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Saab 900 Convertible 86-94

1. 45 5 172 01 6 77 0 04 Bolt hole hc for bumper bracket XO X1 amp nut on engine mounting hc 46 5 517 041 20 3540 04 Width between rear engine mounting Y1 holes hc a s5 73 03 1 2 87 0 04 Internal dimension of front engine v1 0 0 early variants mounting AaB 5 739 042 29 09 0 08 Left rear engin mounting hc amp RH hole Diag 1 in front engine mounting B48 5 751 042 29 56 0 08 RH rear engine mounting hc amp left hole Diag 1 in front engine mounting hc 49 1 55 541 2 181 0 04 Bolt hole in bumper hc amp hole in front X1 crossmember hc 50 8 197 042 7 75 0 08 Front hole in rack and pinion gear hc X2 amp vertical part of bulkhead not to strengthening crease 51 9 660 0 3 25 980 12 YO on windscreen flange amp top of Direct 2 exhaust pipe tunnel edge at bulkhead 52 9 217 52 8 56 0 08 YO at windscreen flange amp top edge of Direct 2 steering column member 53 9n 636 2 25 03 0 08 Distance between windscreen edges at Direct 2 flange 54 4 1180 014 46 4540 16 Distance between insides of sills v 55 34 1336 0 4 52 59 0 16 Distance between outside edges of sills Y1 56 4 150 042 5 90 0 08 ZO amp top of sill z 57 31 1766 5 2 69 54 0 08 Bumper hole hc amp locating hole in xi windscreen frame hc 58 1 800 0 1 31 50 0 04 Distance between locating holes in vi windscreen frame 59 2 1078 5 2 42 44 0 08 ae locating hole in windscreen frame Z1 c 60 1 14
2. Saab 900 Top assembly 812 55 To fit 1 Remove all traces of old adhesive from the corner of the windscreen frame 2 Remove all traces of old adhesive from the striker plate sane 3 Pul back the striker plate and secure by means of the retaining screws 4 Fit the sun visor Saab 800 812 56 Top assembly 5 Apply contact adhesive to the A pillar seal and push in the fastener 6 Apply Sikaflex 255 3007127 around the striker plate to seal it 7 Use a spatula to remove surplus sealant Spoiler assembly 830 1 Spoiler assembly Side assembly 22s 8304 Rear assembly Side assembly Chassis no L7011109 amp earlier To remove 1 Remove the rear seat cushion see page 852 1 2 Remove the rear seat backrest see page 852 1 3 Remove the side trim see page 851 1 Note Save the washers from the spoiler mountings as these will be needed in the fitting of a new spoiler where applicable 4 Remove the nut from the front securing stud 5 Open the top hallway and remove the nut from the middle stud 830 2 Spoiler assembly 6 Remove the wing nut from the rear fasten ing access through the flap in the trim in side the luggage compartment 7 Use a heat gun to release the tape Take care not to apply too much heat as this can damage the paintwork or spoiler assembly Caution The spoiler assembly must be eased off gen
3. screw the feature strip retainer into place on the no 4 crossmember 28 Apply a bead of adhesive along the retainer Saab 500 Top assembly 812 35 29 Press the fealure strip ino position and Screw on the end caps 30 Trim the edges to remove surplus fabric 31 Remove the spacers from the windscreen frame and raise the top assembly Check that the top comes to rest 20 30 mm from the windscreen frame If adjustment is necessary see page 800 4 Check the adjustment of the latching hooks by latching the lop in position and then pressing down on the front corners of the top No play should be present If adjustment is necessary see page 800 5 812 36 Top assembly 32 Secure the side panels of the headlining by means of the Velcro fasteners 33 Fit the spoiler assembly see section 830 Hydraulic system To remove 1 Remove the rear seat cushion see page 85231 2 Remove the rear seat backrest see page 852 1 3 Remove the side trim see page 851 1 4 Release the handbrake to pul slack in the cable over the servo pump 5 Open the bypass valve accessible behind the flap on the RH side at the back of the luggage compartment 6 Release the clips securing the hydraulic hoses to the rear side panel on either side Top assembly 812 37 7 Remove the pin etaining clip split pin from the piston rod on either side Note the positions
4. Technical description Removal TE Fitting Hydraulic system Technical data Technical description Removal Fitting eas Measuring pressur Bleeding Latching handle assembly Technical description Removal c Fitting Adjustment Pressure sensor Special tools Measuring pressure Quarterlight Removal Fitting Adjustment Rear screen Technical description Removal Fitting Rear seal Technical description Removal Fitting Adjustment Rear seat Removal fitting Sealant Technical data Seals Technical description Removal fitting Adjustment 028 1 800 3 800 3 812 42 812 43 028 1 800 3 812 36 812 39 812 46 812 44 800 2 812 49 812 51 800 5 108 1 812 46 843 20 843 23 800 9 800 2 812 25 812 28 8004 844 4 8445 800 7 852 1 028 2 800 4 844 1 800 7 Saab 900 899 2 Alphabetical section guide Servo cylinders Technical description Removaliting Technical description Removal fiting Side seal Technical descripiion Removal Fitting Adjustment Side trim Removal Fitting Spacers Special tools Spoiler assembly Removaliiting Spoiler side assembly chassis no 17011108 amp parien Removal Fitting Spoiler side assembly chassis no L7011110 HORWATES Removal Fitting Staple gun Staples Special tool Technical data Technical description Stretcher Striker plate aiem Removal Fitting Technical data Techn
5. centrally by lining up the marks made before the strip was removed W a new headlining is being installed ensure that the retainer strip is equidistant from either end of the no 2 crossmember Press the headlining onto the double sided adhesive tape on the no 4 cross member and screw the metal strip into position Note that the strap for the rear screen is retained by means of the middle screw Top assembly 812 25 5 Hang the rear screen from the strap and zip up the fastener 6 Secure the headlining side panels at the rear by means of the press studs and Velcro fasteners 7 Secure the Velcro fasteners along the side rails Rear screen To remove To ensure that the rear screen remains positioned equidistant from either side the complete screen assembly including the panel secured by a zip to the no 4 top frame crossmember must be replaced 1 Remove the spoiler assembly see page 830 1 2 Fit the spacers part no 8292492 or 8292799 as appropriate in the wind screen frame Saab 900 812 26 Top assembly 3 Engage the latching hooks but do nol close the latching handles 4 Remove the finisher from the tail edge of the top cover 5 Remove all the staples from the tail edge of the cover 6 Remove the feature strip end caps from the no 4 crossmember Top assembly 812 27 7 Remove the feature strip 8 Mark the ends of the aluminium retainer strip to s
6. hoses and hose fittings Operate the pistons a number of times and check that there are no leaks Saab 900 812 46 Top assembly 13 Return the pistons to the fully retracted position 14 Reinstall the hydraulic system in the car see page 812 39 Measuring the hydraulic pressure Note Hydraulic fluid must not be allowed to come into contact with upholstery or paintwork 1 The top must be up 2 Release the handbrake to put slack in the cable over the servo pump 3 Remove the rear seat cushion see page 852 1 4 Check the level of hydraulic fluid in the system and top up as necessary 5 Check to see whether there is an excessive amount of air in the system If so the system must be bled before the pressure can be measured see page 81244 Top assembly 812 47 6 Disconnect the hoses from the tee pieces to the rear of the pump Plug the open ends using the hose union contained in hose kit 82 92 815 Place absorbent paper underneath the pump to soak up any spilt fluid 7 Remove the tee piece and connect adap tor 87 91584 in its place B Connect pressure sensor 8996522 to the hose contained in hose kit 8292815 9 Connect the other end of the hose to the adaptor on the pump Saab 900 812 48 Top assembly 10 Connect the ABS system tester to the battery 11 Connect the pressure sensor to the ABS tester 12 Set the ABS tester to meas
7. of the washers and spacers and withdraw the clevice pin on either side Close the bypass valve Switch on the ignition and by means of the switch for the top fully retract the pistons Switch off the ignition 9 Undo the securing bolts for the servo cylinders 10 Lift the servo pump off its seating and un plug the con nectors from the relays 812 38 Top assembly 11 Label the connectors and disconnect the leads from the pump 12 Remove the moisture barrier on either side 13 Lift the servo cylinders and feed them out through the apertures in the side panels 14 Pass the cylinder on the RH side under neath the fuel lines and handbrake cable Lift out the hydraulic system complete Label the bracket for each cylinder right amp left and put them to one side Top assembly 812 39 To fit 1 Bleed the hydraulic system to expel all air see page 81244 This must be done before the system is installed in the car Ensure that the pistons are fully retracted H 3 Pass the RH servo cylinder and bypass valve under the handbrake cable and fuel lines 4 Plug in the pump connectors noling the markings lo ensure thal the right con nectors are plugged together 812 40 Top assembly 5 Plug the connectors onto the relays Pass the pump underneath the handbrake cable and press the rubber bushes on the pump into the mounting plate 6 Mount the bracket for the RH cylinder onto
