Saab 900 Convertible User manual

Saab 900

SERVICE

MANUAL

SAAB

8:5

Convertible

Irt t985

-

t990

-

Saab

900

SERVICE

MANUAL

8:5

Convertlble

M i986

-

r99r

-

om&3Fl.m!andconpoMbarcd.ah

blidinged@l*roh'iglibhdo

6.n$sjoh€pddo'gp€.ilc|ong

108 Special tools

800

Technical

descl

plion

028 Technrcal

data

810 Body

shel

812

Top

assembly

851 Inteior rrim

830

Spoiler assembly

843 Window

glass

844

Weatherstrips

and seats

t;,

|

,-,

852 Rear seat

899 Alphabetical seclion

guide

UnKt3

lshoul lh. s.'vl6

Mmur m h

[email protected] ri6 tho Sl sydo.n.

Fdl)slra.1oni|br}i''m.€|unib'

qrvs

rn bEdd and m. @p*[E sr unn.

Th€ l.ro$iq synboE ed dbt€vralffi e u!d:

St untt

Equlvaleni unli 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.s blrlf

lF€l=o07b.ll|=1'05l|qql

1 US rrq

d

=

0.43

uKqr

1 USg.l

=

0S3 Uxsdr

qc-cF.32)r5/l

o

Martel code6

no 6d6

Bid b mnd .p.df€fon8

Technical dala 028-1

Technical

data

worlung pressure

ol

pump

Chas.is

no. H7003109

hin 2s

(36s)

Iighr€nin9

Iorque

hosefi nings

5.142

{3.3,4.5)

Recommended

creaning

agents

Soap and walef For

stubboh slains or din

use

Sikkens Feducer M600

as

per

the ma

Chass's no N7003200

oneards

Sraples ror one rabnc rayer

I s

(0

3S)pad

no

69 35 7r2

12.7

(0.50)pan

no

69 34 245

a

3M Super Weathersttip

Adhesive

3M Super W6alherslfip

Adhesive

Contact adh€sive

(Loctite

Btackmar

3AO,

Loclile

Superglue or oqulvalent)

Betasealadhesile

kil,

pan

no.

{45)3007119

Fenll

parl

no.

(45)3016045

Hydraullcs lor

convertiblo top

028-2

Technical data

Seglant

Too fab.lc and s€als

Sealanl

ToP

lab c.nd

seals

Recommended

tyre

pressures

(cold tyros)

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

L

a,

Special lools 108-1

Special

tools

I

olo Fast

Modilm

B1-5324

Press!re

sensor

(included

285

662

Pre3sure

sensor

adaplor

oouble

sided

adhesive hp€

a2

92 815

+t

Technical

descnptron 800-1

Technical

description

Top

.s8embly . . . . . . . . . . . . . . .

a001 Adiustrnents

.... ......

Bo0-4

Top trame assembly ..,,........

300.1 Top

assembty ... ..... ..

. .. BOO-4

rop cover

..... ..........

3002 Seals . ........

.... .. 800.7

Head|ining ......,,........

300.3

[email protected] .......

... 3oo3

Hyd6u1ics

........... ........

300-3 Rearqlanenighls

.. ...... ... 3oo.g

sears ........,

... .........

800-4

Top

assembly

The

lop assembly consisls

ol a top fane as.

sembry

a top cove. and an inner haadinino

The top 's

operakd oy an

etecr'catry coi.

lrolled hydraulic sy.tem.

'rh€

iop

lrame

consisls ol lvo side rails,

each

ol which

comprises lhree seclons

a

lfont

a

middle

and a rear sec. tion.

The seclions

are held togeher by hinges.

which allow rhe

side

ralls

lo

lord

as lhe bp ts

Four

crossmembers, somelimes

known as

bows run belveen

lhe side rails and are

each

idenlilied

by a number, no. 1

being the cross.

member

d$e

lront

oi lhe lrame

800-2

T€chnical description

!p.

it is locked lo lhe wind

means ol a lalching

mocha.

side, atached

lo lhe no 1

Th€ lop cover is in two

pad6i

lha

top covor

iGell and a rearccreen

panel

The kont ollhe lop cover ls

glued

onto

lh€ no.

1 crossmembe.. and

lhe trailinq edge is

siapled to a slrelcher lhal

is rilered onto the

body.The top

is

also

glued

to the rear seclrons

The .ear screan

is

glued

to lhe rear screen

panel,

rhich

is slapled lo the no. 4 cross

m€mber and ro lhe strelcher

ilsl

rofrard

ol

lhe

luggago.cohpanmenl lid. The lop s€cton

ot the

raa.screan

panel,

between the top ol

lh€

r€a. screen and lhe no. 4 cfos6memb€r

is iast€n€d by a zip to allow lhe rear screen

to be lowered

lor

increased

venlilalion inside

t-.

