Page 521
800-2
Body-General
hand tools. The instrument cluster is removable as a unit
without removing the instrument panel. All electrical repairs
to the instrument cluster are covered in 3 ELECTRICAL
SYSTEM.
Some of the cars covered by this manual may be
equipped with a Supplemental Restraint System (SRS)
that automatically deploys an airbag. See Fig. 4.
Fig. 2.
Unitized Saab 900 body shell.
WARNING
l
1L - - -
87834
The SRS airbag unit uses an explosive device to electrically
ignite a powerful gas. Use extreme care when working on the
body, the steering wheel or steering column on cars equipped
with SRS. Working involving the SRS, the steering wheel or
the steering column should only be performed by an authorized Saab dealer.
-----'
Fig. 3. Front fenders are ventilated (arrows) for corrosion protection.
INSTRUMENT CLUSTER, CENTER
CONSOLE, AND INSTRUMENT PANEL
Fig. 4. Schematic of SRS (airbag) system.
The padded instrument panel houses the instrument
cluster and the ventilation and heating system. It is
fastened to the body and can be removed using ordinary
INSTRUMENT CLUSTER, CENTER CONSOLE, AND INSTRUMENT PANEL
Page 522
Convertible Top
812-1
812 Convertible Top
General
812-1
Top Assembly
812-1
812-1
812-2
812-2
812-2
812-3
Adjustments
To check and adjust park position
To check and adjust latched position
To check and adjust side rail position
To check and adjust fully open position
Hydraulic System
To remove hydraulic system
To install hydraulic system
To bleed hydraulic system
Spoiler Assembly
To remove spoiler
812-3
812-4
812-5
812-5
812-6
812-6
GENERAL
The convertible top consists of a top cover, a frame assembly, and an inner headliner. See Fig. 1. The top has a heated
rear window element. A mercury switch prevents the heated
rear window from coming on if the top is in the down position.
See 371 Wiring Diagrams, Fuses and Relays for the heated
rear window circuit.
2
87780-S81776
1. Electric motor (pump)
2. Actuating pistons
3. Bypass valve
Fig. 2. Hydraulic system beneath rear seal.
87779-S81770
1. Top cover
2. Frame assembly
3. Headliner
Fig. 1. Convertible top.
The top is operated by an electrically-controlled hydraulic
system. The system consists of an electric motor/pump assembly, two actuating pistons, a bypass valve, and connecting hoses. See Fig. 2. The motor/pump assembly is located
under the rear seat and is thermally-protected (the motor
shuts off after approximately 20 seconds of operation). A bypass valve enables the top to be operated manually in the
event of an electrical failure. This valve is behind a trim flap at
the back of the luggage compartment.
TOP ASSEMBLY
The top does not require any maintenance other than normal cleaning. Operate the top periodically to checkthat it functions correctly.
Replacement of the top requires special techniques and
equipment and is beyond the scope of this manual. Information on removing and adjusting the side windows can be found
in 830 Doors, Windows, and Lids.
Adjustments
This section covers adjustments that can be made to the
top. Keep in mind that doing one adjustment can affect the
alignment of the top in other areas. There are five adjustments
that can be made.
Water and wind leaks are usually the result of a defective
seal between the weatherstripping and the top. Water leaks
TOP ASSEMBLY
·
i::
Page 523
812-2
Convertible Top
into the passenger compartment are most easily found using
two people. One person can aim a garden hose at the car
while the other person checks for the leak inside the car. Wind
noise is not as easy to find. One technique is to tape over a
suspected area and then test drive the carto check if the noise
still exists.
The weatherstrips and seals are installed at the factory using adhesive and screws. Generally, seals are glued into
place using 3M® Super Weatherstrip Adhesive. The seals are
non-adjustable once installed. All fasteners should be checked
and tightened before beginning any adjustment.
NOTE
A service campaign to adjust the convertible top was initiated
by Saab for 1986-1987 models and some 1988 models. See
an authorized Saab dealer for more information on this campaign.
Fig. 4. Park position adjusting cam being adjusted. Cams are located above windows.
To check and adjust park position
The park position allows the top to be latched easily while at
the same time pulling the top taught.