8. over it Check for leaks 15 Do no more work on the car until the adhesive has hardened Caution The hardening time for the adhesive is 15 hours To prevent the bond being broken and the glass from moving the car must nol be moved during this time Do not slam the doors luggage compartment lid or bonnet hood knock the car or roll it lorwards or backwards The windscreen must not be touched belore the adhesive has hardened properly 16 Pull the dash panel forward and install the A pillar trim on either side Saab S00 Window glass 843 11 17 Press in the fasteners for the A pillar trim 18 Push the dash panel back into position checking to ensure that the spindle for the temperature control is still properly con nected 19 Fit the screw at the outboard end under neath the dash panel 20 Fit the two screws underneath the glove compartment Saab 900 843 12 Window glass 21 Fit the two screws at the back of the dash panel 22 Reconnect the speakers and fit the grilles 23 Press in the fastener and fit the two screws holding the steering column cow in place 24 Refil the padded trim plug in the connec lor and screw the rearview mirror back into position Window glass 843 13 25 Remove all traces of adhesive from the lop corners of the windscreen frame 26 Remove all traces of adhesive from the siriker plates 27 Screw the striker plates
9. screwed to the no 1 crossmembersand on either side glued to a retainer that is screwed to the side rails of the top frame Sealant is applied at the corners The intermediate seal on either side is glued to a seal retainer screwed onto the middle section of the side rail The rear seals are glued screwed and secured by ties to the side rail rear sections These seals also serve as guides for the quarterlights Adjustments This section explains the adjustments that can be made to the top door windows rear quar terlights and seals The terms fore and aff and lateral and vertical when applied to adjustments refer to adjustment relative to the car It should be noted that adjustment of one com ponent can aller the adjustment of other com ponents Top 1 Park position on raising top The park position on raising the top i e the position in which the top stops before being latched is adjusted by means of balancinglink cams located inside the lop adjacent to the top of the quarter lights 1 Front seal 2 Side seal 3 Rear seal 4 Mepillar seal Technical description 800 5 On being raised the leading edge of the top should stop in the park position 20 30 mm 0 79 1 18 in above the wind screen frame The front of the top must also be parallel with the frame Guide pin To adjust the guide pin which inhibits la leral movement of the top loosen the nut Latching me
10. the cylinder ensuring that the hose con neclions are towards the rear of the car 7 Pass the cylinder through the aperture in the side panel 8 Put the cylinder into position and tighten the securing bolts gaining access through the aperture in the panel Top assembly 812 41 9 Mount the bracket on the other cylinder again ensuring that the hose connections are towards the rear of the car 10 Pass the cylinder through the rear aper ture in the side panel Note that the hydraulic hoses should not go underneath the handbrake cable 11 Put the cylinder into position and tighten the securing bolts gaining access through the aperture in the panel 12 Put back the moisture barriers on either side 13 Pass the bypass valve through the aper ture in the rear side panel and secure it in its clips 14 Secure the hydraulic hoses in their clips 15 Release the latching handles for the top to facilitate adjustment of the servo cylin der piston rods 812 42 Top assembly 16 Operate the pump to bring the pistons into the fully extended position Reconnect the rods by inserting the Clevice pin and securing with the split pin Work on one piston at a time S s 17 Refit the side trim see page 851 2 18 Fit the backrest see page 852 2 18 Fit the seat cushion see page 852 1 20 Close the latching handles for the top E E Servo pump To remove 1 Remove the hydraulic system from the
11. 31 32 33 34 35 36 37 38 39 3 10 10 3 10 3 10 3 10 10 3 10 3 10 27 27 27 89 89 11 89 1 811 89 416 5 3 16 394 0 12 136 0 2 5 35 0 08 144 0 2 5 66 0 08 986 5 3 38 19 0 08 1060 0 3 41 734 0 12 33 021 1 29 0 04 1200 0 3 47 24 0 12 13 04 2 0 51 0 08 171032 6 73 0 08 1 0 04 277 0 4 10 90 0 16 319 044 12 55 0 16 489 0 4 19 25 0 16 505 0 4 19 88 0 16 1321 5 4 52 02 0 16 1321 0 4 52 00 0 16 2 0 8 1044 0 4 41 10 0 16 687 5 2 27 06 0 08 808 5 3 31 83 0 12 1535 0 5 60 43 0 20 1279 0 2 50 35 0 08 720 0 3 28 34 0 12 489 0 3 19 254 0 12 193 0 3 7 591 0 12 1132 5 4 2 44 58 0 08 Front hole for spring link hc amp centre X1 line through Panhard rod bracket ZO hc amp Panhard rod bracket Zz Rear hole for Panhard rod bracket hc X1 amp edge of recess in floor pan ref Front hole for Panhard rod bracket hc Diag 2 amp front hole for RH spring link hc Holes for spring link hc vi Recess in rear floor pan Direct 2 Width at rear floor pan y YO hc amp line through hole in collision Y1 member Aperture for rearlight cluster z2 ZO amp top of crossmember at YO z ZO amp top of tie plate at YO z ZO amp corner at tail edge of luggage Z1 compartment aperture ZO amp waist line at tail edge corner z D
12. 4 Apply a bead of adhesive along the pillar 5 Adjust the seal so that it fits snugly against the seal on the top assembly Apply con tact adhesive to the top of the seal and press in the fastener b 9 Interior trim 851 1 Interior trim Side trim E eaen nee 851 1 Appillar trim Side trim To remove 1 Remove the seat cushion see page 852 1 2 Remove the backrest see page 852 1 3 Remove the speaker trim and unplug the connector for the light 4 Remove the rubber cover piece glued onto trim 851 2 Interior trim 5 Remove the trim retaining screws 6 Unplug the speaker connectors and lift away the trim To fit 1 Lift the trim into position and reconnect he speaker leads 2 Ensure that the rubber door seal does not become trapped behind the trim and tighten the trim retaining screws 3 Plug on the connector for the light and Press the light fitting into the clips Refit the speaker trim Interior trim 851 3 4 Apply adhesive to the rubber cover piece and press it inlo position 5 Refit the backrest see page 852 1 6 Refit the seat cushion see page 852 2 A pillar trim K To remove 1 Remove the striker plate assembly see page 812 53 2 Remove the lower steering column cowl 9 3 Remove the speaker grilles a 851 4 Interior trim 4 Remove the two screws in the leading edge of the top of t
13. 648 Saab 800 812 32 Top assembly 17 Stretch the top cover on either side by pulling it down and towards the rear and Secure by means of a couple of staples 18 Remove the staples in the side panels strelch the fabric again and secure with a couple of staples 19 Remove the staples from the middle of the no 4 crossmember stretch the cover again and secure by means of a couple of staples 20 Stretch the cover by pulling it towards the rear of the car and staple it to the no 4 crossmember Stapling should be done along the centredine between the seams alternating between the right and left sides of the car Top assembly 812 33 21 Stretch the cover towards the rear on either side Staple the fabric at the out board ends of the no 4 crossmember outboard of the seams 22 Remove the staples from the side panels restretch the fabric and staple in position using a couple of staples 23 Pull down the top cover side flaps to Stretch them and staple the front part of the side flaps in position Do not staple in the holes in the stretcher ae 24 Pull down and stretch the inner fabric and staple it in position Saab 900 812 34 Top assembly 25 Pull down and stretch the side flaps stapling them in the order shown seit 26 Apply a bead of adhesive along the line of staples in the no 4 crossmember 27 With the left and right marks correctly orientated
14. 66 0 12 Bottom corner at rearof door aperture Diag 3 amp top corner of windscreen frame 75 2 1080 5 3 42 53 0 12 Bottom corner at rearof door aperture Diag 3 amp top rivet hole for A pillar trim 76 3 1553 5 3 61 16 0 12 Belt anchorage point on secondary B Direct2 pillar hc amp bolt hole for rear spoiler he m d 1382 0 2 54 40 0 08 Width between bolt holes hc for rear Y1 spoiler 78 7 664 0 1 26 14 0 04 Belt anchorage at rear seat hc T 7 37 3289 5 4 129 50 0 16 Belt anchorage at rear seat hc amp x bumper hole hc 80 17 116422 45 83 0 08 Diagonal between rearseatbelt Diag 2 anchorage point hc amp belt anchorage point at front seat hc Cars with three point belt fitted in rear seat chassis no J7005072 onwards Saab S00 810 6 Body 21118S oz x TZ M E ge ue 96 182 DAN S a Nez 6s TZ vL A oz oe s4 sr 6s HOA 8 19 3 L E ox T 72 i Body 810 7 859 8 S 810 8 Body 81118S Top assembly 812 1 Top assembly Topcover 8124 Headlining 81221 Rearscreen 81225 Hydraulic system 812 36 Servo pump 812 42 Hydraulic hoses 812 42 Servo cylinders Bypass valve Bleeding the system Measuring the pressure Lalching handle assembly Striker plate assem
