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Maintenance and serviceMaintenance schedule The scheduled maintenance items required to be ser- viced at regular intervals are shown in the “ Saab War- ranty and Service Record Booklet”. For details of your maintenance schedule, read the separate “Saab Warranty and Service Record Book- let”.
18 February 2004
Maintenance and serviceMaintenance precautions When maintenance and service are required, it is rec- ommended that all work be done by an authorized Saab dealer. If you perform maintenance and service by yourself, you should familiarize yourself with the information provided in this section on general maintenance and service for your Saab. Incorrect or incomplete service could cause improper or unsafe vehicle operation. Any problems caused by improper maintenance and service performed by you are not eligible for warranty coverage.
! Testing of an All-Wheel Drive vehicle must NEVER be performed on a single two-wheel dy- namometer or similar apparatus. Attempting to do so will result in transmission damage and in uncontrolled vehicle movement and may cause an accident or injuries to persons nearby. ! Always select a safe area when performing maintenance on your vehicle. ! Always be very careful to avoid injury when working on the vehicle. Remember that some of the materials in the vehicle may be hazardous if – CONTINUED – 11-3
11
Maintenance and service
improperly used or handled, for example, bat- tery acid. ! Your vehicle should only be serviced by per- sons fully competent to do so. Serious person- al injury may result to persons not experienced in servicing vehicles. ! Always use the proper tools and make certain that they are well maintained. ! Never get under the vehicle supported only by a jack. Always use a safety stands to sup- port the vehicle. ! Never keep the engine running in a poorly ventilated area, such as a garage or other closed areas. ! Do not smoke or allow open flames around the fuel or battery. This will cause a fire. ! Because the fuel system is under pressure, replacement of the fuel filter should be per- formed only by your Saab dealer. ! Wear adequate eye protection to guard against getting oil or fluids in your eyes. If something does get in your eyes, thoroughly wash them out with clean water. ! Do not tamper with the wiring of the SRS air- bag system or seatbelt pretensioner system, or attempt to take its connectors apart, as that may activate the system or it can render it inop-
11-4
26 December 2003
erative. The wiring and connectors of these systems are yellow for easy identification. NEV- ER use a circuit tester for these wiring. If your SRS airbag or seatbelt pretensioner needs service, consult your nearest Saab deal- er.
" Before checking or servicing in the en-
gine compartment
! Always stop the engine and set the parking brake firmly to prevent the vehicle from mov- ing. ! Always let the engine cool down. Engine parts become very hot when the engine is run- ning and remain hot for some time after the en- gine is stopped. ! Do not spill engine oil, engine coolant, brake fluid or any other fluid on hot engine compo- nents. This may cause a fire. ! Always remove the key from the ignition switch. When the ignition switch is in the “ON” position, the cooling fan may operate suddenly even when the engine is stopped.
" When you do checking or servicing in the engine compartment while the en- gine is running
Engine hood
26 December 2003
Maintenance and serviceA running engine can be dangerous. Keep your fingers, hands, clothing, hair and tools away from the cooling fan, belts and any other mov- ing engine parts. Removing rings, watches and ties is advisable.
HSB014BA
To open the hood: 1. If the wiper blades are lifted off the windshield, re- turn them to their original positions. 2. Pull the hood release knob under the instrument panel.
11
– CONTINUED – 11-5
Maintenance and service
18 February 2004
UGB089BA
UGB503BA
3. Release the secondary hood release located under the front grille by moving the lever toward the left.
Lift up the hood, release the hood prop from its retain- er and put the end of the hood prop into the slot in the hood. To close the hood: 1. Lift the hood slightly and remove the hood prop from the slot in the hood and return the prop to its re- tainer. 2. Lower the hood until it approaches about 5.9 in (15
cm) from the closed position and let it drop. After closing the hood, be sure the hood is securely locked. If this does not close the hood, release it from a slightly11-6
26 December 2003
Maintenance and servicehigher position. Do not push the hood forcibly to close it. It could deform the metal.
Always check that the hood is properly locked before you start driving. If it is not, it might fly open while the vehicle is moving and block your view, which may cause an accident and serious bodily injury.
