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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$sjoh€pddo'gp€.ilc|ong
108 Special tools
800
Technical
descl
plion
028 Technrcal
data
810 Body
shel
812
Top
assembly
851 Inteior rrim
830
Spoiler assembly
843 Window
glass
844
Weatherstrips
and seats
t;,
|
,-,
852 Rear seat
899 Alphabetical seclion
guide
UnKt3
lshoul lh. s.'vl6
Mmur m h
Fdl)slra.1oni|br}i''m.€|unib'
qrvs
rn bEdd and m. @p*[E sr unn.
Th€ l.ro$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
o
o
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
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
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
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)
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)
/