15. 99 0 2 59 02 0 12 Locating hole in windscreen frame hc Direct 2 amp belt anchorage point hc on secondary B pillar 61 1 2 7 10 1801 02 70 91 0 08 Locating hole in windscreen frame hc Direct 2 amp front hole in spring link 62 16 1259 0 2 49 56 0 08 Width between locating holes in v secondary B pillars hc Saab 800 Ul MU Body 810 5 Item Fig no Dimension mm in Measuring points Direction 63 1 2922 0 2 115 04 0 08 Bumper holes he amp locating hole in X1 secondary B pillar hc 64 6 543 512 21 39 0 08 20 amp locating hole insecondary B pillar Z1 hc 65 1 2817 5 3 110 92 0 12 Bumper hole hc amp belt anchorage point hc in secondary B pillar 66 16 1259 01 49 56 0 04 Distance between belt anchorage points Y1 in secondary B pillars hc 67 26 792 042 31 18 0 08 ZO amp top face of secondary B pillar z 6 1 800 0 2 31 50 0 08 Distance between guide pin holes in vi windscreen frame hc 9 n 1860 2 2 53 55 0 08 Maximum diagonal distance between Direct 3 insides of windscreen frame 7 2 70 40 2 2 77 0 08 ZO amp top corner at front of side panel Z1 42 2513 03 98 93 0 12 Bumper hole hc amp front corner of side X1 panel 72 16 1469 0 3 57 83 0 12 Distance between top corners at front of Y1 side panels 7 2 1225 543 48 23 0 12 Bottom corner al front of door aperture Diag 3 amp top corner at front of side panel 74 2 1160 0 3 45
16. O line front x bumper bracket hc amp tail edge of body 2 3 668 5 3 26 31 0 12 Bumper bracket hc amp front hole for x wishbone hc 3 269 01 1 10 59 0 04 Distance between front X1 and rear x holes for wishbone hc 4 8 1931 542 76 0440 08 Wishbone rear hole hc amp front hole for X1 spring link hc 5 3 0 1506 044 59 29 0 16 Front hole for spring link hc amp tail edge X1 of body at YO e 2 83 0 2 3 26 0 08 ZO amp edge of front crossmember ral 2132 218 042 8 58 0 08 ZO amp bottom edge of bumper bracket Z1 8 18 1064 0 2 41 88 0 08 Holes for bumper bracket hc v1 9 8H 1078 0 2 42 44 0 08 Width between inner wheekarch panel Y1 i holes hc 10 3 1223 5 2 48 16 0 08 Outer bolt hole in front crossmember Diag 2 hc amp rear hole in strengthener under bulkhead x 38 600 042 23 62 0 08 Outer holes in front crossmember hc Y1 12 38 502 041 19 7640 04 Holes for rack and pinion gear hc vi 4S 8 2137 5 2 84 15 0 08 Rear outer holes for wishbone hc amp Diag 2 front hole for spring link hc 14 2 97 10 1301 543 56 24 0 12 Front hole for spring link hc amp YO Direct 2 centre hole hc 15 3 10 448041 176420 04 Front hole for spring link hc amp front Direct 2 hole for Panhard rod bracket Saab 500 Body 810 3 Item Fig no Dimension mm in Measuring points Direction 16 7 18 19 20 2 22 23 24 25 26 27 28 29 30
17. Saab 900 SERVICE MANUAL c ETT S 8 5 Convertible M 1986 1990 028 Technical data 108 Special tools Saab 900 800 Technical description 810 Body shell SERVICE 812 Top assembly MANUAL 830 Spoiler assembly 843 Window glass 8 5 Cony erable 844 Weatherstrips and seals 851 Interior trim 852 Rear seat 899 Alphabetical section guide Pretace This section of the Manual deals with systems and components fitted only to the 900 Convertible Other systems and components are dealt with elsewhere in the relevant sections of the Service Manual The information contained herein is not binding and we reserve the right to make changes to the product or specifications without prior notice Saab Automobile AB Units The basic and derived units used throughout the Service Manual are in accordance with the SI system i For users not familiar with the SI units some non Continental units are given in brackets after the respective SI unit e The following symbols and abbreviations are used t SI unit Equivalent unit and i symbol mm inch in kg pound Ib N pound force lbf Nm pound force foot lbf ft bar pound force per square inch Ibl in 1 itor Also abbreviated psi C US liquid quart iiq qt Also abbreviated qts US gallon USgal F Conversion factors 1 in 254mm 1 kg 220 Ib 1 Ib 045
18. bly 812 43 812 43 812 44 812 46 812 49 812 53 Top cover To remove 1 Remove the headlining see page 812 21 2 Remove the spoiler assembly see page 830 1 3 Lower the top to the midway position 4 Pull away the corners of the front seal and remove the screw at the front of each seal retainer 812 2 Top assembly 5 Remove the nuts securing the seal re tainer to the front section of the side rail 6 Remove the screws in the leading edge of the seal and remove the seal 7 Lower the top completely 8 Pull away the welt cord the folded strip of fabric along the leading edge of the top from the no 1 crossmember the welt cord is glued in place Top assembly 812 3 9 Remove all the staples from the plastic strip and then remove the well cord 10 Pull away the top cover from the no 1 crossmembers 11 Raise the top 12 Drill out the rivets in the front cable re tainers 812 4 Top assembly 13 Carefully withdraw the cables from the envelopes in the side of the top cover and leave them hanging from the rear re tainers 14 Remove the acorn nuts and snip off the ties holding the rear seals in place Re move the seals 15 Pull away the top cover from the side rail rear sections fabric glued to rails 16 Pull up the top cover side flaps release the hooks from the flaps and hook them onto the body panel Top assembly 812 5 17 Remo
19. cal description Top assembly 800 1 Top frame assembly 8001 Top cover 800 2 Headlining 800 3 Hydraulics 800 3 Seals 800 4 Adjustments Door window glass Rear quarterlights Top assembly The top assembly consists of a top frame as sembly a top cover and an inner headlining The top is operated by an electrically con trolled hydraulic system Top frame assembly The top frame consists of two side rails each 1 Top cover 2 Top frame assembly 3 Headining of which comprises three sections a front a middle and a rear sec tion The sections are held together by hinges which allow the side rails to fold as the lop is lowered Four crossmembers sometimes known as bows run between the side rails and are each identified by a number no 1 being the cross member at the front of the frame No 1 crossmember No 2 crossmember No 3 crossmember No 4 crossmember Front section of side rail Middle section of side rail Rear section of side rail Noonan 800 2 Technical description When the top is up it is locked to the wind screen frame by means of a latching mecha nism on either side attached to the no 1 crossmember Top cover The top cover is in two parts the top cover itself and a rear screen panel The front of the top cover is glued onto the no 1 crossmember and the trailing edge is stapled to a sireicher that is riveted o
20. car see page 812 36 2 Label the hose connections to indicate which is towards the front and which is towards the rear and remove the pump To fit 1 Reconnect the hoses to their respective fittings on the new pump Tightening torque 5 1 6 2 Nm 3 8 4 5 Ibf ft 2 Reinstall the hydraulic system in the car see page 812 39 Hydraulic hoses To remove 1 Remove the hydraulic system from the car see page 812 36 2 Note and mark the position of the hoses A and then disconnect them from the cylin D der and pump g s81719 Top assembly 812 43 When replacing the RH set of hoses the bypass valve must be transferred from the old to the new set To fit 1 Reconnect the hoses to their respective fittings on the pump and cylinder Tightening torque 5 1 6 2 Nm 3 8 4 5 Ibf ft 2 Reinstall the hydraulic system in the car see page 812 39 Servo cylinders To remove 1 Remove the hydraulic system from the car see page 812 36 2 Disconnect the cylinder from the hoses To fit 1 Reconnect the hoses to the cylinder The lighter coloured hose should be connect ed to the fitting nearer the piston rod Tightening torque 5 1 6 2 Nm 3 8 45 Ibf ft 2 Reinstall the hydraulic system in the car see page 812 39 Bypass valve To remove 1 Remove the hydraulic system from the car see page 812 36 2 Remove the bypass valve To fit 1 Fit the new bypass valve Tightenin
21. chanism hooks To adjust the height of the latching mechanism hook slacken off the Torx Screw and then rotale the hook One complete turn of the hook increases or decreases its height depending on which way it is turned by 1 mm 0 04 in Press down on the front corner of the top to ensure that no play is present Side rail front section Use the screw in the hinge between the front and middle sections of the side rail to bring the front section of the side rail in line parallel with the door window and middle section sas Saab 900 800 6 Technical description 5 Top assembly folded position To adjust the end position of the top when folded down slacken off the nuts on the rear stop on the top frame mechanism when the top is down A special gauge as shown must be used for correct adjustment aS Position the gauge as shown and then adjust the stop to the correct position Correct position for stop bracket Saab 800 Technical description 800 7 Seals As a general rule all seals must be glued into position using 3M Super Weatherstrip Adhe sive with any adjustment being made before the adhesive hardens Note that the top of the A pillar seal must be glued into position using a contact adhesive Such as Loctite Blackmax 380 In this case the seal must be correctly positioned before the adhesive is applied No other adjustment of the A p
