Page 561
854-8
Heating and Air Conditioning
7
1.
2.
3.
4.
5.
6.
7.
8.
9,
Compressor
Condenser
Receiver/drier shell
Expansion valve
Evaporator
Temperature-sensitive expansion valve body
Compensating hose
Anti-freezing thermostat
Temperature-sensitive anti-frost thermostat body
•
3
2
High pressure liquid
!!!!!!!!!!!!i!!
High pressure vapor- •
•
•
••
Low pressure liquid • • • • • • • • • • t
Low pressure vapor
_
87766-87546
l-
Fig. 11. Schematic view of AlC system,
AIR CONDITIONING
_
Page 562
...........
Heating and Air Conditioning
O
Clear sight glass - system correctly
charged or overcaharged
i
I
I
I
~ Heavy stream of bubbles -serious
i
~ shortage of refrigerant
I
I
I
Oil streaks on glass - no refrigerant
in system
~
~ contaminants
D_a_r_k_o_rC_I_oU_d_e_present
_d_s_i9_h_t_g_la_s_s_----=----=-_
L
87767
more than five minutes the receiver/drier must be replaced.
Table c. Ale System Refrigerant Specifications
~ fully charged
G
NOTE
If the AlC system has been opened up to the atmosphere for
I
I!'Jt;. Occasional bubbles - system not
_
854-9
I
I
J!
Fig. 12. Air conditioning sight glass indicators,
Refrigerant capacity (R12)
1.0 kg. (2.2 Ib)
Refrigerant oil capacity
(compressor replacement) .. " , . . .. . ... " .. 1.75 dl (4.9 oz.)
Refrigerant oil capacity per component
(due to sudden leakage)
Evaporato r
0.5 dl ( 1.4 oz.)
Receiver/drier
"
0.2 dl (0.57 oz.)
Condenser
0.2 dl (0.57 oz.)
Hose
0.2 dl (0.57 oz.)
Oil fill plug torque
8-12 Nm (6-9 ft-Ib)
Air Conditioning Electrical Tests
Covered under this heading are tests for the AlC compressor clutch, pressure and temperature safety switches, and the
AlC selector switch.
NOTE
WARNING
Discharging the system or adding refrigerant without the proper tools, equipment, or knowledge may cause severe personal injury as well as damage to the AlC components.
Additional wiring infonnation can be found in 371 Wiring Diagrams, Fuses and Relays.
To test Ale compressor
AlC Component Replacement
The information given below is intended to be used by those
experienced in AlC service. When replacing components, always use new O-rings and gaskets. Lubricate the fittings and
O-rings with refrigerant oil during installation. Table c lists the
appropriate amount of refrigerant oil that should be added to
the system when replacing individual components. Fig. 13
shows tightening torques for the various hoses and components.
WARNING
The system must be discharged before replacing any AlC
components or hoses. Always evacuate the system before recharging it.
CAUTION
The oil filler plug on the AlC compressor is not an oil level plug.
Do not check the compressor oil level through this plug.
1. Turn the ignition on and turn the temperature regulating
knob to its full cold position. Turn the AlC switch on and
listen for the compressor clutch to click on. If no click is
heard, the compressor clutch may not be receiving
voltage or the clutch itself may be faulty.
2. Check for voltage between the single-wire connector
leading out of the compressor and ground. If voltage is
present, the compressor clutch is faulty and should be
replaced.
3. If voltage is not present, check for a faulty compressor
fuse in the main fuse/relay panel. Check the AlC coolant temperature switch, the low pressure switch, and
the anti-frost switch as described below. Check for
damaged wiring or a faulty (open) suppression diode
using an ohmmeter.
NOTE
The AlC diode is in the wiring hamess at the rear of the camshaft cover. See 371 Wiring Diagrams, Fuses and Relays
for AlC wiring diagrams.
4. If no faults are found up to this point, test the anti-frost
valve as described below.
AIR CONDITIONING
Page 563
854-10
Heating and Air Conditioning
21-27 Nm
(15-20 ft-Ib)
14-20 Nm
(10-15 ft-Ib)
B7768-SF3663-AAB90
Fig. 13. Ale hose and component tightening torques.