When

lnzipped

lh€ rear

lowered and not allowed

0_

t-.

Th€ r6ar screen can be .eplaced wilhoul lhe

need lo ,emove lhe lop cov€r.

Two variants or the lop cover are

n use on

ca.s

with chasss no H700319s or ea.rie. tne

lab c is made by cambria,

whdeas on cars

wilh lal€r

chassis

nos fie top labric ls oade

Alter trinming or culting, lhe edges

ol lhe

Cambria

labric hust be lused by use ot 6

heat

gun

lo

prevent

lraying

Siaptes are available

in

lwo

l6nglhs, lhe

long6. on6s

being used when lwo or

mor€

layers ollabric need lo be slapl€d.

Technicai

descnprron

800-3

Headllnlng

The h6adlining

ls secur€d

to the und6rsides

or

the

rou.

crossmembers.

on fte no.

1 and

no.

4 crossnembers

it is h€td

an

ptace

by

both

double,sided adh€sive

iape

and sc.ews

and on $6 no.

2 and no. 3 crossmembers

by

m6ans

ol

plaslic

rglain€r

slrips. Ih€

bdck ol

the headlining

is secured by

press

studs

.nd

Hydraulics

Th6lop

is raised

and lowered by h€an!

ot a.

.lectrically

controlred hydraulics

system. The

setoo

pump

and moio.

are tocai€d

on the

ightnand

side, undernoath

th€ rear

seat

Plastic hoses

run tlom

lhe

pump

to the htro

setuo cylinders,

which ar€

atached to lha

operatng

mechanism lor

lhe top.

The

hydrautic

systen is

precha.ged

al

$e

ractory wilh

special hydGutic

fluid

9a.t

no.

(45)

3014604. Please

nore lhar rhis is rh.

only ttuid

lhal may

be !sed. Eartier

par

ricurars

staring rharATF

ud or

eng'ne ortmay

be us€d

are lhus no longer ,alrd

A

bypass valve is

titted in

lhe ci.cuit bolw€en

rhe

PUmp

and

lhe

nghlhand

s

enabre lhe lop

Io be operatod manuaty

The

vaNe is

accessible behind

a lap in lhelim

ar

lhe back ollhe ruoqaqe

companoenr

To

prevent

the

pump

ftoh overheating,

an

overload

devce isolales it

aulomaticatty

it it

has

been

runninq tor more

than 10

-

20

se

conds

with lhe

top

lulry

up or down

.A

800-4

Technical descriplion

Seals

The seal on the

A

pillar

is

glued

lo

a retainer

scfew€d

onlo lh€

p'llar Ai lhe bonom.lhe

seai

'5

herd

'n

prace

by

rhree lasle

sided

adhesiv.

tape. At$6top,lhe

slrrp

is se'

cured

by

one lastBner

and co

acladhesive

The lop

has a seal al lhel.od

one

on eilh€r

side and

lwo atlhs

reat.

The seal at $e

tont

is

glued

and

screw€d

to

$e

no

1 crossmombersand,

on eith6r slde

orued

b a

retainer lhal

ie screwad

lo the side

;ails ot the top

lrame. Sealdnl

is appliBd

atlhe

The

iniemediata

seal on eilher

side

is

glued

ro a s€al

retainer

sc.ewed

onlo lhe

middle

The .ear

seals 8re

gl!6d,

scr4€d

and

secured

by li€s

lo lh€ side

rail

r€ar seclions

These seals also

setoe as

quid6

lor Ine

I

t

t,

L

Adiustments

This s€clion

exDbins

lhe adiusltneds

mal can

be made

lo lh€

top, door

windows,

rea.

quaF

Th. tenE.

lore a.d

all, and

lated

and

ve,lical,

when applied

to adjustm€nE

rerer io

adju

ment relaliv€

to lhe car'

ll should

be nol€d

lhal adiustmenl

ol

one com_

ponont

6an afier

lhe adiushenl

ol oth€r com

i P.rr

P@iton

o. r.ising

toP

The oark Dosilion

on

raising lhe

top.

i€

lh6 oosilion

in

qhich

the top

sloF bolore

belno

larched,

is adiusled

bv

means or

bala;c'n9.link

cams

locarad inside

lhe

bp, adjacenl

to lhe

top ol $e

quaner

Technrcal

descnptron 800-5

on belng raised,

lh6 l€ading

edqe ot

he

lop sholld slop in

lhe

park

poslion,

20

-

30 mm

(0.79

.