22. crossmember lo ensure a mini mum of creasing 18 Trim the fabric along the edge of the no 1 crossmember 19 Cut away the top layer of fabric between the seams 812 12 Top assembly 20 Cut through any creases along the length and smooth the fabric down 21 Cut off the surplus seam at the edge 22 Place the welt cord in position on the no 1 crossmember The fore and aft position is determined by aligning the seam with the front edge of the crossmember Also ensure that the midpoint of the cord is equidistant from either side 23 Open up the bottom flap of the welt cord and staple it to the plastic strip starting in the middle and working out towards the ends Use the long staples part no 6934 285 Note The long staples part no 6934285 are used for stapling two or more layers of fabric The short staples part no 6935712 are used when only one layer of fabric needs to be stapled Saab 900 Top assembly 812 13 24 Glue the top fold of the welt cord onto the crossmember 25 Glue the welt cord ends 26 Apply a bead of adhesive along the edge of the well cord 27 Place the front seal into position and thread the nuts onto the seakretainer bolts Saab 500 812 14 Top assembly 28 Fit the screws securing the seal to the no 1 crossmember 29 Fit the front screws in the strip retainer 30 Seal the ends of the strip using Sikaflex 255 3007 127 31 Plac
23. d Saab 900 843 8 Window glass 8 Fit the windscreen moulding 9 Apply the adhesive as follows Adjust the pressure ol the air gun and the width of the nozzle to oblain a bead of the correct shape Keep the gun perpendicular to the screen and apply a bead of adhesive to the primed surface along the edge of the retainer strip Check that there are no cavities or voids in the adhesive Window glass 843 9 10 Lift the glass into position aligning it with the frame A gap of at least 2 mm must be main tained between the retainer strip and the frame At the top of the screen the surface of the glass must lie between 1 0 and 2 5 mm inside the edge of the frame At the bottom of the glass the front edge of the retainer strip must lie between 1 5 and 3 0 mm outside the front edge of the frame 11 To prevent the windscreen from slipping out of position use adhesive tape to hold the glass in piace until the adhesive has hardened 12 Use a spatula to smooth out the adhesive Start at the bottom corner of one of the A pillars and work upwards across the top of the screen and down to the corner on the other side 843 10 Window glass 13 Remove the masking tape from the inside of the windscreen seien 14 Lift the edge of the moulding midway along the top of the glass and pour water
24. e strap and lower the rear screen 3 Undo the retaining screws and remove the strip from the no 4 top assembly cross member 4 Pull away the headlining from the ad hesive tape holding it in place on the no 4 crossmember and let it hang free 5 Mark the position of the cover strip on the no 3 crossmember and ease the strip off Top assembly 812 23 6 Mark the position of the strip on the no 2 crossmember and ease the strip off 7 Remove the screws from the finisher strip on the no 1 top assembly crossmember 8 Release the latching handle and remove the finisher strip secured by adhesive tape 9 Pull the headlining away from the ad hesive tape holding it in position on the no 1 crossmember and lift it out of the car 812 24 Top assembly To fit 1 Lift the headlining into position and press the plastic retaining strip onto the no 2 crossmember of the top assembly En sure the strip is positioned centrally by lining up the marks made before the sirip was removed If a new headlining is being installed en sure that the retainer strip is equidistant from either end of the no 2 crossmember Using double sided adhesive tape press the headlining into position on the no 1 crossmember and screw the finisher strip into place Take care to align the finisher it itis bent Press the plastic retainer strip into posi tion on the no 3 crossmember Ensure the strip is positioned
25. e the spacers part no 8292492 or 8292799 as appropriate in the wind screen frame Raise Ihe lop and engage the latching hooks but do not close the latching handles Top assembly 812 15 32 Stretch the top fabric by pulling it down over the rails at the back and glue the top to the rails 33 Apply adhesive along the outside edges of the rear seals 34 Place the rear seals in position tighten the acorn nuts and fit the ties Use cable ties part no 10 79 71 899 In order not to leave sharp edges that Could damage the fabric do not cut the ends of the lies but tuck them in instead 812 16 Top assembly 35 Hang the rear screen from the strap and close the zip 36 Place a protective cover over the luggage compariment lid Using a drift centre the top cover over the centre hole in the no 4 crossmember Stretch the fabric by pulling it towards the rear of the car and use a couple of staples to fix it into position Note To ensure that the top cover is not pulled out of alignment carry out each of the following steps up to and including step 45 on both sides of the car before going on to the next step 37 Stretch the top cover side flaps and ensure that the edge of the fabric is parallel with the edge of the rear screen Secure the flaps with a couple of staples 38 Stretch the top cover by pulling it down and towards the rear of the car at the side and secure with a couple of s
26. e window Window glass 843 19 4 Carefully put back the moisture barrier 5 Pul the door handle in position and hook on the link rod 6 Fit the handle retaining screws 7 Fit the inboard window seal moulding 843 20 Window glass 8 Check the position of the glass and adjust as necessary For delails of how to adjust the window see page 800 8 9 Refit the door trim panel and clip for the insert panel 10 Refit the trim insert panel followed by the door pull Rear quarterlight glass and regulator assembly To remove 1 Remove the rear seat cushion see page 2 Remove the rear seat backrest see page 85241 3 Remove the side trim see page 851 1 4 Remove the securing screws for the co ver over the belt guide Slide the cover down the belt Window glass 843 21 5 Slacken the bolt in the belt guide and twist the guide inboard 6 Remove the securing bolls for the quarter light bracket assembly and lift off the bracket assembly 7 Remove the quarterlight outboard seal The front of the seal is glued in place 8 Raise the glass until it collides with the stop and remove the moisture barrier La bel and disconnect the leads from the electric motor 843 22 Window glass 9 Remove the securing bolts for the regula lor assembly 10 Screw in the studs to make it easier to lift the glass 11 Lift out the glass complete with regulator assembl
27. er 5 Unhook the spring Saab 800 Top assembly 812 51 6 Remove the latching handle pivot bolt and lift off the latching handle assembly Transfer the bolt washer and bush to the new assembly To fit 1 Lift the latching handle assembly into position insert the pivot bolt bush and washer and tighten the bolt 2 Hook on the spring 3 Fit the two screws securing the latching handle assembly to the no 1 cross member 4 Fit and tighten the two nuts and the Phillips screw securing the assembly to the front section of the side rail Saab 500 812 52 Top assembly 5 Screw in the screw at the front of the seal retainer 6 Seal the corner using Sikaflex 255 30 07 127 7 Press the seal into the retainer strip 8 Thread the remaining nuts onto the bolts leaving them slack Saab 500 Top assembly 812 53 9 Raise the top Align the seal with the marks and tighten the nuts 10 Check the adjustment of the latching hooks by latching the top in position and then pressing down on the front corners of the top No play should be present If adjustment is necessary see page 800 5 Striker plate To remove 1 Lower the top 812 54 Top assembly 2 Remove the sun visor 3 Remove the striker plate securing screws 4 Pull out the fastener to release the top of the A pillar seal 5 Cut away the seal and remove the striker plate
28. f old adhesive and dirt from the seal retainer Apply a bead of adhesive along the seal retainer 2 Press the new seal into the seal retainer Adjust the ends of the seal so that they fit snugly against the adjacent seals This must be done before the adhesive hardens Rear seal To remove 1 Remove the acorn nuts snip through the tie and remove the seal Saab 800 Weatherstrips and seals 844 5 To fit 1 Apply a bead of adhesive along the new seal put the seal in place and loosely fit the acorn nuts 2 Adjust the end of the seal so that it fits snugly against the adjacent seal Fit a new tie and tighten the acorn nuls Do not cut off the end of the tie but tuck it inside Sharp ends can chale against the top fabric A pillar seal To remove 1 Pull out the fastener securing the top end of the seal 844 6 Weatherstrips and seals 2 Carefully pull the seal away from the A pillar pry out the three fasteners at the bottom and remove the seal To fit 1 Remove all traces of old adhesive and dirt from the metal and seal surfaces 2 Apply a length about 4 cm of double d sided adhesive tape part no 7874662 over the top one of the three fasteners Use a piece of sandpaper to roughen the top end of the seal sexes Saab 900 Weatherstrips and seals 844 7 3 Press home the three fasteners at the bot lom of the seal and press the seal onto the tape
