Page 551
Dashboard and Consoles
853-1
853 Dashboard and Consoles
Dashboard
853-1
To remove padded dashboard . . . . . . . . . . . . 853-1
To remove storage console
853-1
Instrument Cluster
853-2
853-3
To remove instrument cluster
DASHBOARD
The one-piece padded dashboard panel is removed after
the instrument panel, radio and steering wheel have been removed. Removal of the steering wheel is given in 641 Steering Column. Removal of the instrument panel that holds the
dashboard switches is covered in 364 Electric Controls and
Switches.
WARNING
1990 and later models are equipped with an airbag or SRS
system. The airbag is an explosive device. Do not attempt to
remove the steering wheel or service the wiring inthe steering
column assembly. You could accidentally ignite the airbag,
causing serious personal injury. See an authorized Saab dealer for any repairs to the SRS system or to disarm the system
prior to removing the steering wheel.
Fig. 1. Dashboard upper mounting screws (arrows).
NOTE
Removal of the center console between the front seats is covered in 432 Manual Transmission Controls.
To remove padded dashboard
1. Remove the battery negative (-) cable.
2. Remove the instrument panel as described in 364
Electric Controls and Switches.
3. Remove the left and right front speaker grilles.
Fig. 2.
NOTE
Use an offset screwdriver to remove the speaker grille mounting screws.
4. Working through the speaker grille openings, remove
the left and right upper dashboard mounting screws.
See Fig. 1
5. Working below the glove box, remove the two screws
shown in Fig. 2.
6. Working under the left-hand side of the dash, remove
the corner mounting screw shown in Fig. 3.
Lower dashboard mounting screws below glovebox (arrows).
7. Remove the dashboard as shown in Fig. 4.
Installation is the reverse of removal. Check that the defroster hoses are attached to the speaker grilles. Check all instrument panel functions.
To remove storage console
,
1. Remove the rubber boot in front of the shift lever by
squeezing it in pulling it out. See Fig. 5.
2. Remove the ashtray. Remove the screws holding the
ashtray bracket to the console. See Fig. 6.
DASHBOARD
:.
:::::::::::::::::::}:::'
:.:-:-:-:.".:.:.:.: ::::
Page 552
853-2
Dashboard and Consoles
Fig. 3. Mounting screw on under left-hand side of dash (arrow).
Fig. 6. Ashtray bracket being removed. Console bolt (not shown)
is removed through opening (arrow).
4. Disconnect the ashtray illumination wires and remove
the bulb holder.
5. Where applicable, remove the gauges or the radio
equipment in the center of the console. Disconnect and
label the wiring.
6. Remove the six screws holding the console to the car
body and dash. Remove the console.
INSTRUMENT CLUSTER
Fig. 4. Padded dashboard being removed.
The instrument cluster can be easily removed once the instrument panel is removed as described in 364 Electric Controls and Switches. To replace bulbs in the cluster, remove
the left speaker grille and reach into the opening. See Fig. 7.
The bulbs can be removed and tested by checking for continuity at the socket terminals.
Fig. 5. Rubber boot being removed.
3. Working through the ashtray opening, remove the bolt
holding the console to the dashboard.
INSTRUMENT CLUSTER
Fig. 7. Instrument cluster bulbs (arrows) as viewed through left
speaker opening
Page 553
Dashboard and Consoles
Instrument cluster bulb rating
• instrument ilium ination
• charge warning lamp
• other warning/indicator lamps
3 watt
2 watt
1.2 watt
To remove instrument cluster
853-3
NOTE
If the speedometer cable is being replaced, free the cable
from the grommet in the bulkhead then pull the cable into the
engine compartment. Remove the other end of the cable from
the transmission.
•
5. Remove the screws holding the cluster to the dash.
See Fig. 9. Remove the cluster.
1. Remove the battery negative (-) cable. Remove the
steering wheel as described in 641 Steering Column.
WARNING
1990 and later models are equipped with an airbag or SRS
system. The airbag is an explosive device. Do not attempt to
remove the steering wheel or service the wiring in the steering
column assembly. You could accidentally ignite the airbag,
causing serious personal injury. See an authorized Saab dealer for any repairs to the SRS system or to disarm the system
prior to removing the steering wheel.
2. Remove the instrument panel as described in 364
Electric Controls and Switches.
3. Remove the left speaker grille.
Fig. 9. Instrument cluster retaining screw being removed.
