Page 531
Hood and Fenders
820-3
Installation is the reverse of removal. If installing a new
hood, adjust its fit as described below.
internal-hex head screws. Loosen the guide plate mounting
screws and then adjust the position of the guides. When the
guide position is correct, tighten the guide pin plate screws.
Hood Alignment and Adjustment
If the front of the hood is not centered from left to right, the
release mechanism mounting bolts can be loosened to
reposition the mechanism. See Fig. 8.
The hood can be adjusted up-down, left-right, and fore-aft.
The front up-down adjustment may require special shims on
1985 through 1989 models.
To adjust the up-down position at the front of the hood,
loosen the locking pin. See Fig. 7. On 1985 through 1989
models, add or subtract shims under the pin until the
adjustment is correct. On 1990 and later models, the shims
are not required owing to the return spring. When the lock pin
adjustment is correct, turn the two rubber adjusting screws
(shown in Fig. 1) so that there is no play when pressing down
on the top of the hood.
NOTE
A maximum shim thickness of 5 mm (3/16 in.) can be added
between the pin and the hood.
87699-581515
Fig. 8.
Hood release mechanism mounting bolt being loosened.
Adjusting the fore/aft position of the hood can be done by
changing the position of the hinge adjusting bolts at the
radiator member. See Fig. 9. Making this adjustment requires
removal of the front grille.
Fig. 7. Locking pin on 1985 through 1989 models. Adjustment
shims are between pin and hood (arrow).
To adjust the up-down position and the left-right position at
the rear of the hood, the guides and guide pin plates can be
repositioned. The guide is mounted to the hood (see Fig. 1)
and the guide pin plate is mounted to the body with the
Fig. 9. Hood fore/aft adjusting screw at front radiator crossmember.
GENERAL
Page 532
Doors, Windows, and Lids
830-1
830 Doors, Windows, and Lids
Doors and Windows
830-1
Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 830-1
To remove and install doors
830-1
To adjust doors
830-2
To remove interior door panel.
830-3
Windows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 830-3
To remove and install front
power window regulator
830-4
To remove and install rear power
window regulator (except convertible) ..... 830-5
To remove and install rear
power window regulator (convertible) ..... 830-6
To remove and install front
manual window regulator.
830-6
To remove and install rear
manual window regulator.
830-7
Locks, Handles,
and Latch Mechanisms
To replace door handle
To replace door lock mechanism
To replace trunk lid lock mechanism
To replace hatchback lock mechanism
To replace door lock cylinder
To replace trunk lid or hatchback
lid lock cylinder
To remove central locking motors
Hatchback and Trunk Lid
To remove and install hatchback lid
To remove and install trunk lid
Sunroof
830-7
830-7
830-8
830-8
830-9
830-9
830-10
830-10
830-11
830-11
830-11
830-12
830-12
830-13
To remove sunroof
To install sunroof
DOORS AND WINDOWS
This section covers the removal and installation of the
doors, the interior door panels, the window regulators, and the
window glass.
Doors
The doors can be easily removed once the interior trim panels have been removed and the electrical connectors disconnected. Models with Torx head hinge bolts require a special
Torx socket. After installing, adjust the door so that it correctly
aligns with the body allowing it to open and close properly.
To remove and install doors
Fig. 1. Front door hinge-to-body bolts being removed.
1. Disconnect the negative (-) battery cable.
2. Remove the interior door panel and moisture barrier as
described later under To remove interior door panel.
Where applicable, disconnect the connectors for the
power windows, power mirrors, and central locking.
Pull the wiring harness from the door.
3. Have a helper hold the door, then remove the six hinge
bolts for the upper and lower hinges and remove the
door. See Fig. 1.
NOTE
• Before loosening the bolts, scribe a mar1< showing the position of the hinge on the body so the door can be realigned in
its original position.
• If a helper is not available, support the door with a noor jack
and protective padding.
• On rear doors, the trim covering the B-pillar must be removed to reach the nuts. See Fig. 2.
DOORS AND WINDOWS
Page 533
830-2
Doors, Windows, and Lids
1. Lubricate the hinges and latch mechanism with engine
oil.
2. To adjust the flush fit of the front doors to the body, loosen the hinge-to-body bolts as shown in Fig. 1 above.
The door can then be moved on the slotted holes in the
hinge. Tighten the bolts, close the door and check the
adjustment. Readjust as necessary.
3. To adjust the up-down or fore-aft position of the front
doors, loosen the hinge-to-door bolts. See Fig. 4. This
adjustment can only be done after the interior trim panel has been removed.
Fig. 2. Rear door hinge-to-body nuts being removed. Trim (arrow) has been removed from the B-pillar to reveal nuts.
Installation is the reverse of removal. After installing the
door, adjust it as described below. When installing a new replacement door, the door parts from the old door will have to
be transferred to the new door.