29. g torque 5 1 6 2 Nm 3 8 4 5 Ibf ft 2 Reinstall the hydraulic system in the car see page 812 39 381720 ET 4 Disconnect one of the hoses from one of 812 44 Top assembly Bleeding the hydraulic system Note To avoid possible damage to paintwork or upholstery the hydraulic system must be bled off the car 1 Remove the hydraulic system from the car see page 812 36 2 Place the pump on the workbench and the cylinders inside a tray on the floor 3 Fill the fluid reservoir leaving the plug off Use special hydraulic fluid part no 45 3018694 the cylinders Allow the fluid to run out until the hose is full Reconnect the hose to the cylinder Repeat the procedure for the other hoses topping up the reservoir as necessary Top assembly 812 45 5 Connect a power supply to the pump and Tun it to bring the pistons to their end of travel BDC or TDC Keep the reservoir topped up with fluid to ensure that the fluid never reaches the minimum level 6 Repeat step 4 7 Run the pistons to the opposing end of travel 8 Repeat step 4 9 Repeat the procedure until the system has been properly bled A small amount of air in the system will not affect operation of the top 10 Check the level in the reservoir and top up as necessary Fit Ihe plug 11 Retorque all hose fittings that have been disconnected Tightening torque 3 8 4 5 Nm 5 1 6 2 Ibf ft 12 Wipe clean the
30. he dash 5 Remove the two securing screws from un derneath the glove compartment 6 Remove the end screw underneath the dash panel on the left hand side 7 Remove the fasteners for the A pillar trim Interior trim 851 5 8 Pull the dash panel forward push the A pillar trim towards the front of the car on both sides and remove it To fit 1 Pull the dash panel forward and install the Apillar trim on either side 2 Press in the fasteners for the A pillar trim 3 Push the dash panel back into position checking to ensure that the spindle for the temperature control is still properly con nected g 4 Fit the screw at the outboard end under neath the dash panel Saab 800 851 6 Interior trim 5 Fit the two screws underneath the glove compartment 6 Fit the two screws at the back of the dash panel 7 Reconnect the speakers and fit the grilles 8 Press in the fastener and fit the two screws holding the steering column cowl in place 9 Fit the striker plate assembly see page 812 55 Rear seat 852 1 Rear seat Rear seat 852 1 Seat cushion 852 1 Backrest 852 1 Rear seat Seat cushion To remove 1 Remove the four bolts in the metal strip along the leading edge of the cushion Lift the cushion out of the car To fit 1 Put back the seat cushion and tighten the four bolts in the leading edge of the cushion Backrest To remo
31. how which is left and which is right and remove the strip retainer 9 Remove the staples from the no 4 cross member 10 Fold back the top cover and mark the Position of the stay pad Remove the staples securing the stay pad to the no 4 crossmember 11 Remove the staples holding the top panel of the rear screen lo the no 4 cross member Saab 500 812 28 Top assembly 12 Unzip the fastener and release the strap for the rear screen Unplug the electrical connector from the screen and pull the leads out of the fabric To fit 1 Using a setsquare mark the screen centre as shown 2 Mark the midway position along the no 4 crossmember This should be in line with the retaining screw for the strap 3 Unzip the fastener on the new screen Top assembly 812 29 4 Align the top panel of the rear screen with ihe mark on the no 4 crossmember The top edge of the panel must also be aligned with the forward edge of the no 4 crossmember Staple the panel into posi tion Note The long staples part no 6934285 are used for stapling two or more layers of fabric The short staples part no 6935712 are used when only one layer of fabric needs to be stapled 5 Line up the stay pad with the marks and staple it onto the no 4 crossmember 6 Place a protective cover over the luggage compartment lid 7 Feed the electrical leads through the pa nel and plug in the connector 8 Hang the
32. ical description Top assembly guide pins Adjustment 800 3 81243 028 1 81242 830 1 830 2 830 4 830 6 108 1 801 1 028 1 800 2 800 2 81253 81255 028 1 800 1 800 5 Top assembly Technical description Removal fitting Adjustment Top cover Technical data Technical description Removal Fitting Top frame assembly Top frame crossmembers Adjustment Tyre pressures Upholstery Removal fitting Window glass Removal fitting Windscreen Removal Fitting Workshop information User feedback To From SAAB SCANIA AB Saab Car Division Workshop Information AFSVE S 461 80 TROLLH TTAN Sweden Telefax phone no 46 520 84370 Comments suggestions wit Manual concerned Itis important that Saab technicians in the field regard the Workshop Service Manual as their bible and we therefore strive to make the manual easy to use and to provide accurate information By letting us have your views on this manual you will be helping us to maintain a high standard in our literature Note down any comments or suggestions you may have on a sheet of paper or take a copy of this page and send us your views at the above address For greater convenience you are also welcome to send your comments by fax using the telephone number shown sei ay orowan qms O vapens 4 pena UOQpo UROUOLLY OrzOvt ON Buvopio CS Saab Automobile AB Tr
33. illar seal can be made 1 Top assembly front seal The lateral positioning of the trailing ends of the front seal can be adjusted by loosening the nuts on the bolts securing the seal retainers Fore and aft adjust ment of the seal must be made before the adhesive hardens 2 Top assembly side seals Adjustment of the lateral positioning of the Side seals can be made by slackening off the nuts on the bolts securing the seal retainers Fore and aft adjustment of the seal must be made before the adhesive hardens 3 Top assembly rear seal Vertical adjustment of the rear seal can be made alter the nuts and tie have been loosened and the adhesive bond broken 800 8 Technical description Door windows When adjusting the door window check the adjustment of the front section of the side rail at the same time Height adjustment 1 To adjust the height of the front of the window glass loosen the screw in the front stop 2 To adjust the height of the rear end of the glass loosen the screw in the rear glass stop 3 The height of the trailing end of the door can also be adjusted by undoing the rear nut on the window glass lift mechanism Technical description 800 9 Fore and aft adjustment 4 To adjust the fore and aft position of the window glass loosen the glass stop bracket on the rear channel Lateral adjustment 5 To adjust the lateral position of the window glass lo
34. into position 28 Refit the sun visors and catch brackets 581554 843 14 Window glass 29 Apply contact adhesive to the Apillar seals and press in the fasteners 30 Apply Sikallex 255 3007127 to seal the striker plates 31 Use a spatula to remove surplus sealant 32 Fit the windscreen wipers Window glass 843 15 Door windows To remove 1 Remove the door pull and trim insert panel 2 Remove the door trim panel 3 Undo the retaining screws for the door handle 843 16 Window glass 4 Disconnect the link rod from the handle 5 Remove the moisture barrier 6 Remove the inboard window seal 7 Remove the front and rear stops for the glass Lower the glass far enough to gain access to the stop Saab 500 Window glass 843 17 8 Fully lower the glass Undo the screws se curing the glass to the glassift mecha nism 9 Lift up the glass trailing edge first Take care not to damage the outboard window seal 843 18 Window glass To fit 1 Lower the glass into position taking care nol to damage the outboard window seal 2 Slide the glassiift channel into position and tighten the screws that secure the glass in the middle mounting 3 Refit the stop rollers on the front and rear carriers Adjust the height of the glass by moving the rollers To gain access to the mountings on the glass carriers raise or lower th