To test Ale safety switches
Ale Safety Switches
A low pressure switch in the receiver/drier interrupts power
to the compressor clutch if the pressure is too low. An antifrost switch automatically disengages the compressor clutch
when the temperature at the evaporator drops below a certain
level. An NC coolant temperature switch on the hose to the
thermostat interrupts the compressor if the coolant temperature is excessive.
NOTE
The radiator cooling fan should run when the Ale is switched
on (key on). When the compressor clutch cycles (engine running), the additional cooling fan should also run.
AIR CONDITIONING
• Low pressure switch
opening pressure
2.9 bar (42 psi)
• Coolant temperature switch
opening temperature
115°C (239°F)
• Anti-frost switch
switch closed
4.0 to 6.2 °C (39.2 to 43.1 OF)
switch open
0.4 to 2.6 °C (33 to 36.6 OF)
1. Disconnect the connector from the low pressure switch
and connect and ohmmeter across the switch terminals. With the engine running and the NC on, there
should continuity. If not, either the refrigerant charge is
low or the switch is faulty.
Page 564
Heating and Air Conditioning
854-11
WARNING
• Do not loosen or remove the low pressure switch. Refrigerant will be expelled. The system must be discharged before
this switch is removed.
Evaporator
housing - - - -
• Operate the NC only long enough to make the tests.
2. Check the anti-frost switch by disconnecting the switch
connector and connecting and ohmmeter across the
switch terminals. There should continuity with the
switch at room temperature. If not the switch is faulty
and should be replaced. See Fig. 14.
87769·S8082
NOTE
• When installing a new anti-frost switch, be sure the capillary
tube is in its original position.
• Check that the capillary tube does not interfere with the recirculation door.
Fig. 14. Anti-frost switch being removed from evaporator housing.
NOTE
To replace the NC coolant temperature switch, drain the coolant as described in 261 Radiator and Cooling System.
3. Check the AlC coolant temperature switch by disconnecting the switch connector and connecting and ohmmeter across the switch terminals. There should be
continuity across the terminals at all temperatures up to
239°F (115°C). If the switch is open, it is faulty and
should be replaced.
AIR CONDITIONING
Page 565
Bumpers
860-1
860 Bumpers
Removing and Installing Bumpers
To remove bumpers
860-1
860-2
REMOVING AND INSTALLING BUMPERS
Two types of bumpers are used on cars covered by this
manual, depending on model year. See Fig. 1 and Fig. 2.
Fig. 2. Exploded view of front bumper used on 1987 and later models, Rear bumper IS similar,
Fig. 1. Exploded view of front bumper used on 1985 and 1986 models. Rear bumper is similar.
To remove bumpers
1. To remove the front bumper, remove the two internalhex head screws holding the bumper to the bumper
brackets. See Fig. 3. Remove the bumper.
NOTE
On cars with headlight wipers, remove the wipers before removing the front bumper as described in 363 Wipers and
Washers.
Fig. 3. Front bumper internal-hex head screw as viewed from below, Early style bumper shown,
2. To remove the rear bumper, remove the four nuts holding the bumper to the bumper mounting brackets. See
Fig. 4.
REMOVING AND INSTALLING BUMPERS
Page 566
860-2
Bumpers
I
i
87777-88/5121
Fig. 4. Rear bumper mounting bracket (right-hand side). Early style
bumper shown,
Installation is the reverse of removal. Individual bumper
replacement parts are available from an authorized Saab
dealer.
REMOVING AND INSTALLING BUMPERS
Page 567
INDEX
1
INDEX
Subjects are indexed by repair group number, followed by the page
number(s) within the repair group where the subject can be found.
For example 210-4 refers to repair group 210 Engine Disassembly
and Assembly, page 4.
WARNING• Automotive service and repair is serious
business. You must be alen, use common
sense, and exercise good judgement to
prevent personal injury and complete the
work safely.