4. Working through the speaker grille, disconnect the
electrical connectors at the back of the cluster. Disconnect the speedometer cable by bending the spring out
of the way and pulling the cable from the instrument. See
Fig. 8.
NOTE
• Replacement instruments are available from an authorized
Saab dealer. Fig. 10 shows the individual instruments removed from the cluster housing.
• Laws in some areas require that you fill outan odometerverification sticker when replacing a speedometer.
(
Fig. 8. Speedometer cable retaining clip being pried up to removed cable from speedometer.
Fig. 10. Instruments.
INSTRUMENT CLUSTER
Page 554
Heating and Air Conditioning
854-1
854 Heating and Air Conditioning
General
854-1
Troubleshooting
854-2
Heater and Controls
854-3
854-3
854-3
854-5
854-5
Heater Core and Heater Valve
To replace heater valve and heater core
Ventilation Blower and Blower Switch
To remove and install ventilation blower.
Air Distribution Control Switch,
Vacuum Servos and Air Flaps
To test vacuum servos and air 'flaps
Checking Refrigerant Charge
854-7
Discharging. Evacuating, and Recharging
AlC System
,
854-7
AlC Component Replacement
854-9
Air Conditioning Electrical Tests
854-9
To test AlC compressor
854-9
To test AlC safety switches . . . . . . . . . . . . . . 854-1 0
TABLES
854-5
854-6
Air Conditioning
854-7
System Description. . . . . . . . . . . . . . . . . . . . . 854-7
GENERAL
This section of the manual covers repairs and troubleshooting for the heating and air conditioning (AlC) systems. This includes repair information for the heater core, the heater valve,
the ventilation blower, the dash-mounted controls, and the
AlC components.
a. Heating and Air Conditioning System
Troubleshooting
b. Vacuum Servo Fault Tracing
c. Ale System Refrigerant Specifications
854-3
854-6
854-9
Heating is controlled by regulating coolant flow through the
heater core via the heater valve. The temperature regulating
knob is directly connected to the heater valve, using a control
rod.
All of the cars covered by this manual are equipped with factory-installed AlC. The major components of the AlC system
are shown in Fig. 2.
CAUTION
The AlC system is a sealed system and should only be serviced by an authorized Saab dealer or other qualified repair
shop. Special tools and equipment are necessary to service
the AlC system.
The AlC system is protected by a pressure switch, a fuse for
the compressor, an anti-frost switch and an AlC coolant temperature switch. See 261 Radiator and Cooling System for
information on the AlC coolant temperature switch. These
components switch off the compressor to prevent damage to
the AlC system.
NOTE
• Repairs to the cooling system, including heater hose replacement, are covered in 261 Radiator and Cooling System.
WARNING
• Adding refrigerant or servicing the AlC system without the
proper tools, equipment, or knowledge may cause severe personal injury as well as damage to the A/C components.
• Additional electrical troubleshooting is covered in 371 Wiring Diagrams, Fuses and Relays.
Fig. 1 shows the heating and air conditioning system's air
distribution system. Fresh air enters the car through the vent
in the hood and passes through the AlC evaporator and
through the heater core. Air exits through the rear slots near
the luggage area. Air flow through the system is directed
through vacuum-actuated dampers.
Temperature, air flow, and ventilation fan speeds are controlled by separate instrument panel knobs. The air distribution knob also contains electric contacts for the ventilation
blower.
• Wear eye protection when inspecting the system. R-12 at
normal atmospheric pressures can evaporate and freeze anything it contacts.
• At normal operating temperature the heating system is pressurized with hot engine coolant. Allow the system to cool as
long as possible before opening-a minimum of an hourthen release the coolant expansion cap very slowly to allow
safe release of pressure.
• Releasing cooling system pressure lowers the coolant's boiling point, and the coolant may boil suddenly. Use heavy
gloves and wear eye and face protection to guard against
scalding.
GENERAL
Page 555
Heating and Air Conditioning
854-2
1
7
9
1. Air intake
7. Vacuum servo (single stage)
4. Heater core
5. Heater valve
6. Air distribution switch
2. Evaporator
3. Blower motor
8. Vacuum servo (dual stage)
9. Vacuum controlled flaps
Fig. 1. Cut-away view of air distribution system.
CAUTION
Avoid adding cold water to the coolant while the engine is hot
or overheated. If it is absolutely necessary to add coolant to a
hot system, do so only with the engine running and coolant
pump turning.
