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A1910BE-A-GSAAB.book Page 6 Tuesday, September 6, 2005 8:37 AM
11-6 Maintenance and service
Engine compartment overview ¢ Non-turbo models
13
12
11
10
B00464
1) Air cleaner element (page 11-15) 2) Manual transmission oil level gauge (MT) (page 11-19) or Differential gear oil level gauge (AT) (page 11-22) 3) Clutch fluid reservoir (page 11-26) 4) Automatic transmission fluid level
gauge (page 11-20)
5) Brake fluid reservoir (page 11-25) 6) Fuse box (page 11-40) 7) Battery (page 11-39) 8) Windshield washer tank (page 11-35) 9) Engine coolant reservoir
(page 11-13)
10) Engine coolant reservoir
oil level gauge (page 11-8)
11) Engine oil level gauge filler cap
(page 11-8)
12) Radiator cap (page 11-13) 13) Power steering fluid reservoir
(page 11-24)
A1910BE-A-GSAAB.book Page 7 Tuesday, September 6, 2005 8:37 AM
¢ Turbo models
Maintenance and service 11-7
1) Air cleaner element (page 11-15) 2) Manual transmission oil level gauge (MT) (page 11-19) or Differential gear oil level gauge (AT) (page 11-22) 3) Automatic transmission fluid level
gauge (page 11-20)
4) Clutch fluid reservoir (page 11-26) 5) Brake fluid reservoir (page 11-25) 6) Fuse box (page 11-40) 7) Battery (page 11-39) 8) Windshield washer tank (page 11-35) 9) Engine oil filler cap (page 11-8) 10) Engine coolant reservoir
(page 11-13)
11) Engine oil level gauge (page 11-8) 12) Radiator cap (page 11-13) 13) Power steering fluid reservoir
(page 11-24)
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12
11
10
B00466
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A1910BE-A-GSAAB.book Page 8 Tuesday, September 6, 2005 8:37 AM
11-8 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 engine.
B00467
2. Pull out the dipstick, wipe it clean, and insert it again. 3. Be sure the dipstick is correctly insert- ed until it stops with the graphic symbol “ ” on its top appearing as shown in the illustration.
B00418
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 up- per level.
Use only engine oil with the rec-
ommended 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 en- gine oil gets on the exhaust pipe, be sure to wipe it off.
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 engine oil level reading may be in a range between the upper level and the notch mark. This is caused by thermal expansion of the engine oil. To prevent overfilling the engine oil, do not add any additional oil above the upper lev- el when the engine is cold.
¢ Changing the oil and oil filter Change the oil and oil filter according to the maintenance schedule in the “Saab Warranty and Service Record Booklet”. The engine oil and oil filter must be changed more frequently than listed in the maintenance schedule when driving on dusty roads, when short trips are frequent- ly made, or when driving in extremely cold whether. 1. Warm up the engine by letting the en- gine idle for approximately 10 minutes to ease draining the engine oil. 2. Park the vehicle on a level surface and stop the engine. 3. Remove the oil filler cap.
A1910BE-A-GSAAB.book Page 9 Tuesday, September 6, 2005 8:37 AM
Do not touch the exhaust manifold or turbocharger. These get very hot when the engine has been running.
Turbo models
B00449
B00450
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 engine oil.
Do not spill oil on hot parts of the engine as this could cause a fire. Used engine oil is particulary flammable.
Maintenance and service 11-9
Prolonged and repeated exposure of the skin to engine oil can cause serious skin disorders. The risk of cancer cannot be ruled out.
Wash the affected area thorough- ly with soap and water after any contact.
Keep oil out of the reach of chil-
dren.
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 disposal facility.
5. Wipe the seating surface of the drain plug with a clean cloth and tighten it se- curely with a new sealing washer after the oil has completely drained out. 6. Remove under cover.
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11-10 Maintenance and service
8. Before installing a new genuine Saab 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 genu- ine Saab oil filter by hand turning. Be care- ful not to twist or damage the seal. 10.Tighten the oil filter by the amount indi- cated in the following table after the seal makes contact with the bottom of engine.
B00451
Oil filter color
Amount of rotation
Black
White
1 rotation
2/3 – 3/4 rotation
Please see your Saab dealer for correct oil filter information for your vehicle.
Turbo models
B00452
Non-turbo models 7. Remove the oil filter with an oil filter wrench.
Never over tighten the oil filter be- cause that can result in an oil leak. Thoroughly wipe off any engine oil that has spilled over the ex- haust pipe and/or under-cover. If left unremoved, the oil could catch fire.
11.Reinstall under cover. 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 confirm that the level is correct. 13.Start the engine and make sure that no oil leaks appear around the filter’s rubber seal and drain plug. 14.Run the engine until it reaches the nor- mal operating temperature. Then stop the engine and wait a few minutes to allow the oil to drain back. Check the oil level again and if necessary, add more engine oil.
Be careful not to spill engine oil when adding it. If oil touches the ex- haust pipe, it may cause a bad smell, smoke, and/or a fire.
A1910BE-A-GSAAB.book Page 11 Tuesday, September 6, 2005 8:37 AM
¢ Recommended grade and
viscosity
Oil grade:
ILSAC GF-4, which can be identified with the ILSAC certification mark (Starburst mark) or API classification SM with the words “ENERGY CONSERVING”
These recommended oil grades can be identified by looking for either or both of the following marks displayed on the oil container.
API S E RVICE
SAE 5W-30
GY CO N S
R VIN
B00446
API Service label 1) Indicates the oil quality by API designa-
2) Indicates the SAE oil viscosity no. 3) Indicates that the oil has fuel saving ca-
tions
pabilities
Maintenance and service 11-11
-30 -20 -10 0 10 20 30 40
-20 0
20
40
60
80 100
5W-30*
10W-30, 10W-40
B00014
B00522
ILSAC Certification Mark (Starburst Mark) In choosing an oil, you want the proper quality and viscosity, as well as one that will add to fuel economy. The following ta- ble lists the recommended viscosities and applicable temperatures. When adding oil, different brands may be used together as long as they are the same API classification and SAE viscosity as those recommended by Saab.