35. istance between hinge mountings v1 Width of tail edge of luggage vi compartment aperture Hinge pin hole hc amp centre hole hc at Diag 2 YO in rear floor pan Centre hole in rear floor pan hc amp z3 bottom edge of channel in rear screen member along YO Centre hole hc in floor pan YO amp Diag 3 Corner on tail edge of luggage compartment aperture Corner on tail edge of aperture hc amp Diag 3 hole for hinge pin Front hole in inner wheel arch panel Direct 2 m amp locating hole in bulkhead channel hc Front hole for rack and pinion gear hc Diag 2 amp bottom of bulkhead channel midway between holes for wiper spindles Distance between front 2 hole in inner Diag 2 wheel arch panel amp outer hole for spoiler Front hole in inner wheel arch panel Direct 2 hc amp mounting lug on wing hc Mounting lug on wing hc amp locating Direct 2 hole in bulkhead channel hc 810 4 Body Item Fig no Dimension mm in Measuring points Direction 40 89 556 0 1 21 88 0 04 Locating hole in inner wheel arch flange Direct 2 hc amp locating hole in bulkhead channel he 4 5 1340 0 3 52 75 0 12 Distance between lugs on wings hc Y1 42 5 131 541 5 18 0 04 Distance between holes Y1 for front vi engine mounting hc latest variants 43 5 40 05 1 57 0 02 RH bolt hole hc amp YO line vi 44 5 199 0 1 7 83 0 04 ZO amp silencer muffler hole hc z
36. ition and screw on the end caps 50 Trim the edges to remove surplus fabric Mt the fabric is of Cambria make use a heat gun to fuse the edges to prevent their fraying 812 20 Top assembly 51 Pierce a hole in the fabric for subsequent insertion of the stud for the side section of the spoiler assembly 52 Screw the finisher strip into position at the tail end of the top 53 Remove the spacers from the windscreen frame and raise the top assembly Check that the top comes to rest 20 30 mm from the windscreen frame If adjustment is necessary see page 800 4 20 30mm sim Check the adjustment of the latching hooks by latching the top in position and then pressing down on the front corners of the top No play should be present It adjustment is necessary see page 800 5 sers Saab 900 Po A Aa 22 Top assembly 812 21 54 Adjust the position of the front seal snug against the door glass and tighten the nuts securing the seal retainer 55 Fit the screws securing the anti ballooning strips inside the pockels on the no 2 and no 3 crossmembers 56 Fit the spoiler assembly see section 830 57 Fit the headlining see page 812 24 Headlining To remove 1 Release the press studs and Velcro faste ners securing the headlining side flaps at the back Saab S00 812 22 Top assembly 2 Undo the zip release th
37. kg 1 N 0 23 Ibt 1 lbf 445N 1 Nm 074 ibt ft 1 db ft 1 36 Nm 1 bar 14 5 Ibl n 1 psi 0 07 bar 11 1 05 liq qt eee aor aa E e C x 95 32 C F 32 x 5 9 i 1 mm 0 039 in Market codes The codes refer to market specifications AT Austria GB Great Britain AU Australia GR Greece BE Belgium s Iceland CA Canada T Italy cH Switzerland JP Japan DE Germany ME Middle East 1 DK Denmark NL Netherlands ES Spain NO Norway 1 EU Europe SE Sweden FE Far East us USA fl Finland uc US Calilomia FR France iD Saab Automoble AB 1990 Producton Technical Publications Saab Adomoble AB TroHaMan Sweden Technical data 028 1 Technical data Hydraulics for convertible top Hydraulic fluid Part no 45 30 18 694 min 25 365 5 1 5 2 3 8 4 5 Working pressure of pump bar psi Tightening torque hosefitings Nm Ibf ft Top cover fabric Manufacturer Chassis no H7008199 amp earlier Cambria Chassis no H7008200 onwards Happich Recommended cleaning agents Soap and water For stubborn stains or dirt use Sikkens Reducer M600 as per the ma nufacturer s directions Staples Staples for one fabric layer mm in 9 5 0 38 part no 69 35 712 Staples for two or more fabric layers mm in _ 12 7 0 50 part no 69 34 285 Ee Adhesives Top fabric 3M Super Weatherstrip Adhesive part no 45 30 08 075 Weatherstrips amp seal
38. mber Torsion box under rear seat 810 2 Body Body dimensions The directions in which the measurements are made are given inithe Direction column in the Table with reference to the coordinate system X coordinate Datum line for longitudinal measurements Datum line for transverse measurements left to right Datum line for vertical measurements Y coordinate Z coordinate The figure following the coordinate in the column denotes the tolerance as follows 1 2 Design dimension in coordinate system Actual measurement generally a diagonal measurement 3 Tolerance for best fit hc Dimension to be measured from hole centre Each coordinate originates from a datum O line Datum line XO cannot be used in practice and is therefore not shown Datum line YO This is the centre line of the body dividing the shell into left and right halves Transverse dimensions are speci fied between two measuring points To measure the dimension on one side only mark out the YO line between the holes as shown on the drawing and then halve the dimension and tolerance Datum line ZO The line runs along the fold in the body between the floor pan and side panel Measurements to be made below the ZO line are indicated by a negative value i e the value is prefixed by a sign Xx Item Fig no Dimension mm in Measuring points Direction x d 4372 025 1720 20 Overall length along Y
39. nto the body The top is also glued to the rear sections of the side rails The rear screen is glued to the rear screen panel which is stapled to the no 4 cross member and to the stretcher just forward of the luggage compartment lid The top section of the rear screen panel between the top of the rear screen and the no 4 crossmember is fastened by a zip to allow the rear screen to be lowered for increased ventilation inside the car When unzipped the rear screen must be fully lowered and not allowed to rest against the backrest The rear screen can be replaced without the need to remove the lop cover Two variants of the top cover are in use on cars with chassis no H7008199 or earlier the fabric is made by Cambria whereas on cars with later chassis nos the top fabric is made by Happich After trimming or cutting the edges of the Cambria fabric must be fused by use of a heat gun to prevent fraying Staples are available in two lengths the longer ones being used when two or more layers of fabric need to be stapled 1 Top cover 2 Rearscreon panel 3 Stretcher 4 Zip fastener Technical description 800 3 Headlining The headlining is secured to the undersides of the four crossmembers On the no 1 and no 4 crossmembers it is held in place by both double sided adhesive tape and screws and on the no 2 and no 3 crossmembers by means of plastic retainer strips The back of the headlining is secu
40. o be re fitted to a maximum thickness of 2 mm Note Old adhesive adhering firmly provides a good key for fresh adhesive Remove all loose adhesive from the paint work and glass Clean the surfaces thorough ly with a suitable cleaner and apply primer although not to old adhesive 2 Touch up the paintwork thal will be co vered by the moulding Note The enamel finish must be flawless to prevent the onset of corrosion 3 Position the spacers at the bottom of the frame Window glass 843 7 4 Thoroughly clean the edge of the glass and the metal flange with cleaning solu tion Use one cloth to apply the solution taking care to cover the entire surface and use another cloth to wipe the surface dry Note Do not allow the cleaner to dry naturally as streaks of grease will be left Always use clean lint free rags 5 Apply masking tape around the inside edge of the windscreen Position the tape 17 1 mm from the side edges of the glass and 23 1 mm from the top and bottom edges 6 Apply primer to the edge of the glass 7 Check the fit of the moulding retainer strip relative to the glass If the shape of the strip does not match that of the windscreen the strip must be bent to the correct shape Insert a length of bonnet elease cable in side the relaining strip to prevent its be coming distorted during bending Press the strip onto the windscreen after the primer has drie
41. ollhattan Sweden Pen ce Ga St A Og ISS
42. oo much heal as this can damage the paintwork or spoiler assembly 4 Release the spoiler section at the middle fastening Caution The spoiler assembly must be eased off gent ly to prevent the paintwork being damaged 5 Carelull lift off the spoiler assembly 6 Save the cable in the rear mounting hole as this will be needed in the fitting of a new spoiler assembly where applicable D sams Seb 500 830 6 Spoiler assembly To fit 1 Carefully remove all traces of adhesive and dirt from the paintwork 2 Remove all traces of old adhesive and dirt from the spoiler assembly ry X 3 Fit double sided adhesive lape part no 7874662 along the spoiler 4 Make sure thal the rubber washers and cable at the rear fastening are in place If a new spoiler assembly is being fitted the rubber washers and cable must be transferred to the new one Spoiler assembly 830 7 5 Press the spoiler section into the middle fastener 6 Fit and tighten the wing nut on the rear stud I 7 Fitand fasten the front nut 830 8 Spoiler assembly Rear assembly To remove 1 Open the luggage compartment lid and where applicable unplug the connector for the stoplight in the spoiler 2 Remove the rubber plugs followed by the spoiler retaining bolts and nuts 3 Use a heat gun to allow the tape to be pulled away Take care not to apply too much heat as this can damage the
