Page 21
Top stack 812-13
we
To replace the servo cylinder
To remove
1 Remove the side trim.
2 Raise the top
3 Remove the two'screws which are accessible
through the oval hole in the side bracket of
the body. Remove the split pin and the pivat
pin inthe top end. Press the cylinder inwards
into the carand remove It.
= iy
4 Ifthe cylinder must be withdrawn to improve
the accessibility, a clip retaining the oil line
on the rear support wall can be removed
Assemble in the reverse order.
To change the servo pump
1 Lift the pump out of the rubber bearings and
disconnect the electrical connections, Mark
them to facilitate re-connecting.
Sanb 900
Page 22
812-14 Top stack
2 Place pieces of cloth under the pump. Dis-
m connect the hydraulic lines from the pump,
it Mark the connections
3 Connect the new pump and fill its fluid reser-
voir with Motor O11 SAE LOW,
To bieed:
4 Raise and lower the top several times. Every
lime the top is in the lowered position, oper)
{ the filler plug on the fluid reservoir to bleed
' the air, Retighten the plug when no air bub-
bles are visible in the hoses. Make sure that
the system Is not leaking.
Hydraulic system checking procedure
Failures in the hydraulic system can be caused
by lack of hydraulic fluid, leaks in the hydraulic
system, obstructions or kinks in the: hydraulic
hoses ar faulty operation of a cylinder or the
pump.
4 Checking hydraulic fluid level in reservoir,
a) Remove rear seat cushion
bh) Remove plug from reservoir
c) Check level of fluid in the reservoir. Fluid
level should be even with fill hole-
d) If fluid is low, add high grade, light in-
dustrial white mineral oil of Motor Oil SAE
10OW.
e) Install filler plug:
2 Checking operation of hydraulic cylinders.
Operate the top up and down several times
and observe the hydraulic cylinders during
the "up" and “down” cycles for these fol low-
Ing conditions:
« if movement of the cylinders is unccordi-
nated or sluggish when the top is ac-
tuated. check the hydraulic hoses from
the motor/pump to the cylinders for kinks
e if one cylinder rod moves slower than the
other, and the hydraulic hoses are free of
kinks, then the cylinder having the siower
moving rod may be defective.
Saab 900
Page 23
fF
Seon
Top stack 812-15
* Disconnect the cylinders from the top
mechanism and operate the cylinders in
free motion. If one cylinder rod still
moves slower than the other, the cylinder
having the slower moving rod |s defective
and should be replaced.
© If both cylinder rods move slowly ar do not
move: at all, check the pressure of the
pump.
Note:
To insure proper operation of the hydraulic cylin-
ders, the hydraulic cylinder rods should be
cleaned-and lubricated, To perform this opera-
tion, raise the top to its “up” pasition and wipe
the exposed portion of each rod with a cioth dam-
pened with a high grade, light industrial white
mineral or type Motor Oil SAE LOW to remove any
oxidation and/or accumulation of grime,
Caution:
Exercise care so that fluid does not come
in contact with any paint or trim parts of
bady.
3 checking pressure at the pump.
a) Remove the motor/pump assembly from
under the rear Seat,
b) Install a plug into one side of the pump
and 4 pressure gauge into the side being
checked.
©) Actuate motor with an applied terminal
voltage withinthe range of 9.5V to 14..0V.
Pressure gauge should show pressure
between 2344.2 kPa to 2620.0 kPa
(340 P.$.|, ta 380'P.S.1.).
d) Check pressure on the opposite side of
the pump.
NOTE:
A difference in pressure readings may exist be-
tween the pressure port of the top of the cylin-
ders and the pressure port for the bottom of the
cylinders. This condition is acceptable if both
teadings are within the limits 2344.2 kPa to
2620-0 kPa (340 P.S.1. to 380 P'S,|.).
e) lf the pressure is not within specified
limits, the motor/pump unit is. defective
and should be replaced.