• Before beginning any work on your vehicle, thoroughly read the safety notice,
disclaimer, and all the Cautions and
War nings listed near the front of this
manual.
• Always read the complete procedure
before you begin the work. Pay special
attention to any Cautions and Warnings
that accompany that procedure, or other
information on a specific topic.
A
ABS unit
installing 521-5
removing 521-3
wiring diagrams 371-8
Accelerator and throttle linkage,
lubricating 110-13
NC compressor
See also Air conditioning
testi ng 854-1 0
AIC system
See Automatic Idle Control (AIC)
system
AIC valve
adjusting/removing 240-24
Advice for the beginner 100-10
bolt torque 100-10
cleaning 100-11
cleanliness 100-10
general information 100-12
getting started 100-8
Air bag system
See Supplemental Restraint
System (SRS)
Air conditioning (NC) 854-7
component replacement 854-9
discharging and recharging 854-7
electrical tests 854-9
general 854-1
safety switches, testing 854-11
system description 854-7
technical data 028-1
troubleshooting 854-2
wiring diagrams 371-13
Air distribution control switch 854-5
Air filter element
replacing 110-12
Air mass meter 240-13
removing 240-22
testing 240-14
Alignment
See Front wheel alignment
Alternator
brushes, replacing 321-3
removing 321-2
testing 321-1
Alternator and charging system
wiring diagrams 371-19
Antenna, electric 851-4
replacing/testing 851-4
Antifreeze
See Coolant
Anti-lock braking system (ABS) 500-2
See alsoABS
ABS wheel speed sensor
replacing 500-3
warning indicator 100-20
Anti-roll bar
See Rear Suspension
Automatic Performance Control (APC)
See Turbocharger
ATF
See Automatic transmission fluid
Automatic Idle Control (AIC) system
testing 240-17
wiring diagrams 371-23
Automatic transmission 110-14, 400-2
gear selector cable 444-1
gear system, planetary 400-4
general 472-1
governor, removing 444-4
hydraulic system 400-5
pan (sump) gasket 472-1
pressure test 400-8
removing 201-9
stall speed test 400-7
troubleshooting 400-6
Automatic transmission final drive
110-16
Automatic transmission fluid (ATF)
ATF cooler, replacing 472-2
ATF pump 400-4
replacing fluid/filter 110-15
Axle, rear
See Rear suspension
Axle, front
See Drive axle
B
Back-up light switch 364-4
Back-up lights
wiring diagrams 371-26
Ball joints
checking and replacing 631-1
Ball joints, steering joints (tie rod ends)
110-19
Battery
charging 311-2
general 311-1
service 110-13
testing 311-1
voltage 200-1 0
Belts
See Drive belts
Body
general 100-7, 800-1
maintenance 110-20
technical data 028-1
Boost pressure (turbo) 291-4
See also Turbocharger
Brake calipers 523-1
front, removing 523-1
rear, removing 523-2
Brake discs
general 516-1
inspecting and replacing 516-1
removing 516-2
Brake fluid
bleeding and changing 520-1
Brake fluid level warning light 100-20
Brake fluid warning lamp switch 364-6
Brake lights
wiring diagrams 371-28
Brake lines and hoses 522-1
replacing 522-1
Brake master cylinder
removing 521-2
Brake pads
general 517-1
inspecting 517-1
replacing 517-1
Brake pedal
general 524-1
removing 524-1
Brake system
general 520-1
Brake system bleeding
cars with ABS 520-2
cars without ABS 520-1
general 110-18
Page 568
2
INDEX
Brakes 110-17
See also Anti-lock Braking System
(ABS)
general 100-6, 500-1
technical data 025-1
troubleshooting 500-5
Brake fluid bleeding
See Brake system bleeding
Brake fluid specifications 520-2
Bumpers
removing and installing 860-1
Burglar alarm
wiring diagrams 371-3
c
Camshaft
checking 215-1
general 200-1 ,215-1
reconditioning 214-11
removing and installing 214-5
technical data 022-5
Cam followers
See Hydraulic cam followers
Camshaft timing chain
checking and replacing 215-1
Camshaft valve cover
See Cylinder head