11
– CONTINUED – 11-7
Maintenance and service
Engine compartment overview " 2.5-liter non-turbo models
43
13
12
11
10
UGB090BB
11-8
18 February 2004
1) Air cleaner element (page 11-
22)
38)
37)
2) Manual transmission oil level
gauge (MT) (page 11-28) or Dif- ferential gear oil level gauge (AT) (page 11-32)
3) Clutch fluid reservoir (page 11-
4) Automatic transmission fluid lev-
el gauge (page 11-30)
5) Brake fluid reservoir (page 11-
6) Fuse box (page 11-62) 7) Battery (page 11-60) 8) Windshield washer tank (page
9) Engine oil filler cap (page 11-10) 10) Engine coolant reservoir (page
11) Engine oil level gauge (page 11-
11-52)
11-17)
10)
12) Radiator cap (page 11-17) 13) Power steering fluid reservoir
(page 11-35)
" 2.0-liter turbo models
43
13
12
11 10
UGB091BB
18 February 2004
Maintenance and service1) Air cleaner element (page 11-
22)
38)
37)
2) Manual transmission oil level
gauge (MT) (page 11-28) or Dif- ferential gear oil level gauge (AT) (page 11-32)
3) Clutch fluid reservoir (page 11-
4) Automatic transmission fluid lev-
el gauge (page 11-30)
5) Brake fluid reservoir (page 11-
6) Fuse box (page 11-62) 7) Battery (page 11-60) 8) Windshield washer tank (page
9) Engine oil filler cap (page 11-10) 10) Engine coolant reservoir (page
11) Engine oil level gauge (page 11-
11-52)
11-17)
10)
12) Radiator cap (page 11-17) 13) Power steering fluid reservoir
(page 11-35)
– CONTINUED – 11-9
11
Maintenance and service
Engine oil " Checking the oil level Check the engine oil level at each fuel stop. 1. Park the vehicle on a level surface and stop the en- gine.
UG9032CA
2. Pull out the dipstick, wipe it clean, and insert it again. 3. Be sure the dipstick is correctly inserted until it stops with the graphic symbol on its top appear- ing as shown in the illustration.
11-10
26 December 2003
UGB082BB
1) Notch 2) Upper level 3) Lower level 4. Pull out the dipstick again and check the oil level on it. If it is below the lower level, add oil to bring the level up to the upper level.
! Use only engine oil with the recommended grade and viscosity. ! Be careful not to spill engine oil when adding it. If oil touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire.
If you check the oil level just after stopping the engine, wait a few minutes for the oil to drain back into the oil pan before checking the level. Just after driving or while the engine is warm, the en- gine oil level reading may be in a range between the upper level and the notch mark. This is caused by ther- mal expansion of the engine oil. To prevent overfilling the engine oil, do not add any additional oil above the upper level when the engine is cold.
" Changing the oil and oil filter Change the oil and oil filter according to the mainte- nance schedule in the “Saab Warranty and Service Record Booklet”. The engine oil and oil filter must be changed more fre- quently than listed in the maintenance schedule when driving on dusty roads, when short trips are frequently made, or when driving in extremely cold whether. 1. Warm up the engine by letting the engine idle for about 10 minutes to ease draining the engine oil. 2. Park the vehicle on a level surface and stop the en- gine. 3. Remove the oil filler cap.
18 February 2004
Maintenance and serviceDo not touch the exhaust manifold or turbo- charger. These get very hot when the engine has been running.
2.0-liter turbo models
UGB105BA
11
– CONTINUED – 11-11
Maintenance and service
UGB057DA
Non-turbo models 4. Drain out the engine oil by removing the drain plug while the engine is still warm. The used oil should be drained into an appropriate container and disposed of properly.
! Be careful not to burn yourself with hot en- gine oil. ! Do not spill oil on hot parts of the engine as this could cause a fire. Used engine oil is partic- ulary flammable. ! Prolonged and repeated exposure of the skin
11-12
26 December 2003
to engine oil can cause serious skin disorders. The risk of cancer cannot be ruled out ! Wash the affected area thoroughly with soap and water after any contact. ! Keep oil out of the reach of children. ! Protect the environment. Do not dispose of oil into the ground or down a drain. Dispose of all used oil and oil filters at an appropriate dis- posal facility. 5. Wipe the seating surface of the drain plug with a clean cloth and tighten it securely with a new sealing washer after the oil has completely drained out. 6. Remove under cover (for Turbo).
Turbo models
UGB123BA
18 February 2004
Maintenance and serviceNever over tighten the oil filter because that can result in an oil leak.
11.Reinstall under cover (for Turbo). 12.Pour engine oil through the filler neck.
Oil capacity (guideline):
4.2 US qt (4.0 liters, 3.5 Imp qt)
The oil quantity indicated above is only guideline. The necessary quantity of oil depends on the quantity of oil that has been drained. The quantity of drained oil differs slightly depending on the temperature of the oil and the time the oil is left flowing out. After refilling the engine with oil, therefore, you must the dipstick to con- firm that the level is correct. 13.Start the engine and make sure that no oil leaks ap- pear around the filter’s rubber seal and drain plug. 14.Run the engine until it reaches the normal operat- ing temperature. Then stop the engine and wait a few minutes to allow the oil to drain back. Check the oil lev- el again and if necessary, add more engine oil.