1. Raise the top until it stops. The leading edge of the top
should be above the windshield by the amount shown
in Fig. 3.
t
20-30 mm
87781-81171
Fig. 5. Guide pin 1 and latching hook 2. Arrow shows location of
Fig. 3. Correct park position of top.
Torx adjusting screw.
2. If the gap is incorrect, adjust the cam links on each side
of the top until the gap is as specified. See Fig. 4.
1. With the top latched in position, push down on each
corner of the top. If any play is found, the latching
hooks should be adjusted.
NOTE
The adjustment is made using an intemal hex-head key. Be
sure to tighten the locknut after adjustment.
2. Adjust the height of the latching hook by loosening the
Torx screw and rotating the hook.
To check and adjust latched position
When the top is latched closed, there should be no side-toside or up-down play. The guide pins, which control side-toside movement, do not usually require adjustment. The latching hooks, which control up and down play, can be easily adjusted. See Fig. 5.
TOP ASSEMBLY
NOTE
One tum of the hook changes the height by 1 mm (0.04 in.).
To check and adjust side rail position
The side rail position controls the seal between the front
windows and the top.
Page 524
Convertible Top
1. Check that the side rail is parallel with the windows.
Check that no air gap exists. If any faults are found, the
side rail should be adjusted.
2. Adjust the side rail by loosening the hinge screw between the front and middle rail sections. Adjust the rails
sections until they are in parallel with the window and
then tighten the screw. See Fig. 6.
812-3
HYDRAULIC SYSTEM
If the top does not operate, begin by checking the motor fuses. There are two fuses used in the circuit. See 371 Wiring Diagrams, Fuses and Relays for locations. Check the fluid
level in the pump reservoir. See Fig. 8. If the level is low, check
for any visible leaks. Use only the special Saab hydraulic fluid
when adding fluid to the system.
CAUTION
Use only the approved hydraulic fluid when adding or replacing fluid. Engine oil or ATF should not be used in the system.
Pump hydraulic fluid
• Aeroshell Fluid 4/Shell Code 60 421 (Saab part no. 30
18 694)
Fig. 6.
Front section side rail hinge,
To check and adjust fully open position
Checking and adjusting the fully open and stowed position
of the top requires a special gauge that can be made from
wood or cardboard.
1. To check the open position of the top, open the top to
its fully stowed position. Using the special gauge,
check the top position as shown in Fig. 7.
Fig. 8.
Hydraulic pump fluid level. Fluid level should be at A with top
down and at B with top up, Fill plug is shown at c.
To replace an individual component, the entire hydraulic
system should be removed 'from the car as described below.
This allows for proper bleeding of the system and also prevents any spilled hydraulic fluid from contacting and damaging painted surfaces.
WARNING
Do not allow the top to be operated when your hands are near
the top mechanisms. The pistons have sufficient force to
cause injury.
Fig. 7. Stop bracket position being checked (arrows) using special
gauge, If position is incorrect loosen adjusting bolts,
CAUTION
Leaking hydraulic fluid can damage paint and upholstery. Correct any leaks as soon as possible.
2. If the position is incorrect, loosen, but do not remove,
the adjusting bolts and adjust the stop bracket. Tighten
the bolts.
HYDRAULIC SYSTEM
Page 525
812-4
Convertible Top
To remove hydraulic system
1. Remove the rear seat as described in 851 Interior
Trim and Upholstery.
2. Remove the interior trim panels below the rear side
windows as described in 830 Doors, Windows, and
Lids.
7. Close the bypass valve. Switch on the ignition and fully
retract the pistons by placing the top switch in the down
position. Switch off the ignition.
8. Remove the bolts holding the piston to the side body
panel. See Fig. 11.
3. Working in the luggage compartment, open the bypass
valve to release the pressure in the system. See Fig. 9.
Fig. 11. Piston mounting bolts (arrow).
Fig. 9.
Hydraulic system bypass valve in luggage compartment.
Uft up carpet flap to access.
9. On 1987 and 1988 models, remove the pump from its
mountings and disconnect the harness connectors
from the relays on the bulkhead. Remove and label the
pump wires from the relay connectors. See Fig. 12.
4. Release the handbrake to allow for slack in the handbrake cables near the pump.
5. Working in the passenger compartment, release the
hydraulic hoses from the body clips.