Carbon deposits
See Driveability and engine
management
Carpets 851-2
removing 851-2
Cautions
general 100-7
Central locking
locking motors, removing 830-10
wiring diagrams 371-40
Charging system
general 321-1
quick-check 321-1
testing 321-1
troubleshooting 321-1
wiring 371-19
Chassis service 110-17
Check Engine light 200-5,240-5,340-3
Cigarette lighter
wiring diagrams 371-75
Clutch
controls 412-1
disc, pressure plate, release
bearing replacing 411-1
general 400-2, 411-1
master and slave cylinders
bleeding 412-2
replacing 412-1
Coil springs
See Front Suspension or Rear
Suspension
Combined instruments
removing 853-3
wiring diagrams 371-44
Connecting rods
general 212-1
See also Pistons
Continuity, checking for 300-7
Control arms
removing and installing 632-2
Control arm bushings
replacing 632-1
Convertible top
adjustments 812-1
general 812-1
hydraulic system 812-3
wiring diagrams 371-49
Coolant (antifreeze) and cooling system
Coolant pump 261-1
replacing 261-6
Coolant temperature gauge
sender 261-4
Coolant temperature sensor (LH fuel
injection) 240-12
removing 240-22
Cooling system 022-8
draining and filling 261-5
general description 200-2
hoses, replacing 261-5
maintenance 110-7
troubleshooting 261-3
Crankcase ventilation hoses 110-11
Crankshaft 216-1
general 200-2
inspecting/reconditioning 216-1
removing/installing 210-1
technical data 022-6,
Crankshaft oil seals
See Cylinder block oil seals
Cruise control
component locations 368-1
control switch, checking 368-3
electrical tests 368-2
general 368-1
pedal switches 368-2
vacuum pump, checking 368-3
wiring diagrams 371-51
CV joint
See Drive axle
Cylinder block
clearances (piston/cylinder) 212-3
disassembly 210-2
general 200-1, 210-1
reconditioning 212-2
technical data 022-3
Cylinder block oil seals
replacing 216-3
Cylinder head
See also Valve train
disassembly and assembly 214-9
general 200-1
reconditioning 214-11
removal/installation 211-1, 211-3
technical data 022-4
valve cover, removing 214-4
Cylinders (engine)
See Cylinder block
D
Dashboard and consoles
general 853-1
Dashpot (LH 2.2)
See Fuel Injection (LH)
Differential and final drive 400-5
Directional indicators
wiring diagrams 371-55
Distributor
cap and rotor, replacing 340-11
Distributor cap, rotor, and spark plugs
general 110-10
Doors
adjusting fit 830-2
general 830-1
interior panel, removing 830-3
lock and handle mechanism 830-8
See also Central Locking
removing and installing 830-1
Drive axle
general 774-1
joint boots, inspecting 110-17
replacing 774-5
Drive belts 110-8
Drive plate (automatic trans.) 216-3
Driveability and engine management
basic adjustments 200-8
carbon deposits 200-7
mechanical condition 200-7
troubleshooting 200-4
warnings and cautions 200-7
wiring and harness connectors
200-10
E
EGR
See Exhaust gas recirculation
system (EGR)
Electric controls and switches
extra gauges 364-6
general 364·1
Electrical system
components, connectors and
ground locations (list) 371-6
general 100-4, 300-1
safety precautions 300·1
switches, engine 364-5
service 110-13
short circuits, checking for 300-7
technical data 023-1
test equipment 300-2
testing, general 100-11
troubleshooting 300-4
wiring diagrams 371-1
Emergencies 100-18
Engine
general 100-2, 201-1
maintenance schedules 110-5
mechanical troubleshooting 200-4
removing and installing 201-1
removing from transmission 201-9
technical data 022-1
Engine oil and oil filter 110-5
Evaporative loss control device (ELCD)
110-11 , 254-1
Exhaust emission control
general 254-1
Exhaust manifold
removing and installing 252-4
Page 569
INDEX
3
INDEX
Subjects are indexed by repair group number, followed by the page
number(s) within the repair group where the subject can be found.