– CONTINUED – 11-13
11
UGB057EA
Non-turbo models 7. Remove the oil filter with an oil filter wrench. 8. Before installing a new oil filter, apply a thin coat of engine oil to the seal. 9. Clean the rubber seal seating area of the bottom of engine and install the oil filter by hand turning. Be careful not to twist or damage the seal. 10.Tighten the oil filter by the amount indicated below after the seal makes contact with the bottom of engine. Please see your Saab dealer for correct oil filter infor- mation for your vehicle.
Maintenance and service
26 December 2003
A PI S E RVICE
SAE
5W−30
GY CO N S E
R VIN
HSB022BB
API Service label 1) Indicates the oil quality by API designations 2) Indicates the SAE oil viscosity no. 3) Indicates that the oil has fuel saving capabilities
Be careful not to spill engine oil when adding it. If oil touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire.
" Recommended grade and viscosity
Oil grade:
ILSAC GF-3, which can be identified with the new API certification mark (Starburst mark) or API classification SL with the words “ENERGY CONSERVING” (if you cannot obtain the oil with SL grade, you may use SJ grade “ENERGY CON- SERVING” oil).
These recommended oil grades can be identified by looking for either or both of the following marks dis- played on the oil container.
11-14
26 December 2003
Maintenance and service-30 -20 -10
10 20 30 40
-20
20
40
60
80 100
5W-30*
10W-30, 10W-40
HSB023AA
UGB084BA
RICAN P
T ROLEUM
IN
CERTIF I
New API Certification Mark (Starburst Mark) In choosing an oil, you want the proper quality and vis- cosity, as well as one that will add to fuel economy. The following table lists the recommended viscosities and applicable temperatures. When adding oil, different brands may be used togeth- er as long as they are the same API classification and SAE viscosity as those recommended by Saab.
SAE viscosity No. and applicable temperature *: 5W-30 is preferred. Engine oil viscosity (thickness) affects fuel economy. Oils of lower viscosity provide better fuel economy. However, in hot weather, oil of higher viscosity is re- quired to properly lubricate the engine.
Use only engine oil with the recommended grade and viscosity.
11
– CONTINUED – 11-15
Maintenance and service
" Recommended grade and viscosity
under severe driving conditions
If the vehicle is used in desert areas, in areas with very high temperatures, or used for heavy-duty applica- tions such as towing a trailer, use of oil with the follow- ing grade and viscosities is recommended.
API classification SL (or SJ):
SAE viscosity no.: 30, 40, 10W-50, 20W-40, 20W-50
" Synthetic oil You can use synthetic engine oil that meets the same requirements given for conventional engine oil. When using synthetic oil, you must use oil of the same clas- sification, viscosity and grade shown in this owner’s manual, and must follow the oil and filter changing in- tervals shown in the maintenance schedule.
11-16
26 December 2003
Cooling system
Never attempt to remove the radiator cap until the engine has been shut off and has cooled down completely. Since the coolant is under pressure, you may suffer serious burns from a spray of boiling hot coolant when the cap is re- moved.
! The cooling system has been filled at the fac- tory with a high quality, corrosion-inhibiting, year-around coolant which provides protection against freezing down to –33°F (–36°C). For adding, use genuine Saab coolant or an equiv- alent: a mixture of 50% soft water and 50% eth- ylene-glycol basis coolant. Use of improper coolants may result in corrosion in the cooling system. It is important to maintain protection against freezing and corrosion, even if freezing temperatures are not expected. Never mix dif- ferent kinds of coolant. ! Do not splash the engine coolant over paint-
ed parts. The alcohol contained in the engine coolant may damage the paint surface.
" Engine coolant ! Checking the coolant level
26 December 2003
Maintenance and service" Cooling fan, hose and connections Your vehicle employs an electric cooling fan which is thermostatically controlled to operate when the engine coolant reaches a specific temperature. If the radiator cooling fan does not operate even when the engine coolant temperature gauge exceeds the normal operating range, the cooling fan circuit may be defective. Check the fuse and replace it if necessary. If the fuse is not blown, have the cooling system checked by your Saab dealer. If frequent addition of coolant is necessary, there may be a leak in the engine cooling system. It is recom- mended that the cooling system and connections be checked for leaks, damage, or looseness.
FULL
LOW
UG9032DB
1) “FULL” level mark 2) “LOW” level mark Check the coolant level at each fuel stop. 1. Check the coolant level on the outside of the reser- voir while the engine is cool. 2. If the level is close to or lower than the “LOW” level mark, add coolant up to the “FULL” level mark. If the reserve tank is empty, remove the radiator cap and re- fill as required.
– CONTINUED – 11-17
11
Maintenance and service
18 February 2004
! Changing the coolant
HSB026BB
1) Rubber gaskets 3. After refilling the reserve tank and the radiator, re- install the caps and check that the rubber gaskets in- side the radiator cap are in the proper position.