6. Remove the split pin and clevis pin from the pistons on
both sides of the car. Note the position of the washers
and spacers. See Fig. 10.
Fig. 12. Pump wiring being removed from relay connector on
1987 and 1988 moldels. Label wires before removal.
10. On 1989 and later models, disconnect the pump harness connector.
11. Remove the moisture barrier from each body panel
cavity.
B7788-S81775
Fig. 10. Split pin, clevis pin and washers for piston.
HYDRAULIC SYSTEM
12. Remove the pistons by lifting them up while feeding the
bottom of the piston through the cutout in the body
Page 526
Convertible Top
13. Label each piston and bracket before removing the entire hydraulic system from the car. Carefully slide the
right-hand piston out from under the fuel lines and the
parking brake cable during removal. See Fig. 13
NOTE
If the piston brackets are to be removed, label their positions
before removal. The left and right brackets are different.
812-5
5. Reinstall the moisture barrier in each body cavity.
6. Mount the bypass valve and hoses in their clips.
7. Operate the pump to fully extend the pistons. With the
top unlatched, install the washers, spacers, clevis pin
and split pin in the piston. See Fig. 10.
The remaining of installation is the reverse of removal.
To bleed hydraulic system
The hydraulic system is bled with the complete system removed from the car. This will prevent any damage to painted
surfaces.
1. With all lines connected, place the pump on a workbench. Place the pistons in a tray on the floor. The pistons should be at a lower level than the pump.
2. Fill the reservoir with hydraulic fluid up to the top level
mark. See Fig. 14. Leave the fill plug off.
Pump hydraulic fluid
Fig. 13. Right-hand piston must pass under fuel lines A and handbrake cable B to remove,
• Aeroshell Fluid 4/Shell Code 60 421
(Saab part no. 30 18694)
If necessary, the individual components can be replaced
once the system is removed. If any component is replaced or
the system has been opened, the system must be bled as described below before installing the system.
Tightening torque
• Hydraulic hose
fittings
5.1 to 6.2 Nm (45 to 54 in-Ib)
To install hydraulic system
1. Make sure the pistons are fully retracted. If necessary
run the pump as described below.
Fig. 14. Hydraulic pump being filled with hydraulic oil.
2. Slide the right-hand piston and hoses under the fuel
lines and handbrake cable.
3. Install the pump under the handbrake cable. Plug in the
pump electrical connectors. If applicable, reconnect the
harness connectors to the relays. Fit the pump to its
mount.
4. Install the pistons in the body cavities. Make sure the
hose connections on the pistons are toward the rear of
the car.
3. Loosen one hose fitting at one of the pistons. Allow fluid
to run out until no air bubbles are present. Tighten the
hose and repeat the procedure at the remaining three
fittings. See Fig. 15.
4. Connect a battery to the pump. Run the sysre~fully
retract or fully extend the pistons.
HYDRAULIC SYSTEM
Page 527
812-6
Convertible Top
SPOILER ASSEMBLY
The spoiler assembly is held to the body using adhesive
tape and nuts. There are two side pieces and one trunk lid
piece.
To remove spoiler
1. Remove the rear seat as described in 851 Interior
Trim and Upholstery.
2. Remove the interior trim panels below the rear side
windows as described in 830 Doors, Windows, and
Lids.
Fig. 15. Hydraulic hose fittings (arrows) at pistons used to bleed
lines.
3. With the top down, remove the front nut holding the
side spoiler to the body. See Fig. 16.
NOTE
• The electrical connection should have fuse protection. Use
the same rating fuse as used in the circuit.
• Replenish the hydraulic fluid as the level drops during bleeding.
5. Repeat step 3 above. Run the pump and pistons in the
opposite direction.
6. Repeat step 5 until the system is free of air.
7. Top up the fluid, tighten all hose connections, reinstall
the fill plug and check for leaks.
Fig. 16. Spoiler mounting nut (arrow) in body cavity.
Tightening torque
• Hydraulic hose
fittings
5.1 to 6.2 Nm (45 to 54 in-Ib)
NOTE
The hydraulic system can be tested using a pressure gauge
and fitting. The pressure gauge can be installed in place of the
rear T-fitting. Be sure to bleed the system after pressure testing the pump.