1
TROUBLESHOOTING
Table a shows common heating and air conditioning problems. Each system has its own causes and corrective actions.
1. Compressor
2. Condenser
3. Expansion valve
Fig. 2. AlC components.
TROUBLESHOOTING
4. Evaporator
5. Receiver/drier
Insufficient heater output may be caused by a faulty heater
valve, an air flap not opening, or a cooling system fault. Coolant leaking visibly into the passenger compartment is a sign of
a faulty heater core. A sweet, anti-freeze odor in the car's interior, or a constantly fogged windshield may also indicate a
faulty core. Inspect the carpet and the area near the footwell
vents for any moisture or coolant. Water appearing on the carpets or near the footwells could be a clogged AlC evaporator
condensation drain hose.
Page 556
Heating and Air Conditioning
854-3
Table a. Heating and Air Conditioning System Troubleshooting
Symptom
Corrective action
Probable cause
1. Heater output
inadequate
(temperature
gauge reading
normal)
a. Heater hose restricted
b. Heater core or heater valve clogged
or faulty
c. Heater controls broken
a. Replace hose. See 261 Radiator and Cooling System
b. Clean or replace heater valve. Have heater core cleaned
2. Heat always
present at side
vents, temperature
regUlation erraticcannot be
regulated to cooler
settings
a. Heater valve not fully closed due to
disconnected or damaged control rod
a. Check control rod operation
b. Internal seals in heater valve faulty
b. Replace heater valve
3. AlC cooling output
inadequate
a. System charge (refrigerant) low
a. Check system charge at sight glass. Have system recharged if
necessary. Check for leaks
b. Test switch and replace if necessary
c. Test system pressure and replace expansion valve if necessary
b. Anti-frost switch faulty
c. Expansion valve faulty
HEATER AND CONTROLS
Heater Core and Heater Valve
Coolant flow through the heater core is controlled by the
heater valve. The heater valve is connected directly to the
temperature knob. See Fig. 3. There are no adjustments that
can be made to the valve or control rod.
c. Inspect and replace any faulty controls
3. Working in the engine compartment, label and remove
the heater hoses at the heater valve fittings. Plug the
ends of the fittings on the valve.
4. Remove the lower steering column cover, the storage
console (where applicable), and lower dashboard pad
as described in 851 Interior Trim and Upholstery.
WARNING
1990 and later models are equipped with an airbag or SRS
system. The airbag is an explosive device. Do not attempt to
remove the steering wheel or service the wiring in the steering
column assembly. You could accidentally ignite the airbag,
causing serious personal injury. See an authorized Saab dealer for any repairs to the-SRS system or to disarm the system
prior to removing the steering wheel.
5. Remove the left speaker grille, then slide the heater
control rod forward to disengage it from the knob. Slide
rod backwards to remove it from the heater valve. See
Fig. 3 above.
6. If removing just the heater valve use a long 4-mm hexhead driver to remove the screws securing the heater
valve to the heater core. See Fig. 4.
Fig. 3. Heater valve (2) and control rod (1) as viewed through leftfront speaker grille opening,
To replace heater valve and heater core
1. Disconnect the negative
NOTE
A ball type (swivel) hex-head driver will help make removal
and installation of the heater valve screws easier.
H cable from the battery.
2. Drain the coolant as described in 261 Radiator and
Cooling System.
HEA TER AND CONTROLS
Page 557
854-4
Heating and Air Conditioning
Steering
column
Fig. 5. Ventilation air diffuser being removed.
"
87758
Fig. 4.
Heater valve being removed from heater core.
WARNING
• Replacement heater valves may interfere with throttle pedal
operation and require a new throttle pedal arm. See an authorized Saab dealer for correct parts information.
• On cars with cruise control, be sure to refit the actuator chain
guard to the heater valve to prevent interference with the
chain.
Fig. 6.
Lower heater box section being removed, Also visible is
ti,e heater valve capillary tUbe (arrow).
7. Remove the ventilation air diffuser in the footwell. See
Fig. 5.
8. Remove the screws securing the lower section of the
heater box and remove the lower section. See Fig. 6.
9. Unhook the brake pedal return spring from the pedal
and depress the pedal slightly. Lower the heater core
and heater valve assembly out of the car.
10. Where applicable, remove the heater valve capillary
tube from the heater core. Separate the heater valve
from the heater core. See Fig. 7.
CAUTION
Handle the capillary tube carefully. Do not crease or bend the
tube.