For example 210-4 refers to repair group 210 Engine Disassembly
and Assembly, page 4.
WARNING• Automotive service and repair is serious
business. You must be alert, use common
sense, and exercise good judgement to
prevent personal injury and complete the
work safely.
• Before beginning any work on your vehicle, thoroughly read the safety notice,
disclaimer, and all the Cautions and
War nings listed near the front of this
manual.
• Always read the complete procedure
before you begin the work. Pay special
attention to any Cautions and Warnings
that accompany that procedure, or other
information on a specific topic.
Exhaust gas recirculation system (EGR)
254-2
checking operation 254-3
temperature sensor, testing 254-4
valve testing 254-3
Exhaust system
general 110-13, 252-1
removing and installing 252-1
Exhaust valves
See Valve train
ElK ignition system
See also Ignition system
general 340-1
knock sensor 340-2
replacing 340-14
system testing 340-8
wiring diagrams 371-83
F
Fan belts
See Drive belts
Fasteners
non-reusable fasteners 100-10
tightening 100-10
Fault code memory (LH fuel injection)
canceling 240-7
Fault diagnosis 240-4
Feeler gauges 100-17
Flywheel (manual transmission) 216-3
Foglamps
wiring diagrams 371-58
Front Suspension
coil springs 731-2
checking 731-4
removing 731-2
general 731-1
shock absorbers
general 110-3
removing/installing 731-1
technical data 027-1
troubleshooting 700-2
Front wheel bearings
See wheel bearings
Fuel filter, replacing 110-13
Fuel gauge sender unit
removing and installing 234-15
Fuel injection (LH)
basic requirements 240-4
component replacement 240-22
component testing 240-10
fault codes 240-5
fault tracing 240-4
fuel injectors 240-14
removing 240-23
testing 240-15
general 100-3, 240-1
LH control unit, removing 240-22
LH variants 240-3
oxygen sensor
See Oxygen sensor
safety precautions 240-3
system adjustments 240-24
technical data 022-7
Fuel lines 234-16
replacing 234-16
Fuel pressure regulator 240-9
removing 240-23
Fuel pressure tests 240-8
Fuel pump 234-6
delivery pressure 240-10
delivery rate 234-6
electrical tests 234-6
noise 234-4
operating pump tor tests 234-4
screen (filter), replacing 234-13
replacing pump
roller-type 234-8
rotor-type 234-1 0
safety precautions 234-2
testing 234-7
troubleshooting 234-3
variants 234-1
wiring diagrams 371-60
Fuel pump check valve
replacing 234-13
Fuel pump relay, testing 234-7
Fuel supply 200-2, 200-11
Fuel system
See Fuel Injection (LH)
Fuel tank
general 234-1
removing and installing 234-14
rollover valve, replacing 234-15
Fuse and relay locations, main 371-1
G
Gaskets
general information 100-11
Gauges
See Electric controls and switches
or instrument cluster
Gear lever housing
See Manual transmission
Gear shift lever
See Manual transmission
Glovebox I~ghting
wiring diagrams 371-71
Ground
connections 200-10,300-1,371-6
H
Hall sensor 340-12
replacing 340-13
Hall ignition system 340-1
See also Ignition system
testing 340-6
wiring diagrams 371-83
Handbrake warning lamp switch 364-4
Hatchback and trunk lid 830-11
lock mechanism, replacing 830-9
See also Central Locking
removing/installing 830-11
Headlight wiper motor
removing 363-2
Headlights
replacing 351-1
wipers and washers 363-2
wiring diagrams 371-73
Heated rear window
wiring diagrams 371-75
Heater and controls 854-3
Heater core and heater valve 854-3
replacing 854-3
Page 570
..............