To adjust doors
Correct adjustment or alignment of the door allows for proper opening and closing. Adjustment also prevents wind noise.
If the hinge bolts inside the door or the striker plate have not
been disturbed, there is no need to adjust them.
NOTE
Some models have a locating screw in the hinge plate which
must be removed before adjusting the door. See Fig. 3. This
screw can be discarded after adjusting the door.
Fig. 4. Hinge-to-door bolt being loosened to adjust up-down or
for-aft position of front door. The bolts for adjusting the
flush fit of the door can also be seen (arrows).
4. Rear door flush fit and up-down position can be adjusted after loosening the hinge-to-door bolts. See Fig. 5.
Fig. 5. Rear hinge-to-door bolt being loosened to adjust flush fit
and up-down position of door.
Fig. 3. Locating screw being removed before adjusting door.
DOORS AND WINDOWS
Page 534
Doors, Windows, and Lids
830-3
5. Adjust the striker plate so the door is not forced up or
down when closing. Also check that the door opens and
closes smoothly. Loosen the screws as shown in Fig. 6
to adjust the striker plate.
Fig. 7. Window crank trim cover being pried off.
Fig. 6. Striker plate being adjusted. An impact driver can be
used to loosen screws.
NOTE
Additional adjustment of the rear doors can be done by loosening the hinge-to-body nuts. See Fig. 2 shown above.
To remove interior door panel
Although the procedures given below apply to the front
doors, they can also be used as a guide for removing the interior trim for the rear doors.
1. Unscrew the locking knob. Where applicable, carefully
pry off the disc from the window crank and remove the
crank screw and crank. See Fig. 7.
NOTE
Before removing the window crank, make a note of its position
with the window closed.
2. On sedan models, pry out the trim cover for the inner
door handle. Remove the screws that hold the armrest
to the door. Then carefully pry off the panel by working
around the perimeter of the door. The panel is held in
place by retaining clips. Lift the panel up slightly to remove it.
3. On hatchback and convertible models, remove the
door pull retaining screw and remove the door pull.
Slide the trim insert panel up and off its mounting clips.
Remove the screws holding the panel to the door. See
Fig. 8.
Fig. 8.
Door panel retaining screws (arrows) on hatchback and
convertible models. Door pull and upper trim insert panel
removed.
4. Carefully remove the moisture barrier from the door.
Installation is the reverse of removal. Always test the window, mirror, and locking functions before reinstalling the panel. Replace any damaged retaining clips. If the moisture
barrier is handled carefully and kept clean, it can be reused.
Apply thread locking compound to the window crank handle
screw.
NOTE
Always replace the moisture barrier if it becomes damaged.
Windows
This section covers removal and installation of the door windows, window regulators, and power window motors. The
door windows are controlled by window regulators that move
the glass in fixed channels. To replace the power window mo-
DOORS AND WINDOWS
Page 535
830-4
Doors, Windows, and Lids
tor, the regulator assembly must first be removed from the
door.
WARNING
Always disconnect the electric window motor when working
on it. The motor is powerful enough to cause injury if it should
come on by accident.
NOTE
Replacement of the windshield, the rear windows, and fixed
side windows is not covered here. These windows are held in
place with weather-tight seals. Special equipment and techniques are required to replace these windows.
To remove and install front power window
regulator
Fig. 10. Connector for power window motor disconnected. Also
shown is motor (A) and gear sector (B),
1. Disconnect the negative (-) battery cable.
2. Remove the interior door trim and moisture barrier as
described earlier.
3. Pry off the inner window weatherstrip spring clips and
remove the inner weatherstrip from the door. See Fig. 9.
Fig. 11. Regulator-to-window glass support mounting screws (arrows), Support glass after removing screws,
Fig. 9. Spring clip for inner weatherstrip being removed,
4. Locate the window motor electrical connector inside
the door and disconnect it. See Fig. 10.
5. While supporting the window glass, remove the screws
holding the glass to the regulator. See Fig. 11.
6. Remove the window glass by rotating it to the vertical
position and sliding it up out of the door.
7. Remove the four bolts holding the regulator assembly
to the door and remove the assembly through the
opening in the door. See Fig. 12.
DOORS AND WINDOWS
Fig. 12. Regulator-to-door mounting bolt being removed, Two
bolts (not shown) at top must be removed also.
Page 536
Doors, Windows, and Lids
8. Remove the three bolts holding the motor to the regulator. See Fig. 13.
830-5
CAUTION
Once the window-to-regulator screws are removed, the window should be supported. With the window fully closed, tape
the glass to the door frame to prevent it from falling.
NOTE
Removal of the rear door window requires that the fixed side
pane be removed so that the rear window channel can be
moved out of the way. The window channel is held in place
with two screws that can be accessed after removing the rubber concealing plugs in the door.