1 13 in)

above Ihe wind

screen rrame.

The rronr

ot rhe rop must

also be

parallelwilh

the lrame

To

adjusr rhe

guide pin,

which inhrbits

ta.

€rar movemenr

olhe

lop. toosen

the

nul

Lalchinq mechanlsm

hoo*s

Io adjusl

rhe heiohr

ot rhe tar.hing

mechansm

hook.

slacken ott lhe Tod

rotale

$e hook

One

complele

lurn or lhe hook increases

or

decrerses

rs heqhr

ldependng

on which

way

rt rs turned)

by 1 mm

(0.04

in)

Press dow.

on the tront

corner ot lhe lop

lo ensure that no

play

is

presenl

in

rhe hinge

beMeen the

Ironl

and middle

secuons ol rhe s'de ral

to bring

lhe

iionl

se.lion

or the side rait n

line

(parallel)

with

lhe door windor

and

800-6

Technical desc

plion

5

ToP .ssembly lold€d

po3ilion

To

adjust $6

end

position

or lhe lop

when

lolded down. slack€n ofi

lhe nurc on lhe

rear $op on the lop frame mechanism

when lhe top

is down.

A.p€cial

qause (as

shown) mlsl be used

Posilion lhe

gaaqe

as shown and lhen

adjusl lhe

stop lo rhe co.iecl

posirion.

L

t

fl,'

conect

pasition

lot slap bftctol

T€chnical

description 800-7

As

a

geno€l

rule,

atts6ats hust

be

gtu€d

'n|o

pos'rion

u5in9 3M super weaher.ho

Adh6.

sjv€,

wirh .ny adjustment

b€inq

nad; b€tore

NoLe

lhat rhe rop

or lhe Atilar

s€at musl

be

gfued

nlo

posi0on

usino a contact

ddhesNe,

such as Loctile

glackhax

3a0. In

tis case,

$e

s€ar musl be cor€c

y positionad

betora

[lo

adhesive is applied.

No olher

adtush€nl

ol lhe A'pillar

sealcan

b€ made.

1

Top a3!.Ebty

tronr

.€61

rh€

lale/at positionrng

ot tl€

tra't'ng ends

or |ne rronl

se.l

can be adusl€d bt

roosanhg

lh6 nuts

on th6 botd

securina

lhe soal r€tainers.

Foreand,aft

adjusi-

m€nl

otlhe

s€al mustbe nade

betoro th€

lop as$mbly

stde

3€ats

Adjusrmenr

or rhe talerar

posilroning

or the

s'de seaE

can be

nad€

by slacleninq

on

lhe nuls

on lh€

bolts securinq

lhe seal

rerarners. Fore.and.aft

adjuslmed

ot rhe

s€ar mlsl bo made

betore

lhe adhesivo

lop

assembly

rear se.l

verlical adjuslment

ot

lhe rear seat

can

b6 made

after lh€

nuts and o have

been

r@sened

and

the adhesiv€

bond broken.

W

A*

Stl

800-8

Technical descrjption

wh€n adrustinq lh€

door shd@

check tle

adru3tmenl

ot lhe

itonr

3eclion

ol the Fid.

tail

1 Io adjusl lh€

heiqht ol lh€

lront ol lhe

window

glass,

loosen lhe screw

n $e

2

To ad)usr rhe heiqhl ol ihe

rear end ol the

glass,

loosBn lhe s6rew

in

lh.

rear

qhss

3 The heighl ol

lhe lrailing 6nd ot

the door

can also

be adjusled by undoing

Ihe

rear

nlt on the

window

qlass

lin mechamsm.

Technical

descriplion 800-9

For$and-afi

adjGrment

4 To adiusl

1116 loreand,atl

posilion

ol the

window

glass,

loosen rh.

glass

stop

5 To adjuslhe lat€ral

posilion

ol the window

grass,

roosen

lhe bonom ol $e rear

guide

channel. As irom

chassis

.o,

K7021110,

rh6lronl

guide

channel can be adjusl€d in

=Jlfa

Qu.rterlighrs

1

Loosen the

scfews

in

the kont and rear

800-10

Technical

description

Fo.€-6nd-afi adiustm€nl

2 Undolhe nuts on lhe

glass.lift

mechanism.