HEA TER AND CONTROLS
Fig. 7. Heater valve being removed from heater core.
Page 558
Heating and Air Conditioning
854-5
Installation is the reverse of removal. Always replace the
heater core-to-heater valve O-rings. The heater valve should
be in the off position (flat surface up) before connecting the
control rod. Reconnect the heater hoses to the valve. Check
the operation of all foot pedals before installing the lower dash
pad. Refill and bleed the cooling system as described in 261
Radiator and Cooling System and check the operation of
the heater functions.
NOTE
Reinstall the heater hoses to the heater valve so that the top
hose leads to the water pump and the lower hose comes from
the intake manifold.
Ventilation Blower and Blower Switch
The blower assembly is mounted in the passeriger compartment footwell and runs except when the air distribution
switch is in the 0 (six o'clock) position. A blower resistor pack,
located below the left speaker grille, controls the speed of the
blower motor. There are three resistors for three speeds of the
motor. If the resistor pack overheats, an internal switch closes
and blows the fuse on the main fuse/relay panel.
To quickly test the blower motor, remove the right speaker
grille and probe the connector with a test lamp. If there is no
voltage reaching the motor with the ignition on and the blower
switch on high, check the fuse on the main fuse/relay panel
and check the wiring. See 371 Wiring Diagrams, Fuses and
Relays. If voltage is present, the motor is probably faulty.
NOTE
• A blower motor that runs only when the air distribution switch
is in position 1 (7 o'clock position) usually indicates a fault with
the blower motor resistors or blower switch.
• To replace the blower switch, remove the switch panel as described in 364 Electric Controls and Switches, then remove
the clip holding the switch and the wire connector.
Fig. 8.
Blower motor being removed.
Installation is the reverse of removal.
NOTE
A sound insulation kit is available from Saab to reduce blower
motor noise. See an authorized Saab dealer for the correct
application and part number.
Air Distribution Control Switch, Vacuum
Servos and Air Flaps
Vacuum operated flaps direct air flow to the various air outlets. The panel-mounted air distribution switch routes vacuum
to the correct vacuum servo to open and close the air flaps. See
Fig. 9. The vacuum for the system is supplied via a vacuum
storage tank. The switch also functions to close microswitches
for the ventilation blower motor and the recirculation valve.
NOTE
To replace the air distribution switch, the instrument panel
must be removed. See 364 Electric Controls and Switches.
To remove and install ventilation blower
1. Disconnect the negative (-) cable from the battery.
2. Remove the dashboard instrument panel as described
in 364 Electric Controls and Switches.
3. Remove the padded dashboard as described in 853
Dashboard and Consoles.
4. Disconnect the blower wiring from the blower.
There are six vacuum servos that open and close air flaps.
The recirculation switch on the instrument panel controls an
electric solenoid that routes vacuum to the recirculation door
servo. See Fig. 10.
To test vacuum servos and air flaps
Many vacuum related faults are the result of pinched or disconnected hoses. Always inspect the hoses carefully when
experiencing problems with the servos.
5. Remove right defroster housing mounting screws.
6. Remove the three blower mounting screws and remove the blower. See Fig. 8.
1. With the engine running, check for vacuum at the vacuum tank on the passenger side wheel liner.
HEA TER AND CONTROLS
Page 559
854-6
Heating and Air Conditioning
IN
6
5
1
NOTE
The servos should be visible when making the tests outlined
in the table below. Remove the two speaker grilles to gain access to the outer vent and defroster servos. The lower instrument panel should be removed as described in 853
Dashboard and Consoles to check the lower servos and
flaps. The switch panel must be removed to test the air distribution switch.
Table b. Vacuum Servo Fault Tracing
blower speeds 1-3
flaps open-defroster
flaps partial-none
flaps closed-floor, center, outer
AlC compressor-selectable
87763
IN - vacuum supply
B-switch
1- to recirculation damper
2- to center outlet
3- to left and right outlets
4- to defroster
5-lefthand footwell outlet
6- righthand foolwell outlet
blower speeds 1-3
flaps open-floor
flaps partial-defroster
flaps closed--center, outer
AlC compressor-selectable
Fig. 9. Air distribution switch showing vacuum hose routing.
blower speeds 1-3
flaps open-floor
flaps partial-none
flaps closed-defroster, center, outer
AlC compressor-selectable
blower speeds 1-3
flaps open-eenter
flaps partial-floor
flaps closed-defroster, outer
AlC compressor-selectable
1. Yellow to heater box vacuum box.
2. Blue to recirculation servo
3. White to T connection vacuum tank
Fig. 10. Air recirculation solenoid (A) on wheel housing next to vacuum tank (8) on 1985 through 1987 models. Recirculation solenoid on 1988 and later models is in passenger
compartment, behind right footwell kickpanel.