43. osen the bottom of the rear guide channel As from chassis no K7021110 the front guide channel can be adjusted in the same way Quarterlights Height adjustment 1 Loosen the screws in the front and rear glass stops 800 10 Technical description Fore and aft adjustment 2 Undo the nuts on the glass ift mechanism Lateral adjustment 3 Undo the securing nuts for the glass lift mechanism and turn the studs in the appropriate direction 4 Undo the nut securing the glass to the glass ift mechanism and turn the stud in the appropriate direction Body 810 1 Body Additional strengthening 8104 Body dimensions 810 2 Additional strengthening As on 900 series saloons sedans and hatch backs the Convertible body is a monocoque To compensate for the absence of a rigid roof additional strengthening has been provide the form of steel members and a load bearing bonded windscreen The strengthening components are as follows 1 Corner plate on radiator top crossmember 2 Anchoring socket on wheel arch for A pillar 3 Side panel strengthener 4 Extended A pillar to wheel arch Top crossmember on windscreen frame B pillar now Secondary B pillar lixing point for top frame 10 12 13 Anchorage for seatbelt guide on se condary B pillar Inner side pane Upper side member Torsion box on rear axle tunnel Sill reinforcing me
44. paint work or spoiler assembly Caution The spoiler assembly must be eased off gent ly to prevent the paintwork being damaged 4 Carefully lit off the spoiler assembly To fit 1 Remove all traces of old adhesive and dirt from the luggage compartment lid d Spoiler assembly 830 9 2 Remove all traces of old adhesive and dirt from the spoiler assembly 3 Fit double sided adhesive tape part no 7874662 along the spoiler 4 Apply Sikaflex 255 around the hole for the wiring to the stoplight 5 Lift the spoiler into position and where applicable feed the wiring loom for the stoplight through the hole in the lid 6 Open the lid Tighten the nuts and bolts and fit the rubber plugs Where applicable plug on the connector for the spoiler stoplight Window glass 843 1 Window glass Windscreen B43 1 Rear quarterlight with sliding glass 843 20 Door glass 843 15 Rear screen See section 812 Windscreen To remove 1 Lower the top i 2 Remove the windscreen wipers 03553 3 Remove the sun visors and catch brackets i 843 2 Window glass 4 Remove the latching mechanism striker plate retaining screws 5 Pull out the fastener to release the top of the A pillar seal 6 Cut away the seal plate ind remove the striker 7 Remove the two screws holding the rear view mirror in place i Window glass 843 3 8 Unplug the connector and remo
45. rear screen from the strap and close the zip Saab S00 812 30 Top assembly 9 Fold the top cover back down over the no 4 crossmember Stretch the panel fabric by pulling it down aligning the notch with the hole in the luggage compartment lid Fix the panel in Position by means of a couple of staples 10 Stretch the bottom flaps on either side and staple them in position 11 Remove the staples from the middle of the panel stretch the panel again and secure by means of a couple of staples 12 Staple the rear panel and side flaps into Position working outwards from the middle Top assembly 812 31 13 Trim off the surplus fabric If the fabric is of Cambria make fuse the edges by means of a heat gun to prevent their fraying 14 Pull the stay pads tight and staple them in position 15 Centre the top cover by inserting a dritt in the hole in the middle of the no 4 crossmember Stretch the cover by pull ing it down towards the rear of the car and fix it in position by means of a couple of staples Note To ensure that the top cover is not pulled out of alignment carry out each of the following steps up to and including step 25 on both sides of the car before going on to the next step 16 Stretch the top cover side panels ensur ing that the edges are parallel to the edges of the rear panel Fix the panels in position by means of a couple of staples N e Ss 1
46. red by press studs and Velcro fasteners Hydraulics The top is raised and lowered by means of an electrically controlled hydraulics system The servo pump and motor are located on the righthand side underneath the rear seat Plastic hoses run from the pump to the two servo cylinders which are attached to the operating mechanism for the top The hydraulic system is precharged at the factory with special hydraulic fluid part no 45 3018694 Please note that this is the only fluid that may be used Earlier par liculars stating that ATF fluid or engine oil may be used are thus no longer valid A bypass valve is fitted in the circuit between the pump and the righthand servo cylinder to enable the top to be operated manually The valve is accessible behind a flap in the trim at the back of the luggage compartment To prevent the pump from overheating an overload device isolates it automatically if it has been running for more than 10 20 se conds with the top fully up or down Servo pump 2 Servo cylinders 3 Bypass valve 800 4 Technical description Seals The seal on the A pillar is glued to a retainer screwed onto the pillar At the bottom the seal is held in place by three fasteners and double sided adhesive tape At the top the strip is se cured by one fastener and contact adhesive The top has a seal at the front one on either side and two at the rear The seal at the front is glued and
47. s 3M Super Weatherstrip Adhesive part no 45 30 08 075 Contact adhesive Loctite Blackmax 380 Loctite Superglue or equivalent Window glass Betaseal adhesive kit part no 45 3007 119 Refill part no 45 30 16 045 028 2 Technical data Sealant Top fabric and seals Sealant Top fabric and seals ikaflex 255 part no 45 30 07 127 Recommended tyre pressures cold tyres Tyre size No of Cruising speed Front Rear Occupants km h bar psi bar psi 185165 R15 87T5 12 0 190 2 0 29 21 30 34 22 32 23 33 185 65 R15 87H 12 0 190 20 29 21 30 34 24 35 25 36 195 60 R15 86 87H 12 0 210 21 30 22 32 34 24 35 25 36 195 60 VR15 12 0210 21 30 23 33 12 gt 210 24 35 25 36 34 24 35 25 36 Special tools 108 1 Special tools 82 92 492 Chassis no 7004737 amp earlier 82 92 799 Chassis no 47004738 onwards 78 74 803 69 34 285 6935 712 78 74 662 Spacer for fitting of top assembly 2 required Spacer for fitting of top assembly 2 required 8 660 89 96 514 89 96 522 Duo Fast Medium B1 5324 87 91 105 slaple gun Staples long Staples short 82 92 815 Double sided adhesive tape ABS system tester for measuring hydraulic pressure Pressure sensor included with ABS system tester Pressure sensor adaptor Set of hoses Saab 800 Technical description 800 1 Techni
48. ssembly about 50 cm and secure the front retainer for each cable by means of a rivet Use rivets with part no 7 Insert the hooks into the eyelets on the cover side panels Top assembly 812 9 8 Fit the spacers part no 8292492 or 8292799 as appropriate into position on the windscreen frame 9 Close the top engage the latching hooks but do not close the handles 10 Clamp the top cover to the no 4 cross member by means of a welding clamp The stitching along the seams and the prepunched holes in the cover must be in line with the leading edge of the cross member 11 Glue the side flaps of the top to the corner of the no 1 crossmember using 3M Super Weatherstrip Adhesive Note 3M Super Weatherstrip Adhesive should be used for all gluing of the top cover unless otherwise stated Saab 900 812 10 Top assembly 12 Stretch the cover over the no 1 cross member and glue it to the middle of the crossmember to fix the side to side posi tion of the cover 13 Remove the welding clamp from the no 14 Lower the top sexes 15 Trim the side flaps by means of a knife or pair of shears If the fabric is of Cambria make use a heat gun to fuse the edges to prevent their fraying n N eer P Top assembly 812 11 16 Glue the side flaps to the no 1 cross member 17 Glue the top cover to the no 1 cross member Fold the fabric carefully over the
49. t ly to prevent the paintwork being damaged 8 Carefully lit off the spoiler assembly 9 Save the cable in the rear mounting hole as this will be needed in the fitting of a new spoiler assembly where applicable To fit 1 Carefully remove all traces of adhesive and dirt from the paintwork Spoiler assembly 830 3 2 Remove all traces of old adhesive and dirt from the spoiler assembly 3 Fit double sided adhesive tape part no 7874662 along the spoiler 4 Make sure that the rubber washers and cable at the rear fastening are in place a new spoiler assembly is being fitted the rubber washers and cable must be transferred to the new one 5 Position the spoiler assembly on the car and screw down tight the wing nut on the rear stud 830 4 Spoiler assembly 6 Fitand tighten the nul on the middle stud 7 Fitand tighten the nut on the front stud 8 Fit the side trim see page 851 2 9 Fit the backrest see page 852 2 10 Fit the seat cushion see page 852 1 Chassis no L701110 onwards To remove Note Save the washers from the spoiler mountings as these will be needed in the fitting of a new spoiler where applicable 1 Remove the front securing nut Spoiler assembly 830 5 2 Remove the wing nut from the rear fastening access through the flap in the trim inside the luggage compartment 3 Use a heat gun to release the tape Take g care not to apply t