4. Remove the five screws that hold the regulator assembly to the door. See Fig. 14. Remove the assembly
through the opening in the door.
Fig. 13. Power motor mounting bolt being removed.
NOTE
Slide the regulator anm forward to help in removing the assembly from the door.
NOTE
The plastic moisture barrier on the old motor must be reinstalled on the new motor to keep out moisture.
Installation is the reverse of removal. Test the new motor
before installing it in the door. A thin film of white grease can
be applied to moving parts.
•
NOTE
The power motor can be tested by disconnecting the connectors at the motor and testing for voltage when the window
switch is pushed in either direction (ignition key on). If power
is present at the connector, the motor is faulty. If voltage is not
present, the problem lies in the switch or other part of the circuit. Troubleshoot the power window circuit using the appropriate diagram in 371 Wiring Diagrams, Fuses and Relays.
Fig. 14. Rear door regulator mounting screws (arrows),
To remove and install rear power window
regulator (except convertible)
1. Disconnect the negative (-) battery cable. Remove the
window switch from the interior trim.
2. Remove the interior door trim and moisture barrier as
described earlier. Disconnect the electrical connector
for the power window located inside the door.
3. While supporting the window glass, remove the screws
that hold the glass to the regulator arm. See Fig. 11
shown above. Then push the window up until it is fully
closed.
5. Remove the screws that hold the motor to the regulator.
NOTE
Always reinstall the old protective cover to the window motor.
Installation is the reverse of removal. Test the new motor
before installing it in the door. A thin film of white grease can
be applied to moving parts.
DOORS AND WINDOWS
Page 537
830-6
Doors, Windows, and Lids
To remove and install rear power window
regulator (convertible)
The regulator assembly on convertibles is located in the
body cavity. The regulator is removed as a complete assembly together with the window glass.
1. Disconnect the negative H battery cable.
2. Remove the rear seat cushion, backrest, and interior
trim panel as described in 851 Interior Trim and Upholstery.
NOTE
The front of the seal is glued to the body.
6. Raise the window up until it contacts the window stop.
Remove the four nuts holding the regulator assembly
to the body.
7. Using a hex key, screw the regulator studs in. See Fig. 17.
3. Remove the seatbelt cover screws and slide the cover
down. See Fig. 15.
Fig. 17. Regulator mounting stud being turned in to gain clearance with body panel,
Fig. 15. Screws for seatbelt cover (arrows) to be removed. Slide cover down seatbelt.
4. Loosen the seatbelt guide bolt and pivot the belt guide
in. Remove the two window bracket bolts. See Fig. 16.
8. Pull the window glass and regulator assembly out of
the body.
NOTE
The glass can be removed from the regulator by removing the
three regulator-to-glass mounting bolts.
Installation is the reverse of removal. Tighten the seatbelt
guide bolt to the value given below. Reinstall the outer window
seal using contact adhesive around the seal and the molding.
Tightening torque
• seatbelt guide bolt to body
(convertible models) . _. 24 to 40 Nm (18 to 30 Ib-ft)
To remove and install front manual window
regulator
Fig. 16. Loosen seatbelt guide bolt A. Remove two window
bracket bolts (arrows),
5. Carefully pry off the outer window seal.
DOORS AND WINDOWS
1. Remove the interior door trim and moisture barrier as
described above.
2. While supporting the window glass, remove the screws
that hold the glass to the regulator arm. See Fig. 11
above.
Page 538
Doors, Windows, and Lids
830-7
NOTE
The window glass can be removed from the door after removing the inner weatherstrip from the door. See Fig. 9 above.
With the weatherstrip removed, rotate the glass to a vertical
position and slide it up and out of the door.
3. Remove the four bolts holding the regulator to the door
and remove the regulator. See Fig. 18.
Fig. 19. Rear door manual regulator being removed.
LOCKS, HANDLES, AND LATCH
MECHANISMS
This section covers replacement of the lock cylinders, the
door handles, and the latch mechanisms. Also covered here
is replacement of the central locking motors.
Fig. 18. Regulator being removed from front door.
Installation is the reverse of removal. A thin film of white
grease can be applied to moving parts. Test the window regulator before installing the interior door trim.
For information on repairing the ignition lock cylinder see
432 Manual Transmission Controls. For information on wiring for the central locking system see 371 Wiring Diagrams,
Fuses and Relays.
NOTE
To remove and install rear manual window
regulator
1. Remove the door handle, interior door trim and moisture barrier as described above.
2. Support the window glass while removing the screws
that hold the glass to the regulator arm. Slide the window up until it is in its fully closed position.
• Always test all of the latch and locking functions including
the child safety feature after completing any repairs.
• When working on the locking system always keep a spare
key outside the car in case the system locks accidentally.
To replace door handle
3. Remove the bolts holding the regulator to the door and
remove the regulator. See Fig. 19.