3 Undo lhe secutng

nuts lor

l-\e

glass.li,l

h€chanism and ium lhe sluds in lhe

appropriate dteclion.

4 Undo lhe nul securinq the

glass

lo lhe

glasslin

mechanism and lum the slud

in

lhe appropriare

direclon

\

-4

Body

810.1

Body

310.t

Additional

strengthenlng

As

on 000-.e

es saloons

(sedans)

and hal6h

backs,

the Convedbb

body is a monocooue

To

compensale

lor lhe

abence or

a

rioid

raot.

add'tionar

srrengihen,ng

has be6n

proitded

in

lhe

lorm ol

sleel

membors

and a toad.bea.ino

bonded

wmdscreen

-rh€

strenglbening

componenb

are astolows

I

Corn€.

plate

on radiator

lop crosshember

2

Anchoring.ocket

onwhe6t

ar6h tora-piuar

3

Side{anelsrenglhene.

4

Enended a

pi

d

0owheelarch)

5 Top

crossmehbd

on tindscr66n trane

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

box under reaf

seat

810-2

Body

Body dimensions

The diroclio.s

in

which the measurements

are

made are

given

in,ihe

Directio

Table, with

rel€rence lo

lhe coordinale

x{oordinale

=

Daum

line lor IongnudinaL

Y

coordinate

=

Oatum

lne lor fiansverse

measu16meils

(len

lo

rlqht)

Z.coordinate

=

Dalum

line

lor v€nrcal

The ligure

lollowinq lhe coordinale

in lhe

corumn denoles lhe

lolerance, as

rollows:

1

=

Oesisn dinension

in coordinale

sysFm

2

=

Ackal

measuremenl

qeneany

a

diaqonal

measuremenl

3

=

Tolerance

lor besl

rit

(hc)= Dimension to

be measured

rrom

hole

Each

coo.dinale

oiginabs

rrom a daum

(o) line oatun

line xO cannot

be used

In

practice

and

is lhererore

nol shown

Datum

Ino YO.

This is ihe canirerine

ol

the

body,

dividlng

the shel

into

leil and

righl

haves T.ansverse

dmensions

are spoc!

led belween

lvo

measuring

points

To

measuro

lhe dimension

on

one side

onlv

mark oul the

Yo

line betveen

lhe

holes as

shorn

on lhe drawinq

and

then

halve $e

dimension

and lolerance

Oatum

line

zO The

line runs along

the

rod

n the body

between

lhe

roor

pan

ano

sde

oanel.

Measlremenls

lo

be made

below$e

zO

ino a.e

indicaled bv

a negafve

value

(i.e.

$e value

ls

prelixed

by a

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

(43.1610 0A)

2137

512

(3415t0.03)

1301.513

(56.2410.r2)

aumper brackel

(hc)&

lronlhole

lor

Oislance

belwee^

lrontXl

and

rear

Xl

Wishbone

red

hole

(hc)& lfonlhole

lor X1

Fronl

hole lor splng

link

(hc)&

tailedge

Xr

zo

& edge

ol lront crossdenber

21

zO I

bonon edge

ol bumper

bracket

Holes

lor bumpot

brackel

(hc)

Width:between

nner wheelarch

pane

Y1

Outor

bolthole

in kont crossmenber

Diag 2

{hc)

&

rear hole

in stenglhener

under

Ouler

holes

in kont crossmember

(hc) Y1

HoLes

ior rackand

pinion

gear (hc)

B6aroule.

holes lor

wishbone

(hc)& olag 2

lronl hoLo

lor sping

Ink

thc)

Fronihore

ror spring

Ink

(hc)

&

Yo

Dneci 2

Fronr hore

lor sorinq

ink

(hc)

&

iront

Direct 2

hoL6 lor Paiha.d{od

brackel

3

13

15

2

3,3

Body

810-3

Item Flg.

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

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)

Fronl hole lor

sonno

r'nk

thcl & c6nlr€.

hne

hrouah Paihaft. rod

br;ckel

zo

(hc)

&

Panhard

rod brackol

Rear

hole lor Panhard{od brackel

(hc)

& edge ol recess in lloor

pan (ret.

Fronl hole lor

Panhardrod brackel

lhcl

& konl hore lor

RH sprinq unk(hc)

Holes ror

spring rink

(hc)

Fecess in rear iloo.

pan

YO

(hc)a

lne

lhrough hore in coUision

Aperlure

lor rearliqht cluster

ZO & lop olcrossmember

at YO

ZO & top

ol lie

plale

al YO

ZO

& corner ar l,arledq€

or

ru9gage.

zo&

waisrline ar

lail4dge corner

Distance

beNeen hinge

mounlidgs

w

dth ot lailodge

ol

ruggage.