4
INDEX
Hood
alignment and adjustment 820-3
general 820-1
release cable 820-2
Horns
wiring diagrams 371-81
How to use this manual 100-7
Hydraulic cam followers 214-1
checking and replacing 214-2
Idle speed (LH 2.2) 240-24
Ignition lock cylinder
installing 432-3
removing 432-2
Ignition switch, replacing 432-2
Ignition timing 340-14
checking and adjusting 340-15
Ignition switch
wiring information 371-7
Ignition system
component removal and
replacement 340-11
disabling ignition system 340-3
electrical tests and fault tracing
340-5
general 100-4, 340-1
quick-check of system 340-4
test equipment 340-3
troubleshooting 340-2
visual inspection 340-4, 5
wiring diagrams 371-83
Injectors
See Fuel injection (LH)
Instruments (cluster) 853-2
removing 853-3
wiring diagrams 371-44
Instrument center console 800-2
Instrument cluster switch panel
removing 364-1
Instrument pad, lower
removing 851-3
Instrument panel 853-1
Interior switches 364-3
Lights (continued)
headlights
see Headlights
interior bulbs, replacing 351-4
parking light bulbs, replacing 351-3
side marker and side reversing light
bulbs, replacing 351-3
stop light bulbs, replacing 351-3
wiring diagrams 371-55
time delay relay 351-5
Lifting the car 100-8
raising the car safely 100-9
Locks, handles, and latch mechanisms
830-7
See also Central locking
Lubrication and maintenance
quick data 010-2
Lubrication system 022-6, 220-1
See also Oil pump
general description 200-2
Luggage compartment lighting
wiring diagrams 371-102
M
Maintenance program
Saab recommended 110-2
Manual transmission 110-16, 400-1
gear selector rod, removing 432-3
gear shift control 432-1
gear shift lever, adjusting 432-6
removing 201-9
troubleshooting 400-5
Manual transmission control 432-1
Master cylinder
See Brakes
Mercury switch (convertible) 364-5
Mirrors, power
wiring diagrams 371-110
Modulating valve
See EGR
testing 254-5
N
Notes, general 100-7
J
o
Jack stands, using 100-16
Jump-starting 100-18
L
Lambda Sensor
See Oxygen Sensor
LH fuel injection
See Fuel injection (LH)
Lighting for controls
wiring diagrams 371-98
Lights
backup
wiring diagrams 371-26
direction indicators light bulbs,
replacing 351-3
general 351-1
hazard warning light bulbs, replacing
351-3
Oil
excessive consumption 200-5
Oil and filter
changing 110-6
Oil change equipment 100-16
Oil cooler (turbo models only) 220-5
removing 220-5
Oil pressure
relief valve 220-4
testing 220-4
warning circuit 220-5
warning systems 220-4
Oil pressure warning light 100-20
Oil pump
removing and installing 220-1
On-board diagnostics (EZK ignition only)
340-3
On-board diagnostics (LH 2.4 and LH
2.4.2 only) 240-5
Overheating 100-19
Oxygen sensor 110-11, 200-8, 240-16
testing 240-16
p
Panhard rod
See Rear suspension
Parking brake 110-18
adjusting 551-3
general 551-1
Parking brake cables
removing/installing 551-1
Parking lights
wiring diagrams 371-104
Parts
buying 100-12
genuine Saab parts 100-12
non-returnable parts 100-14
spare parts kit 100-20
Pistons 212-1
technical data 022-3
Piston rings 022-3, 212-4
Piston-to-cylinder clearance
See Cylinder Block
Power steering fluid 110-18
Power steering system 644-1
pump and lines 644-4
removing/installing 644-1
Pressure plate
See Clutch
R
Radiator
pressure test 261-3
removing 261-8
Radiator and expansion tank
general 261-1
Radiator cooling fan thermoswitch
replacing 261-8
Radiator cooling fans 261-8
general 261-1
quick-check 261-4
removing 261-9
wiring diagrams 371-118
Radio wiring diagrams 371-120
Radio antenna
See Antenna
rear axle, removing 732-7
Rear Suspension 732-1
bump stop 732-10
coil spring link, removing 732-5
coil springs 732-2
panhard rod, removing 732-9
shock absorbers 732-1
torque arm, removing 732-9
Refrigerant charge
checking 854-7
Regulator brushes
See Alternator
Relay positions 371-5
Release bearing
See Clutch