Saab 900 Convertible User manual

Saab900
SERVICE
MANUAL
SAAB
8:5Convertible
Irt t985
- t990
-

Saab
900
SERVICE
MANUAL
8:5Convertlble
Mi986
- r99r
-
om&3Fl.m!andconpoMbarcd.ah
blidinged@l*roh'iglibhdo
6.n$sjoh€pddo'gp€.ilc|ong
108 Specialtools
800 Technical descl
plion
028 Technrcal
data
810 Body
shel
812 Top assembly
851 Inteiorrrim
830 Spoilerassembly
843 Window
glass
844 Weatherstrips
andseats
t;,
| ,-,
852 Rearseat
899 Alphabeticalseclion
guide

UnKt3
lshoullh. s.'vl6 Mmur m h
[email protected] ri6 thoSl sydo.n.
Fdl)slra.1oni|br}i''m.€|unib'
qrvs rnbEdd and m. @p*[E sr unn.
Th€l.ro$iq synboEed dbt€vralffi e u!d:
St untt Equlvaleniunli end
3ymbol
m rnd'
0n)
& polnd{bl
N ldnd.lo€ (bn
'{m poind.rqE r.d (rbr
n)
b' Polid.rde Fl lqu@ hdl (b[tf)
r 0l.4 (aF lbtr.d.bdr tdl
cc us rhurd
$.n (k qr)
(rrs .nhEtral.d|
dd
Us
salhn
(ussrD
Converalon
ftctors 1 k0 = 220 |b
llb=0,451€ 1N=023lbl
1Nn=07rbtfr
1 b{ - 14.sblrlf
lF€l=o07b.ll|=1'05l|qql
1 USrrq
d = 0.43
uKqr 1 USg.l= 0S3 Uxsdr
qc-cF.32)r5/l
o
o
o
o
Martelcode6
no 6d6 Bid b mnd .p.df€fon8

Technicaldala028-1
Technical
data
worlungpressure
ol
pump
Chas.is
no.H7003109
hin 2s
(36s)
Iighr€nin9
Iorque
hosefinings 5.142
{3.3,4.5)
Recommended
creaning
agents SoapandwalefFor
stubbohslainsordin
use
SikkensFeducerM600
as
per
thema
Chass'sno N7003200
oneards
Sraplesroronerabncrayer I s
(0
3S)pad
no
69357r2
12.7
(0.50)pan
no 6934245
a3MSuperWeathersttip
Adhesive
3MSuperW6alherslfip
Adhesive
Contactadh€sive
(Loctite
Btackmar
3AO,
Loclile
Superglueoroqulvalent)
Betasealadhesile
kil,
panno.
{45)3007119
Fenll
parl
no.
(45)3016045
Hydraullcslorconvertiblotop

028-2
Technicaldata
Seglant
Toofab.lcands€als
Sealanl
ToP
lab c.nd seals
Recommended
tyre
pressures
(coldtyros)
Sirarler
255
pan
no (45)30 07
127
2.0 (29) 21 (30)
22 132) 2.3 133)
1.2 G100
2.0 (29) 2.1 (30)
2.4 (35) 25 (36) O
2.1 l.30) 2.2 132)
2.! (3s) 2.5 (36)
2.1 (30) 2.3 (33)
24 (35) 2.s (36)
24 (3s) 2s (36)
0.210 O,
1-2
1-2
L
a,

Speciallools108-1
Special
tools I
olo Fast
Modilm
B1-5324
Press!re
sensor
(included
285
662
Pre3sure
sensor
adaplor
oouble
sided
adhesivehp€
a2
92815
+t

Technical
descnptron800-1
Technical
description
Top
.s8embly............... a001 Adiustrnents .... ...... Bo0-4
Toptrameassembly..,,........ 300.1 Top
assembty... ..... .. ... BOO-4
ropcover ..... .......... 3002 Seals ......... .... .. 800.7
Head|ining ......,,........ 300.3 [email protected]....... ... 3oo3
Hyd6u1ics
........... ........ 300-3 Rearqlanenighls
.. ...... ... 3oo.g
sears........, ... ......... 800-4
Top
assembly
The
lopassemblyconsisls
ola topfane as.
sembry
a topcove.andaninnerhaadinino
Thetop 's operakdoy an etecr'catrycoi.
lrolledhydraulicsy.tem.
'rh€
ioplrame consislsollvo siderails,
each
ol which
compriseslhreeseclons a lfont a
middle
anda rearsec.tion.
The seclions
are held togeher by hinges.
whichallowrhe
side
ralls
lo lord aslhebp ts
Four crossmembers,somelimes
knownas
bows runbelveen
lhesiderailsandare
each
idenlilied
by a number,no.1 beingthecross.
member
d$e lront oilhelrame