Hydraulic pump
• minimum working pressure
SPOILER ASSEMBLY
25 bar (363 psi)
4. Open the top approximately half-way and remove the
center nut. See Fig. 17.
NOTE
Cars from VIN L701110 and later do not have a center nut.
WARNING
Do not allow anyone to operate the top when your hands are
near the mechanism. The pistons have sufficient force to
cause injury.
5. Working in the luggage compartment, remove the rear
nut through the cutout in the carpeting. See Fig. 18.
Page 528
Convertible Top
Fig. 17. Side spoiler center nut being removed through body side
cavity.
812-7
Fig. 19. Arrows show rear mount spoiler nuts and bolts to be removed from trunk lid.
Fig. 20. Heat being applied to spoiler to loosen adhesive.
Fig. 18. Side spoiler rear nut (arrow) behind carpet cutout.
NOTE
6. Unplug the hi-mount brake light connector. Remove the
rubber plugs, retaining bolts and nuts for the rear
mount spoiler. See Fig. 19.
The side spoiler has a cable at the rear mounting hole. This
cable should be saved if the spoiler is being replaced.
7. Heat the spoiler with a heat gun to release the adhesive
tape. See Fig. 20. Remove the spoiler.
8. Remove all old adhesive from the paint and spoiler.
CAUTION
• Use care when applying heat. Too much heat will damage
the paint and spoiler.
• Pull the spoiler off gently to prevent damage to the paint.
Installation is the reverse of removal. New double-sided adhesive tape should be installed to the spoiler. If installing a new
spoiler, install the cable for the side spoiler rear mount and a
rubber washer on each stud. Apply a water sealant such as
Sikaflex 255 around the hole for the hi-mount brake light wire
harness.
SPOILER ASSEMBL Y
Page 529
Hood and Fenders
820-1
820 Hood and Fenders
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 820-1
To open hood if release cable is broken ..... 820·2
To remove hood
Hood Alignment and Adjustment
820-2
820-3
GENERAL
Fig. 1 shows an exploded view of the hood and related
components. The hood is bolted to hinges at the radiator
crossmember. The rear of the hood has locating pins and
guides. The hood release mechanism is also mounted to the
radiator crossmember. When the hood is closed, the locking
pin engages the release mechanism. A safety catch prevents
the hood from opening fully after the release mechanism has
been disengaged.
Radiator
crossmember
WARNING
• Welding and grinding coated steel can produce a poisonous
gas containing zinc-oxide. This type of work should always be
carried out by experienced body technicians having the proper respiratory equipment and work area.
• 1990 and later models are equipped with an airbag or SRS
system. The airbag is an explosive device. Do not do electric
(arc) welding to cars equipped with SRS (airbag) without first
disarming and removing the airbag unit. You could accidentally ignite the airbag. causing serious personal injury. See an
authorized Saab dealer to disarm the system.
1
87770
Fig. 1. Exploded view of hood assembly.
GENERAL
Page 530
820-2
Hood and Fenders
The front fenders are welded to the body to form part of the
unit-body construction. See Fig. 2. Special tools and welding
equipment are needed to replace a fender. Therefore, fender
replacement is not covered in this manual.
Fig. 4.
Hood lock being released using special tool. Grille shown removed for clarity,
Fig. 2. Front fender welds (arrows),
To open hood if release cable is broken
If the hood cannot be opened using the hood release, a
wire tool can be made to release the hood locking pin through
the front grille. The tool dimensions are shown in Fig. 3.
....
~1I
3/4
rr
_.. ,
I
l
!
1/8"
-
16"
,
,
,
!
3"
!
1"
87775-S7586
Fig. 3. Hood t'elease tool can be made using 1/8 in, diameter wire,
All dimensions are approximate,
Fig. 5. Windshield washer nozzle hose (arrow).
1. Insert the tool through the grille and hook the rear of the
lock mechanism. See Fig. 4,
2. Pull the latch toward the driver's side of the car until the
hood releases.
To remove hood
1. Open the hood and then disconnect the hose for the
windshield washer nozzles. See Fig. 5.
2. While supporting the hood with the aid of a helper, remove the mounting bolts for the hinge links. See Fig. 6.
3. Carefully lift the hood off the car.
GENERAL
Fig. 6. Hood hinge link mounting bolt being removed (arrow).