Hnqepin

hole

(h.)&

cenlre

hote

lhctat

Centre hol€ in rear

rroor

pan (hc)&

boflom edae ol

channelin rearscroon

Centre hore

(hc)in

rroor

pan

(yO)&

co.ner on

lailedge ol luooaqe.

Corneron biledqe

oraperluro

(hcl

&

Fronlhole 'n 'nner

*he€larch

panel

lhc)

a bcalinS hoe in bul[head

channel

Fronl

hole ror rack-and

o'nron oear lhcl

3 bofom

or bulrhead .h;nner

am'dwav

belween

holes lor wip6r

spindtes)

Dislance

botween rront

2 hote in inner

wheel'

arch

panel&

outer hol6lor

Fronl hole

in nnor wheerarch

oanel

(hc)&

moununs

rus

on

winq

(hbl

Mounlins lus

on

w'ng (hc)

3 locahns

hore

In bu rhead

channet(hc)

810-4

Body

Item Flg. no. olmenslon, mm

(ln)

Measurlng

polnls

40 3,9 556.011

(21

33!0.04) Locatng hole in inner wheel'arch llange onect 2

(hc)

& localing hole

in

bulkhead channel

{hc)

41 1l 1340.013

(52.7510.r2)

D stance b€leeen lugs on winqs

(hc)

Y1

42

5 131.511(5.1a10.04) D6lance beNveenhoesYl

iorlfont Y]

ens

ne mountns

(hc)(lales(

varianls)

40015(1s71002) FH

bor

hore

(hc)&

Yo Ine Yl

1990!1(7.33!004)

ZO & slencer

(muriler)hole (hc)

z1

45 5 172011(677i0.04) Borrhore

(hc)ror

bunper bracker

(xo)

x1

& nUI on engine mounllng

(hc)

46 5 517.011

(20.3s

10

04) Widlh between rear enoine mounling Y1

holes

(hc)

al

3

73011

(2

3710 04)

rmernardimension

oi

i.ont

engine

Yl

.0

(.0)

(ea.ry

varants) mountinq

A43

5

739012(29.091003)

Lefire& engn

mounling

(hc)&

BH hole oaq l

in rront

engine

mounlLng

843 5 751.012(2s5610.03) RH rear enqine mountinc

(hc)&

lelt hoe Diag 1

rn rronl €ns ne mounhq

(hc)

49 1 55.5i 1

(213i0.04)

ao t hole in bumper

lhc)&

hole n iront X1

c,ossmomb€r

oc)

so 3

197.012

(7

7s

10

03)

Fronl ho

e

in

6ck.and.pinion

gear (hc)

x2

A

verlicalpan

ol

bu khead

(nollo

sr.en9men

n9

crease,

51 s 660 013

(25.931012)

YO on windscreeo knge & lop or

Dnecl2

exhausfpipe runner

(edqe

ar bulkhead)

52 S 217 5r 2

(3

5610.0a) YO ar v ndscreen llange & lop edge ol Dnecl2

ste€rinq.column mehber

53 911 63612

(25

03! 0 03) Oistance belween

w ndscreen

edges

at o recl2

nange

54

4 1r80014(46451016) Dislance

belween

insid€s ol sills Y1

55 34

1336.0!4

(52.591016)

Disla^ce

beMeen

oulsde edg6s ol sils Yl

56

4 150

012

(5

9010 03) ZO & top ol sil

21

57 1 1766.512

(69.5410

03) Sumper ho e

{hc)&

rocaling hore in

wrndscreen rame

(ncj

53

1

800 0

I

1

(3

1

50

I

0 04)

Dbtance

belween ocaling

holes in Y1

59 2 1073512(42.44r0.03) zO & Localing hole in windscreen

rrame

21

{ncl

60

1 14s9.012{59021012) Localing hole n windscreen rrame

(hc)

oned2

& bertanchorage

poinr (hc)

on

secondary B

Pillar

61 127.10 14010r2(709110.04) Locatinq hoe in windscreen lrame

(hc)

Oirect2

& lront hol6 in

spinq

Ink

62

1,6 1259.0!2

(49.5610.03)

W

dlh between ocating holes n

Yr

secondary B

pilars (hc)

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Saab 900 Convertible User manual

Saab 900 Convertible User manual

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