800-2
T€chnicaldescription
!p. it is lockedlo lhewind
meansol a lalching
mocha.
side,atachedlo lhe no 1
Th€lop coveris in twopad6i lha topcovor
iGellanda rearccreen
panel
Thekontollhe lopcoverlsglued onto
lh€no.
1 crossmembe..and lhe trailinqedge is
siapledto a slrelcherlhalis rileredontothe
body.Thetop
isalso
glued
totherearseclrons
The .ear screan
is glued to lhe rearscreen
panel,
rhich is slapledlo the no. 4 cross
m€mberandro lhe strelcher
ilsl rofrard ol
lhe luggago.cohpanmenllid.Thelop s€cton
ot the raa.screan
panel,
betweenthe topol
lh€ r€a.screenandlhe no.4 cfos6memb€r
is iast€n€dby a zip to allowlhe rearscreen
to be lowered
lor increased venlilalioninside
t-.
When
lnzippedlh€rear
loweredand notallowed 0_
t-.
Th€r6arscreencanbe .eplacedwilhoullhe
needlo,emovelhelopcov€r.
Twovariantsorthelop coveraren use on
ca.swithchasssno H700319sorea.rie.tne
lab c is madebycambria,
whdeasoncars
wilhlal€r
chassis
nos fie toplabricls oade
Alter trinming or culting,lhe edges
ol lhe
Cambria
labrichust be lusedby use ot 6
heat
gun
loprevent lraying
Siaptesare available
in lwo l6nglhs,lhe
long6.on6sbeingusedwhenlwo or mor€
layersollabricneedlo beslapl€d.

Technicai
descnprron
800-3
Headllnlng
Theh6adlining
ls secur€d
totheund6rsides
or
the
rou.
crossmembers.
on fte no.
1 and
no.
4 crossnembers
it is h€td
an
ptace
by
both
double,sidedadh€sive
iape
andsc.ews
andon$6 no.
2 andno.3crossmembers
by
m6ans
ol plaslic rglain€r
slrips.Ih€bdckol
theheadlining
issecuredby
press
studs
.nd
Hydraulics
Th6lop
israised
andloweredbyh€an!ota.
.lectrically
controlredhydraulics
system.The
setoo
pump
and moio.
are tocai€d
on the
ightnand side, undernoath
th€ rear seat
Plastichosesrun tlom lhe pumpto the htro
setuocylinders,
whichar€ atachedto lha
operatng
mechanismlor
lhetop.
The hydrautic
systenis precha.ged
al $e
ractorywilhspecialhydGutic
fluid 9a.tno.
(45)
3014604.Please
norelharrhisis rh.
only ttuid
lhal may be !sed. Eartier par
ricurars
staringrharATF
udor
eng'neortmay
beus€d
arelhusnolonger,alrd
A bypassvalveistittedin
lheci.cuitbolw€en
rhe
PUmp
and
lhe
nghlhand
s
enabrelhelopIo beoperatodmanuaty
The
vaNeisaccessiblebehind
alap inlhelim ar
lhebackollhe ruoqaqe
companoenr
To prevent
the pumpftoh overheating,
an
overload
devce isolalesit aulomaticatty
it it
hasbeen
runninqtor more
than10- 20 se
conds
withlhe
top
lulry
upordown
.A

800-4
Technicaldescriplion
Seals
Thesealonthe
A pillar
is glued lo a retainer
scfew€d
onlolh€
p'llarAilhebonom.lhe
seai
'5 herd 'n prace by
rhreelasle
sided
adhesiv.
tape.At$6top,lhe slrrp
isse'
cured
by
onelastBner
andco acladhesive
Thelop hasa sealal lhel.od oneoneilh€r
sideand
lwoatlhs reat.
Thesealat $e tont is glued
andscrew€d
to
$e no 1 crossmombersand,
on eith6rslde
orued
b a retainerlhal
iescrewad
lo theside
;ailsotthetop
lrame.Sealdnl
isappliBd
atlhe
Theiniemediata
sealoneilher
sideis glued
ro a s€al retainer sc.ewed onlo lhe middle
The .ear seals 8re gl!6d, scr4€d and
secured
byli€slo lh€ side
rail
r€arseclions
These seals also setoe as quid6 lor Ine I
t
t,
L
Adiustments
Thiss€clion
exDbins
lheadiusltneds
malcan
bemade
lolh€
top,door
windows,
rea.
quaF
Th. tenE. lore a.d all, and lated and
ve,lical,
whenapplied
toadjustm€nE
rererio
adju mentrelaliv€
tolhecar'
ll should
benol€d
lhaladiustmenl
ol onecom_
ponont
6anafierlhe adiushenl ol oth€rcom
i P.rr P@itono. r.ising toP
TheoarkDosilion
onraisinglhe
top.
i€
lh6 oosilion
in qhich thetopsloF bolore
belno
larched,
is adiusled
bv meansor
bala;c'n9.link
cams locaradinside
lhe
bp, adjacenl
to lhe top ol $e quaner