1. Remove the interior door trim and moisture barrier as
described earlier. Working inside the door, remove the
front door handle mounting screw.
Installation is the reverse of removal. A thin film of white
grease can be applied to moving parts. Test the window regulator before installing the interior door trim.
2. Working at the outside door edge, loosen the rear
screw for the door handle bracket about four turns. See
Fig. 20.
NOTE
NOTE
Removal of the rear door window requires that the fixed side
pane be removed so that the rear window channel can be
moved out of the way. The window channel is held in place
with two screws that can be accessed after removing the rubber concealing plugs in the door.
On 4-door models, the rear screw for the rear door is hidden
behind the weather strip.
3. Rotate the handle to the position shown in Fig. 21 and
remove the handle from the door.
LOCKS, HANDLES, AND LATCH MECHANISMS
Page 539
Doors, Windows, and Lids
830-8
Front
Rear
~Rearscrew
~.........
and bracket
87719
87721
Fig. 20. Door handle assembly.
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Fig. 22. Front (left) and rear (right) door lock mechanisms.
,
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3. Working inside the door, remove the link rods from the
inside door handle, the lock cylinder, and the central
lock motor.
CAUTION
• When removing the link rods from plastic parts do not stress
the plastic as it will break.
• Do not bend or distort the link rods. The latch mechanism will
not work properly when the bent links are reinstalled.
Rg. 21. Rotate door handle as shown to remove.
CAUTION
Do not force the handle when removing it from the door. The
latch mechanism inside the door could be damaged.
NOTE
The central lock molor can be removed to gain more working
space inside the door. Remove the locking motor as described
below.
4. Loosen, but do not remove, the screws for the outer
door handle as described above.
Installation is the reverse of removal.
To replace door lock mechanism
NOTE
Loosening the outer door handle screws will allow some clearance for the latch mechanism to be removed. The outer door
handle can be completely removed if necessary.
Fig. 22 shows the front and rear door lock mechanisms.
1. Close the window. Remove the locking knob, interior
door trim and moisture barrier as described above.
2. Manually rotate the latch mechanism on the door jamb
to the latched (closed) position and remove the three
retaining screws on the door edge.
NOTE
If the screws are frozen they can be removed with an impact
driver.
5. Carefully work the latch mechanism free and remove it
from the door.
Installation is the reverse of removal. Apply a thin film of
chassis grease (Saab special chassis grease -ESSO Nebula EP2 or equivalent) to the latch mechanism. Test all the latch
functions before installing the interior trim panel.
To replace trunk lid lock mechanism
1. Remove the central lock motor as described later under the appropriate heading.
LOCKS, HANDLES, AND LA TCH MECHANISMS
Page 540
Doors, Windows, and Lids
CAUTION
When removing the link rods from plastic parts do not stress
the plastic as it will break.
830-9
Installation is the reverse of removal. Clean, then lubricate
all sliding surfaces with a thin film of grease. The adjusting nut
can be adjusted so the handle has a little slack before it releases the hatchback lid.
2. Remove the trunk lid lock cylinder as described below.
To replace door lock cylinder
3. Remove the two bolts for the latch mechanism, then
carefully remove the latch from its mount.
Replacing the door lock cylinder requires removing the interior trim panel from the door. Fig. 24 shows an exploded view
of the lock including the U-shaped spring clip that holds the
lock to the door.
Installation is the reverse of removal.
To replace hatchback lock mechanism
1. Remove the interior trim panel from the lid.
2. Working from inside the lid, disconnect the link rod from
the control arm on the lock cylinder. Remove the two
screws that hold the latch mechanism to the lid and remove the latch mechanism. See Fig. 23.
NOTE
Lock cylinders matching your key code can be specially ordered from Saab. The key code is also stamped on the lock
cylinder barrel.
1
1. Ring
Driver
Plastic arm
Spring
U-shaped clip
6. Gasket
7. Lock barrel
8. Ring
9. Lock
10. Key
2.
3.
4.
5.
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4
5
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10
L-------87723-$4143
Fig. 24. Door lock cylinder.
87722
1.
2.
3.
4.
5.
6.
Slide lever (shown in unlocked position)
Adjusting nut
Lock cylinder
Latch handle assembly
Link rod
Latch mechanism
Fig. 23. Latch mechanism used on hatchback models.
1. Put the window in the closed (up) position. Remove the
interior door panel trim as described earlier.
2. Unhook the link rod from the lock cylinder plastic arm.
3. Carefully pull down the U-shaped clip using pliers. Note
the cutouts in the lock cylinder body for the clip.
3. Working inside the lid remove the five nuts holding the
latch handle assembly to the lid. Disconnect the license
plate light connectors. Remove the handle assembly.
LOCKS, HANDLES, AND LA TCH MECHANISMS