
will spring back to its central position (locking position)
whereupon two locking devices, equipped with toothed
segments, will extend outwards to engage in the toothed
guide rails, mounted one on each side of the opening.
The sunroof consists of a panel equipped with a locking
mechanism and guides, the top of which is covered by
means of a cover plate. The underside of the panel is
clad in the same material as that of the headlining. On
earlier versions, the underside of the roof is equipped
with a special frame, slotted onto the car roof. In the
later versions, the sunroof frame is screwed to the carroof which is equipped with a special mounting frame.
Mounted in the frame are runners and toothed guide rails.
Rubber drainage hoses run from the frame corners. The
two front hoses run down through the corner pillars
opening at the front wheel housing. The two rear hoses
run down through the rear corner pillars and open in the
evacuation boxes.
Access to the drainage hoses can be gained after the sunroof lining has been removed.
..
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7
5 ----
10
#
7
9
'
3
11
4
S 7509
SUNROOF, LATER VERSION
1. Roof plate
2. Sunroof plate
3. Mounting frame
4. Roof lining
5. Panel
6. Rails
7. Guide clamps with sliding pins
8. Locking arms (serrated)
9. Catch (serrated)
10. Lifting knobs
11. Drainage hoses
SA.1'&
830-11
Page 728
The two front drainage hoses should be cut at an angle
where they open at the wheel housing to ensure efficient
drainage (see illustration).
7
/7/
~I
I
REMOVAL OF THE FOUR SCREWS IN THE FRONT EDGE
DRAINAGE HOSES
S 5184
3. Slide the roof forward until it is around 1 in. (2 cm)
from the closed position.
4. Gripping the front edge of the cover plate, remove it
by pulling it forwards and upwards, thus releasing the
retaining clips at the rear edge of the cover. Care should
be taken to prevent the cover plate being damaged at
the rear edge of the opening.
Removal, earlier version
1. Slide the sunroof back and unscrew the windbreak at
the front of the opening.
THE COVER PLATE IS PULLED AWAY
5. Remove the two fastening irons and plastic wedges at
the side of the rails.
THE WINDBREAK
CAUTION
Before removing the screws, mark the position of
the fastening irons to facilitate adjusting on reassembly.
IS REMOVED
2. Remove the four screws from the front edge of the
sunroof.
830-12
51\AB
Page 729
8. If necessary, it is now possible to dismantle the guide
rails by removing the two screws in the front ends.
Slide the rails forward to release them from the rear
fastenings.
THE FASTENING IRONS WITH PLASTIC WEDGES ARE
REMOVED
6. Unscrew the two front guide clips and guides and save
the serrated lock washer from under the inner nut and
securing plate.
THE TWO SCREWS IN THE FRONT ENDS OF THE GUIDE
RAILS ARE REMOVED
To gain access to the drainage hoses or insulation between the rear part of the sunroof and the car roof,
the roof lining must be removed.
Installation, earlier version
1. Slide the guide rails into position and replace the re-
taining screws without tightening them completely.
THE GUIDE CLIPS ARE REMOVED
7. Lift the front edge of the panel, press the handle to
one side and pull the panel forward to free it from
the guide rails. Remove the panel.
THE TWO SCREWS IN THE FRONT ENDS OF THE GUIDE
RAILS ARE INSTALLED
THE PANEL IS REMOVED
SAAB
830-13
Page 730
2. Install the panel by pushing the handle to one side and
sliding the rear part of the oanel into the guide rails.
ADJUSTING THE LOCKING DEVICE
b. The handle returns to its central position (locking
position) when it is released.
c. The sunroof slides smoothly without excessive play
or sticking and without grating of the cogs.
THE PANEL IS INSTALLED
3. Slide the panel forward to its forward position so that
it will be parallel with the roof opening and touching
the two stops.
4. Fit the front guide clips in such a way that the minimum possible play between the guides and the rail is
obtained.
ADJUSTING THE LOCKING DEVICE
7. Fit the two fastening irons and plastic wedges at the
side of the rails in the position marked on removal.
The position of the guides governs the height of the
rear edge of the roof when it is closed. Check the position and carry out any adjustments after the cover
plate has been fitted.
THE GUIDE CLIPS ARE INSTALLED
5. Adjust the height of the front of the guide rail so that
it makes proper contact with the panel trim and the
runners. Tighten the rail.
6. Adjust the locking device so that:
a. The locking devices on both sides engage simultaneously by loosening and turning the devices
slightly.
THE FASTENING IRONS WITH PLASTIC WEDGES ARE INSTALLED
830-14
we