Technrcal
descnptron800-5
on belngraised,
lh6 l€ading
edqeot he
lop sholld slopin lhe park poslion,
20-
30 mm (0.79
. 113 in) aboveIhe wind
screenrrame.
Therronr
ot rheropmust
alsobeparallelwilh
thelrame
Toadjusrrhe guidepin,
whichinhrbits
ta.
€rarmovemenr
olhe lop.toosen
the
nul
Lalchinqmechanlsm
hoo*s
Io adjusl rhe heiohr
ot rhe tar.hing
mechansm
hook.
slackenott lhe Tod
rotale
$e hook One
complele
lurnorlhe hookincreases
or
decrerses
rs heqhr
ldependng
onwhich
way
rtrsturned)
by1mm
(0.04
in)
Pressdow.
onthetront
cornerotlhelop
loensurethatno
play
is
presenl
in rhehinge
beMeenthe
Ironl
andmiddle
secuonsol rhes'deral
tobring
lhe
iionlse.lion
orthesiderait n
line (parallel)
withlhe door windor and

800-6
Technicaldesc
plion
5 ToP.ssemblylold€d po3ilion
To
adjust$6 end
position
orlhelop
when
loldeddown.slack€nofi
lhenurconlhe
rear$op on thelop framemechanism
whenlhetop
isdown.
A.p€cial
qause(as
shown)mlslbeused
Posilionlhe gaaqe as shownand lhen
adjusllhe stoplo rheco.iecl posirion.
L
t
fl,'
conectpasition
lot slapbftctol

T€chnical
description800-7
As
a
geno€l
rule,
atts6atshust
be
gtu€d
'n|o
pos'rion
u5in93Msuperweaher.hoAdh6.
sjv€,
wirh.ny adjustment
b€inq
nad; b€tore
NoLe
lhatrherop
orlheAtilar s€atmusl
be
gfued
nlo posi0on
usinoa contact
ddhesNe,
suchas Loctile
glackhax
3a0.In
tis case,
$e s€armuslbe cor€c y positionad
betora
[lo adhesiveisapplied.
Noolher
adtush€nl
ollheA'pillar
sealcan
b€made.
1 Topa3!.Ebty tronr.€61
rh€ lale/atpositionrng
ottl€ tra't'ngends
or |ne rronl
se.l can be adusl€dbt
roosanhg
lh6nuts
onth6botd
securina
lhe soal r€tainers. Foreand,aftadjusi-
m€nl
otlhe
s€almustbenade
betoroth€
lop as$mbly
stde
3€ats
Adjusrmenr
orrhetalerar
posilroning
orthe
s'deseaE
canbe
nad€
byslacleninq
on
lhe nuls
on lh€boltssecurinq
lhe seal
rerarners.Fore.and.aft
adjuslmed
ot rhe
s€armlsl bo made
betore
lheadhesivo
lop assembly
rearse.l
verlicaladjuslment
otlhe rearseat
can
b6made
afterlh€
nutsand o have
been
r@sened
and
theadhesiv€
bondbroken.
W
A*
Stl

800-8
Technicaldescrjption
wh€n adrustinqlh€ doorshd@ checktle
adru3tmenl
otlhe
itonr
3eclion
oltheFid.tail
1 Io adjusllh€ heiqhtol lh€ lrontol lhe
window
glass,loosenlhe screw n $e
2 To ad)usrrheheiqhlol ihe
rearendol the
glass,
loosBnlhes6rew
inlh. rear
qhss
3 Theheighlol lhelrailing6ndotthedoor
canalso
beadjusledbyundoing
Ihe
rear
nlt onthe
window
qlass
linmechamsm.