50. t the cover over the belt guide and tighten the retaining screws 13 Adjust the fit of the glass relative to the top assembly seals and the edge of the door see page 800 9 14 Carefully refit the moisture barrier 15 Fit the side trim see page 851 2 16 Fit the backrest see page 852 2 17 Fit the seat cushion see page 852 1 Weatherstrips and seals 844 1 Weatherstrips and seals Top assembly front seal 844 1 Rear seal 844 4 Side seal B44 3 A pillar seal 844 5 Top assembly front seal To remove 1 Lower the top H 2 Undo the screws securing the seal to the front edge of the no 1 crossmember 3 Pull off the seal 844 2 Weatherstrips and seals To fit 1 Remove all traces of old adhesive from the no 1 crossmember and seal retai ners 2 Apply a bead of adhesive along the length between the top assembly guide pins 3 Align the seal and tighten the retaining screws 4 Apply Sikaflex 255 3007127 to seal the corners Weatherstrips and seals 844 3 5 Glue the seal onto the seal retainers on the side rails Remember that any fore and aft adjust ment must be made before the adhesive has hardened 3 6 Raise the top and adjust the lore and aft position of the seal 3 le seal To remove 1 Pull the old seal out of the seal retainer Saab 900 844 4 Weatherstrips and seals To fit 1 Remove all traces o
51. taples Top assembly 812 17 39 Remove the staples in the side panels stretch the fabric again and use a couple of staples to hold it in place 40 Remove the staples from the middle of the no 4 crossmember stretch the top fabric and secure by means of a couple of staples Stretch the cover by pulling it towards the rear of the car and staple it to the no 4 crossmember Stapling should be done along the centredine between the seams alternating between the right and left sides of the car 41 Stretch the cover towards the rear on either side Staple the fabric at the out board ends of the no 4 crossmember outboard of the seams 42 Remove the staples from the side panels restrelch the fabric and staple in position using a couple of staples 812 18 Top assembly 43 Pull down the top cover side flaps to stretch them and staple the front part of the side flaps in position Do not staple in the holes in the stretcher 44 Pull down and stretch the inner fabric and staple in position 45 Pull down and stretch the side flaps stapi ing them in the order shown 46 Apply a bead of adhesive along the line of staples in the no 4 crossmember Saab 500 Top assembly 812 19 47 With the left and right marks correctly orientated screw the feature strip retainer into place on the no 4 crossmember 48 Apply a bead of adhesive along the retainer 49 Press the feature strip into pos
52. ure pressure 13 Measure the pressure as follows Start the car and press the switch to lower the top Hold down the switch unlil the overload protector breaks the circuit Now read off the pressure from the ABS tester Minimum working pressure 25 bar 365 psi Note The presence of air inside the adaptor fitting can give rise to spurious pressure readings Run the pump briefly in the opposite direction to expel any air bubble Read the pressure again 14 Disconnect the ABS tester 15 Disconnect the pressure sensor from the hose and adaptor 16 Remove the adaptor from the pump tiling the pump to avoid fluid spillage Top assembly 812 49 17 Screw on the tee piece 18 Disconnect the hose union and reconnect the hoses to the pump Make sure the hoses run underneath Ihe handbrake cable Press the pump home in its mount ing Tightening torque 5 1 6 2 Nm 3 8 4 5 Ibf ft 19 Put back the seat cushion see page 852 3 Latching handle assembly To remove 1 Open the top hallway and remove the front screw in the seal retainer 812 50 Top assembly 2 Mark the position of the seal retainer and remove the two securing nuts Swivel the retainer up onto the top 3 Remove the two nuts and the Phillips Screw securing the latching handle as sembly to the front section of the side rail 4 Remove the screw securing the latching handle assembly to the no 1 cross memb
53. ve 6 1 Remove the seat cushion see above 2 Remove the two bolts securing the bottom of the backrest Saab 500 852 2 Rear seat 3 Remove the two bolts securing the top of the backrest and lift the backrest out of the car To fit 1 Lift the backrest into position and tighten the securing bolts al the bottom of the backrest 2 Tighten the securing bolts at the top of the backrest 3 Refit the seat cushion see page 852 1 Alphabetical section guide 899 1 Alphabetical section guide A pillar seal Technical description Removal Fitting A pillar trim Removal Fitting ABS system tester Special tools Measuring pressure Adaptor Special tools Measuring pressure Adhesive tape Adhesives Technical data Adjustments Body dimensions Body shell Body strengthening Bypass valve Technical description Removal fitting Cambria top cover fabric Technical dala Technical description Door window Removal Fitting Adjustment Front seal Technical description Removal Fitting Adjustment Headlining Technical description Removal a Fitting 8004 844 5 8446 B51 3 851 5 108 1 812 46 108 1 812 46 108 1 028 1 800 4 810 2 810 1 810 1 800 3 81243 028 1 800 2 843 15 843 18 800 8 800 4 844 1 844 2 800 7 800 3 81221 812 24 Hydraulic fluid Technical data Technical description Hydraulic hoses
54. ve the finisher strip from the tail edge of the top 18 Unscrew the feature strip end caps from the no 4 crossmembers 19 Pull off the feature strip 20 Mark the left and right ends of the alu minium retainer strip and remove the strip 812 6 Top assembly 21 Remove all the staples holding the top fabric to the no 4 crossmember 22 Undo the zip and the strap and lower the rear screen 23 Remove the slaples in the lop cover do not remove those in the rear screen panel 24 Undo the screws securing the anti bal looning strips to the no 2 and no 3 cross members the strips are in the pockets in the top cover Saab 800 m Top assembly 812 7 25 Withdraw the anti ballooning strips from the pockets 26 Lift off the top cover To fit 1 Start with the top frame assembly folded down E 2 Remove all traces of dirt and old adhesive from the underside of the no 1 cross member 3 Raise the frame assembly and lift the top cover into position Insert the anti balloon ing strips in the pockets in the cover Saab S00 812 8 Top assembly 4 Secure the ends of the anti ballooning strips to the no 2 and no 3 cross members by inserting the screws in the holes at the strip ends Ensure that the pockets do not get trapped 5 Insert the top cover cables in the pockets using a hooked welding rod lo pull them through 6 Raise the top a
55. ve the mm rearview mirror and padded trim 9 Remove the lower steering column cover 10 Remove the speaker grilles 11 Remove the two screws in the leading edge of the top of the dash 843 4 Window glass 12 Remove the two securing screws from underneath the glove compartment 13 Remove the end screw underneath the dash panel on the left hand side 14 Remove the fasteners for the A pillar trim 15 Pull the dash panel forward push the A pillar trim towards the front of the car on both sides and remove it Saab 900 Window glass 843 5 16 Remove the windscreen moulding 17 Use a screwdriver to pry off the cover pieces at the bottom corners of the moulding retainer strip 18 Apply tape round the edges of the windscreen to protect the paintwork 19 Insert one end of a cutting wire 2 metres long through the adhesive in one of the corners of the windscreen S afa 843 6 Window glass 20 Attach a toggle to each end of the cutting wire 21 Pull the wire along the glass until the glass is free all the way round Lift out the windscreen Note Do not use a sawing action as the heat gene rated by the friction will cause the wire to break To fit Note For bonding of the windscreen use adhesive kit 45 3007 119 plus one refill 45 30 16 045 1 Trim the bead of adhesive on the frame and on the removed glass if it is t
56. y 12 Undo the bolts securing the glass to the regulator assembly E Window glass 843 23 13 Remove the clip and rubber seal These will have to be transferred to the new glass where applicable To fit 1 Apply glycerol glycerin to the rubber strip and slide the strip onto the retainer 2 Apply primer to the strip relainer and glass 3 Apply a bead of Betaseal along the groove in the strip retainer 4 Press the strip retainer complete with rubber strip onto the leading edge of the glass Fasten the clip and seal the top with Sikaflex 255 30 07 127 5 Position the glass on the regulator assem bly and tighten the bolts 843 24 Window glass 6 Lift the glass and regulator assembly into position This is easier if the studs are Screwed in and the win dow is in the fully raised position 7 Back off the studs and loosely fit the se curing bolts 8 Reconnect the electrical leads to the mo tor noting how they are labelled 9 Align the outboard seal for the glass and press it into position Use contact adhesive between the mould ing and the seal at the door to glue il into position Window glass 843 25 10 Put the quarterlight bracket assembly inlo position and tighlen the bolts 11 Realign the belt guide ensuring that the locating stud engages the hole in the bo dy and tighten the bolt Tightening torque 24 40 Nm 17 7 29 5 Ibf ft 12 Fi

Saab 900 Convertible 86-94

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