2. Check the operation of the system servos and the air
distribution switch using the information found in Table b.
HEA TER AND CONTROLS
blower speeds 1-3
flaps open-outer, center
flaps partial-floor
flaps closed-defroster
AlC compressor-selectable
blower speed-high
flaps open-floor, outer, center
flaps partial-none
flaps closed-defroster
AlC compressor-max. or off
blower speed-off
flaps open-none
flaps partial-none
flaps closed-all
AlC compressor-off
Page 560
Heating and Air Conditioning
Vacuum Servo Location
• outer vent - below speaker grilles
• defroster vents - behind center of dash
• center vent - above heater box
• footwell - passenger side of heater box
• fresh air intake - in engine compartment at AlC
evaporator housing
3. If any faults are found, use a hand vacuum pump to
check the operation of the servos. If the servo operates
correctly, check the hose from the switch. If no faults
are found, the switch is faulty and should be replaced.
NOTE
The vacuum tank, the switch and the lines can also be
checked for leaks using the hand pump.
854-7
housing and is routed away via a drain hose. This is the reason a water puddle is often be seen under the car when the
AlC is operating.
The compressor forGes the R-12 through the system and at
the same time pressurizes it, raising the R-12's boiling pointto
make it more easily condensed. The compressor is engaged
by an electro-magnetic clutch that is actuated when the AlC is
turned on.
The condenser, which looks like a small radiator, is located
in front of the engine radiator. The receiver/drier, located behind the battery, removes small amounts of moisture and dirt
from the system. The evaporator and expansion valve are located in the engine compartment on the passenger side at the
firewall.
WARNING
Wear eye protection when inspecting the system. R-12 at normal atmospheric pressures can evaporate and freeze anything it contacts.
AIR CONDITIONING
It is recommended that all service to the AlC system be left
to an authorized Saab dealer or other qualified repair shop.
For information on the AlC selector switch as well as other
electrical components, see 371 Wiring Diagrams, Fuses
and Relays.
Dismounting of the AlC compressor and the condenser,
without disconnecting the hoses, is covered as part of the engine removal procedure in 201 Engine Removal and Installation. If any of the hoses or components are disconnected
and the system is opened, special equipment will be needed
to remove moisture from the system before it is closed back up.
WARNING
Air conditioning (Ale) service and repair requires special
equipment and knowledge. Incorrect procedures may not only
damage the system, but may also be hazardous. Pressures in
excess of 300 psi are created in the system when it is operating. The refrigerant R-12 is poisonous. In its vapor form it can
accumulate in areas with poor ventilation and cause suffocation. Also, in vapor or liquid form R-12 can immediately freeze
anything it contacts, including eyes and skin.
System Description
Fig. 11 is a schematic view of a typical Saab AlC system. In
an AlC system, the heat from the passenger compartment is
absorbed by the refrigerant (R 12) in the evaporator, causing
ther re'frigerant to boil (evaporate). This heat is then released
into the atmosphere when the R-12 is cooled and condensed
into a liquid at the condenser. Moisture is removed at the
evaporator in the same way that water drops form on a cold
9lass. The moisture drips onto the water tray in the evaporator
NOTE
• Run the air conditioning system for a few minutes, every few
weeks, to keep the seals lubricated.
• Check that the condensation drain hose from the evaporator
housing IS clear. This can be accomplished by blowing it out
with a low pressure compressed air nozzle.
Checking Refrigerant Charge
Inspect the refrigerant charge by starting the engine and
turning the air conditioner on to MAX AlC. With the compressor running (clutch cycled on) view the sight glass on the top
of the receiver/drier (located near the battery). There should
be few or no bubbles visible in the glass. See Fig. 12.
Discharging, Evacuating and Recharging
the AlC System
Discharging the system is necessary any time a defective
component is replaced. To prevent component damage, a totally discharged system must be evacuated (sometimes
called pulling a vacuum) using special equipment before recharging. This removes any moisture from the lines and components, wbich can damage the system. For system
discharging, evacuating and recharging, see an authorized
Saab dealer or other shop qualified to do AlC repair work.
AIR CONDITIONING