Technical
descriplion800-9
For$and-afi adjGrment
4 To adiusl 1116loreand,atl posilion ol the
window glass, loosen rh. glass stop
5 Toadjuslhe lat€ral
posilion
olthewindow
grass,
roosen
lhebonomol$e rear
guide
channel.As irom chassis .o, K7021110,
rh6lronl
guide
channelcanbeadjusl€din
=Jlfa
Qu.rterlighrs
1 Loosenthescfews
in thekontandrear

800-10
Technical
description
Fo.€-6nd-afiadiustm€nl
2 Undolhenutsonlhe
glass.lift
mechanism.
3 Undolhe secutng
nutslor l-\e
glass.li,l
h€chanismand ium lhe sludsin lhe
appropriatedteclion.
4 Undolhe nulsecurinqthe
glass
lo lhe
glasslin
mechanismandlumtheslud
in
lheappropriare
direclon
\
-4

Body
810.1
Body
310.t
Additional
strengthenlng
Ason000-.e
essaloons
(sedans)
andhal6h
backs,
theConvedbb
bodyisa monocooue
To
compensale
lorlhe
abenceor
arioid raot.
add'tionar
srrengihen,ng
hasbe6n
proitded
in
lhe
lormolsleel membors
andatoad.bea.ino
bonded
wmdscreen
-rh€
strenglbening
componenb
areastolows
I Corn€. plate
onradiator
lopcrosshember
2 Anchoring.ocket
onwhe6t
ar6htora-piuar
3 Side{anelsrenglhene.
4 Enendeda pid 0owheelarch)
5 Top
crossmehbd
ontindscr66ntrane
7 Secondary
B pilar (ti ng poinl
ror top
3 Anchorage
lor seatb€ll
guide
10 Upp6rside
member
11 Torsion
box
on
reanaxte
tunnel
12 Sill.r€inlorcingmembor
13 Torsion
boxunderreaf
seat

810-2
Body
Bodydimensions
Thediroclio.s
in
whichthemeasurements
are
madeare
given
in,iheDirectio
Table, with rel€rence lo lhe coordinale
x{oordinale = Daum line lor IongnudinaL
Ycoordinate
= Oatum lne lor fiansverse
measu16meils
(len
lorlqht)
Z.coordinate
= Dalum line lor v€nrcal
The ligure lollowinqlhe coordinale
in lhe
corumndenoleslhe
lolerance,asrollows:
1 = Oesisndinension
incoordinale
sysFm
2 = Ackal measuremenl qeneany a
diaqonal
measuremenl
3 = Tolerance
lorbesl
rit
(hc)= Dimensionto be measured
rrom
hole
Eachcoo.dinale
oiginabs rroma daum
(o) line oatun linexO cannot
be used
In
practice
and
islhererore
nolshown
Datum
InoYO.
Thisisihecanirerine
olthe
body,
dividlng
the shel intoleil and righl
haves T.ansverse
dmensions
are spoc!
led belween
lvo measuring
points To
measuro
lhe dimension
on one sideonlv
markoulthe
Yo linebetveen
lheholesas
shorn on lhe drawinq
andthenhalve$e
dimension
andlolerance
Oatum
line
zO The
linerunsalong
the
rod
n thebody
between
lheroor pan
anosde
oanel.
Measlremenls
lobe made
below$e
zO inoa.e indicaledbv a negafve
value
(i.e.
$e value
lsprelixed
bya I sign).
ttem Flg-no, Ohenslon,
1506.014
(59
2910.16)
1064.012
(41.3310
0A)
1073.012
(42.44*
0.03)
1223.5!2
(43.16100A)
2137
512(3415t0.03)
1301.513
(56.2410.r2)
aumperbrackel
(hc)&lronlhole lor
Oislance
belwee^
lrontXl and
rear Xl
Wishbone
red hole
(hc)&lfonlhole
lor X1
Fronl
holelorsplnglink
(hc)&
tailedge Xr
zo &edge
ollrontcrossdenber 21
zOI bononedge
olbumper
bracket
Holes
lorbumpot
brackel
(hc)
Width:between
nnerwheelarch
pane Y1
Outor
bolthole
inkontcrossmenber Diag 2
{hc)
&rearhole
instenglhener
under
Ouler
holes
inkontcrossmember
(hc) Y1
HoLes
iorrackandpinion
gear(hc)
B6aroule.
holeslor
wishbone
(hc)& olag 2
lronlhoLo
lorspingInkthc)
Fronihore
rorspring
Ink(hc) &Yo Dneci2
Fronrhore
lorsorinq
ink
(hc)
&
iront Direct2
hoL6lorPaiha.d{od
brackel
3
13
15
2
2
3,3