! Be careful not to spill engine coolant when adding it. If coolant touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. ! Do not splash the engine coolant over paint- ed parts. The alcohol contained in the engine coolant may damage the paint surface.
11-18
HSB027BB
1) Drain plug Always add genuine cooling system conditioner when- ever the coolant is replaced. Change the engine coolant and add genuine cooling system conditioner using the following procedures ac- cording to the maintenance schedule. 1. Remove the under cover. 2. Place a proper container under the drain plug and loosen the drain plug. 3. Loosen the radiator cap to drain the coolant from the radiator. Then drain the coolant from the reserve tank. Tighten the drain plug securely.
NOTE (Turbo model only) The cap (without tabs) on top of the radiator does not need to be removed. To add coolant, remove the cap (with tabs) on the coolant tank on top of the engine.
Never attempt to remove the radiator cap until the engine has been shut off and has cooled down completely. Since the coolant is under pressure, you may suffer serious burns from a spray of boiling hot coolant when the cap is re- moved.
4. Install the under cover.
Non-turbo models 1) Filler neck 2) Fill up to this level
26 December 2003
Maintenance and serviceUGB122BB
– CONTINUED – 11-19
11
Maintenance and service
26 December 2003
Guideline of coolant quantity (including coolant in reservoir tank):
Non-turbo models:
MT. 7.4 US qt (7.0 liters, 6.2 Imp qt) AT. 7.3 US qt (6.9 liters, 6.1 Imp qt)
Turbo models:
MT. 8.1 US qt (7.7 liters, 6.8 Imp qt) AT. 8.0 US qt (7.6 liters, 6.7 Imp qt)
USB518BB
Turbo models 1) Filler neck 2) Fill up to this level 5. Slowly pour the coolant and fill up to just below the filler neck, allowing enough room to add the genuine cooling system conditioner in the radiator. Add genu- ine cooling system conditioner until the coolant level reaches the filler neck. Do not pour the coolant too quickly, as this may lead to insufficient air bleeding and trapped air in the system.
FULL
LOW
1) “FULL” level mark 2) “LOW” level mark
UG9032DB
11-20
! Be careful not to spill engine coolant when adding it. If coolant touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. ! Do not splash the engine coolant over paint- ed parts. The alcohol contained in the engine coolant may damage the paint surface.
6. Pour the coolant and fill to the reservoir tank’s “FULL” level mark.
1) Rubber gaskets
HSB026BB
26 December 2003
Maintenance and service7. Put the radiator cap back on and tighten firmly. At this time, make sure that the rubber gasket in the radi- ator cap is correctly in place. 8. Start and run the engine for more than five minutes at 2,000 to 3,000 rpm. 9. Stop the engine and wait until the coolant cools down (122 to 140°F [50 to 60°C]). If there is any loss of coolant, add coolant to the radiator’s filler neck and to the reserve tank’s “FULL” level. 10.Put the radiator cap and reservoir cap back on and tighten firmly.
11
– CONTINUED – 11-21
Maintenance and service
Air cleaner element The air cleaner element functions as a filter screen. When the element is perforated or removed, engine wear will be excessive and engine life shortened. The air cleaner element is a viscous type. It is unnec- essary to clean or wash the element.
Do not operate the engine with the air cleaner element removed. The air cleaner element not only filters intake air but also stops flames if the engine backfires. If the air cleaner element is not installed when the engine backfires, you could be burned.
26 December 2003
" Replacing the air cleaner element ! Turbo models
1. Unsnap the two clamps holding the air cleaner case cover.
USB521BA
11-22
18 February 2004
Maintenance and serviceUGB126BB
USB523BA
1) Air cleaner case cover 2) Air cleaner element 2. Open the air cleaner case cover and remove the air cleaner element. 3. Clean the inside of the air cleaner cover and case with a damp cloth and install a new air cleaner ele- ment.
4. To install the air cleaner case cover, insert the two projections on the air cleaner case cover into the slits on the air cleaner case and then snap the two clamps on the air cleaner case cover.
11
– CONTINUED – 11-23
Maintenance and service
! Non-turbo models
26 December 2003
1. Unsnap the two clamps holding the air cleaner case cover.
UGB092BA
2. Push the air cleaner case cover in the direction of the arrow shown in the drawing.
UGB104BA
11-24
26 December 2003
Maintenance and serviceUGB093BB
UGB094BA
1) Air cleaner case cover 2) Air cleaner element 3. Open the air cleaner case cover and remove the air cleaner element. 4. Clean the inside of the air cleaner cover and case with a damp cloth and install a new air cleaner ele- ment.
5. To install the air cleaner case cover, insert the three projections on the air cleaner case into the slits on the air cleaner case cover and then snap the two clamps on the air cleaner case cover.
11
– CONTINUED – 11-25
18 February 2004