Saab 900
Page 24
812-16 Top stack
To remove the spoiler
Side spoiler
The side spoiler has three mounting points, one
of which is accessible from the boot. Each of the
other two is accessible from the inside of the cor-
responding tear side. panel after the back-seat
cushion, the backrest and the corresponding
side trim have been removed.
Rear spoiler
The rear spoiler is secured by means of two
screws through the boot lid. The rear spoiler is
fitted with a brake light fitting with three bulbs.
Side spoiler
To remove
1 Remove the back-seat cushion and back-
rest
2 Release the two: front mountings of the
spoller from the Inside of the car,
SE War
Saab 900
Page 25
Top stack 812-17
3 The wing nuts. retaining a wire running
through a tube up to the rear end of the
Spoiler are accessible through holes cut in
the boot trim at the hinges, Remove these
wing nuts and the spoiler can then be re-
moved,
N.B, The spoiler is also secured to the lid
with tape.
Assemble in the reverse order,
3 §
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> eo
Rear spoiler
To remove
i 1 Disconnect the connector to the brake lights
from the inside-of the trunk lid.
2 Remove the nuts on the retaining screws and
lift off the spoiler
N.B. The spoiler is also secured to the Hid
with tape.
Assembie in the reverse order.
Saah 900
Page 26
812-18 Top stack
To replace the weather strip on the A pil-
lar
The strip is glued to the holder which \s secured
to the Apiilar by means of screws,
To remove the strip at the top of the
windscreen frame
Remove a sun visor, the corner plate (four
screws) and the sun visor support. Remove the
rear-view mirror (two screws inthe base), discon-
nect two electric cables and remove the support
for the other Sun visor
Remove the nuts retaining the cover strip,
Saab 900
Page 27
Top stack 812-19
To remove the headliner from the top
The top must be in the raised position.
1 Unzip the rear window and lower it, Release
\he snap fasteners that retain the top fabric
atthe rear,
2 Release the cross-recess Screws retaining
the strip for the rear cross-bar (No, 4 cross-
bar). Pull away the tape retaining the fabric.
3 Let the top drop down and continue with the
next cross-bar
4 Remove the front strip and pull away the
lape revaining the front edge of the top fab-
ric
5 Remove-the No: 2 cross-bar
Saab 900
Page 28
812-20 Top stack
To fit
NOTE
The screws for the two centre cross-bars are fit-
ted into a strip in a V-shaped rai). Ensure thatthe
screws engage in the thread jn the strip.
1. Secure the top to No, 2 cross-bar but don't
tighten the screws hard.
2 Secure the top-at the front edge (make Sure
that it Is centred sideways). Secure the
sheet metal strip with the screws.
3 Pull No. 2 cross-bar towards the rear ‘of the
car to tension the fabric, Then tighten the
screws.
4 Fit and secure No. 3-cross-bar.
5 Tape the top at the rear edge (No. 4 cross-
bar), fit the sheet metal strip and tighten It.
Secure the strap for the rear window by
means of the centre screw,
6 Raise the rear window and zip it up.
Saab 300
Page 29
Top stack 812-21
To change the latch mechanism at front
1 Open the top almost fully. Remove the two
screws retaining the front weather strip and
place the strip on the top. The glued joint
must be broken.
2 Reiease the front rail by removing two nuts
anda cross-recess sorew
3. The socket-head screw retaining the joint of
the mechanism is not accessible from the
outside. Remove a cross-recess screw at the
front edge of the bottom part
ts
The screw retaining the locking handle can
be removed from the underside, between
the fabric and the corner itself
Saab 900
Page 30
aaa
812-22 Top stack
5 Use a pair of pliers to remove the return
spring.
y 6 Remove the mechanism.
Fit in the reverse order. Don't forget to glue the
weather strip in position if any of the glued joints
has been broken.
For particulars of the adhesive, see the technical
specification.
Saab 900