Body
810-3
ItemFlg.
no. Dlmensron,
mm
(in)
22
2A
29
33
36
3.10
3,10
2
2,7
3,9
a9,rr
3,11
zl
oiag.2
22
21
21
21
zl
23
0aq.3
Diag.
2
1060.0!
3
{41.73!012)
1240.O
!3147.24
!0.121
1321.5i4
(s2
02.0 16)
1321
0r4152.0010.16i
-2
(-0.3)
Fronlholelor
sonno
r'nk
thcl&c6nlr€.
hne
hrouahPaihaft.rod
br;ckel
zo (hc)
&
Panhard
rodbrackol
Rear
holelorPanhard{odbrackel
(hc)
&edgeolrecessinlloor
pan(ret.
Fronlholelor
Panhardrodbrackel
lhcl
&konlhorelor
RHsprinqunk(hc)
Holesror
springrink
(hc)
Fecessinreariloo.
pan
YO
(hc)a
lne
lhroughhoreincoUision
Aperlure
lorrearliqhtcluster
ZO&lopolcrossmember
atYO
ZO&top
ollie
plale
alYO
ZO
&cornerarl,arledq€
or
ru9gage.
zo& waisrlinear
lail4dgecorner
Distance
beNeenhinge
mounlidgs
w dthotlailodge
olruggage.
Hnqepin
hole
(h.)&
cenlre
hote
lhctat
Centrehol€inrear
rroor
pan(hc)&
boflomedaeol
channelinrearscroon
Centrehore
(hc)in
rroor
pan
(yO)&
co.neron
lailedgeolluooaqe.
Corneronbiledqe
oraperluro
(hcl
&
Fronlhole'n'nner
*he€larchpanel
lhc)
a bcalinShoe inbul[head
channel
Fronl
holerorrack-and
o'nronoearlhcl
3 bofom
orbulrhead.h;nneram'dwav
belween
holeslorwip6r
spindtes)
Dislance
botweenrront
2 hoteininner
wheel'
arch
panel&
outerhol6lor
Fronlhole
in nnorwheerarch
oanel
(hc)&
moununs
rus
on
winq
(hbl
Mounlinslus
on
w'ng(hc)
3 locahns
hore
Inburhead
channet(hc)

810-4
Body
ItemFlg.no. olmenslon,mm
(ln) Measurlng polnls
40 3,9 556.011
(21
33!0.04) Locatngholeininnerwheel'archllange onect2
(hc)
&localinghole
in
bulkheadchannel
{hc)
41 1l 1340.013
(52.7510.r2) Dstanceb€leeenlugsonwinqs
(hc) Y1
42 5 131.511(5.1a10.04) D6lancebeNveenhoesYl iorlfont Y]
ens
nemountns
(hc)(lales(
varianls)
40015(1s71002) FH
bor
hore
(hc)&
YoIne Yl
1990!1(7.33!004) ZO&slencer
(muriler)hole(hc) z1
45 5 172011(677i0.04) Borrhore
(hc)ror
bunperbracker
(xo) x1
&nUIonenginemounllng
(hc)
46 5 517.011
(20.3s
1004) Widlhbetweenrearenoinemounling Y1
holes
(hc)
al 3 73011
(2
371004) rmernardimension oi
i.ont
engine Yl
.0
(.0)(ea.ry
varants) mountinq
A43 5 739012(29.091003) Lefire&engn mounling
(hc)&
BHhole oaq l
inrront
engine
mounlLng
843 5 751.012(2s5610.03) RHrearenqinemountinc
(hc)&
lelthoe Diag1
rnrronl€nsnemounhq(hc)
49 1 55.5i1
(213i0.04) aotholeinbumper
lhc)&
holeniront X1
c,ossmomb€r
oc)
so 3 197.012
(7
7s
1003) Fronlho
e in 6ck.and.pinion
gear(hc) x2
Averlicalpan olbukhead
(nollo
sr.en9men
n9
crease,
51 s 660013 (25.931012) YOonwindscreeoknge&lopor Dnecl2
exhausfpiperunner
(edqe
arbulkhead)
52 S 2175r 2 (3 5610.0a) YOarv ndscreenllange&lopedgeol Dnecl2
ste€rinq.columnmehber
53 911 63612(25 03! 003) Oistancebelween
wndscreen
edges
at o recl2
nange
54 4 1r80014(46451016) Dislance belween
insid€solsills Y1
55 34 1336.0!4
(52.591016) Disla^ce
beMeen
oulsdeedg6solsils Yl
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