SAE viscosity no. and applicable tem- perature *: 5W-30 is recommended. Engine oil viscosity (thickness) affects fuel economy. Oils of lower viscosity provide better fuel economy. However, in hot weather, oil of higher viscosity is required to properly lubricate the engine.
Use only engine oil with the recom- mended grade and viscosity.
11
¢ Recommended grade and
viscosity under severe driv- ing conditions
If the vehicle is used in desert areas, in ar- – CONTINUED –
A1910BE-A-GSAAB.book Page 12 Tuesday, September 6, 2005 8:37 AM
11-12 Maintenance and service
eas with very high temperatures, or used for heavy-duty applications such as tow- ing a trailer, use of oil with the following grade and viscosities is recommended.
API classification SM (or SL):
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 syn- thetic oil, you must use oil of the same classification, viscosity and grade shown in this owner’s manual, and must follow the oil and filter changing intervals shown in the maintenance schedule.
Cooling system
Never attempt to remove the radia- tor cap until the engine has been shut off and has cooled down com- pletely. Since the coolant is under pressure, you may suffer serious burns from a spray of boiling hot coolant when the cap is removed.
The cooling system has been filled at the factory 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% ethylene-glycol basis coolant. Use of improper coolants may result in corrosion in the cooling system. It is important to maintain protection against freez- ing and corrosion, even if freezing temperatures are not expected. Never mix different kinds of cool- ant.
Do not splash the engine coolant over painted parts. The alcohol contained in the engine coolant may damage the paint surface.
¢ Cooling fan, hose and con-
nections
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 tempera- ture gauge exceeds the normal operating range, the cooling fan circuit may be de- fective. 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 neces- sary, there may be a leak in the engine cooling system. It is recommended that the cooling system and connections be checked for leaks, damage, or looseness.
A1910BE-A-GSAAB.book Page 13 Tuesday, September 6, 2005 8:37 AM
¢ Engine coolant q Checking the coolant level
FULL
LOW
B00468
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 reservoir 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 refill as required.
Maintenance and service 11-13
q Changing the coolant
B00018
3. After refilling the reserve tank and the radiator, reinstall the caps and check that the rubber gaskets inside the radiator cap are in the proper position. Be careful not to spill engine cool- ant when adding it. If coolant touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. If engine coolant gets on the exhaust pipe, be sure to wipe it off.
Do not splash the engine coolant over painted parts. The alcohol contained in the engine coolant may damage the paint surface.
B00019
Always add genuine cooling system con- ditioner whenever the coolant is replaced. Change the engine coolant and add gen- uine cooling system conditioner using the following procedures according 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 ra- diator does not need to be removed. To add coolant, remove the cap (with tabs)– CONTINUED –
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A1910BE-A-GSAAB.book Page 14 Tuesday, September 6, 2005 8:37 AM
11-14 Maintenance and service
on the coolant tank on top of the en- gine.
Never attempt to remove the radia- tor cap until the engine has been shut off and has cooled down com- pletely. Since the coolant is under pressure, you may suffer serious burns from a spray of boiling hot coolant when the cap is removed. 4. Install the under cover.
B00453
Non-turbo models 1) Filler neck 2) Fill up to this level
Guideline of coolant quantity (including cool- ant 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)
B00454
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 genuine cooling system con- ditioner in the radiator. Add genuine cool- ing 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
B00468
A1910BE-A-GSAAB.book Page 15 Tuesday, September 6, 2005 8:37 AM
rubber gasket in the radiator cap is cor- rectly 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 cool- ant 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.
Be careful not to spill engine cool- ant when adding it. If coolant touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. If engine coolant gets on the exhaust pipe, be sure to wipe it off.
Do not splash the engine coolant over painted 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.
Maintenance and service 11-15
Air cleaner element The air cleaner element functions as a fil- ter screen. When the element is perforat- ed or removed, engine wear will be exces- sive and engine life shortened. The air cleaner element is a viscous type. It is unnecessary to clean or wash the ele- ment.
Do not operate the engine with the air cleaner element removed. The air cleaner element not only filters in- take air but also stops flames if the engine backfires. If the air cleaner element is not installed when the en- gine backfires, you could be burned.
7. Put the radiator cap back on and tight- en firmly. At this time, make sure that the
B00018
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11-16 Maintenance and service
¢ Replacing the air cleaner ele-
ment
q Turbo models
B00024
1. Unsnap the two clamps holding the air cleaner case cover.B00025
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 cov- er and case with a damp cloth and install a new air cleaner element.
B00026
4. To install the air cleaner case cover, in- sert 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.A1910BE-A-GSAAB.book Page 17 Tuesday, September 6, 2005 8:37 AM
q Non-turbo models
direction of the arrow shown in the draw- ing.
Maintenance and service 11-17
B00363
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 cov- er and case with a damp cloth and install a new air cleaner element.
B00364
5. To install the air cleaner case cover, in- sert the three projections on the air clean- er case into the slits on the air cleaner case cover and then snap the two clamps on the air cleaner case cover.11
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B00361
1. Unsnap the two clamps holding the air cleaner case cover.2. Push the air cleaner case cover in the
B00362
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11-18 Maintenance and service
Spark plugs
¢ Recommended spark plugs
Drive belts
Non-turbo models:
FR5AP-11 (NGK)
Turbo models:
ILFR6B (NGK)
B00027
It may be difficult to replace the spark plugs. It is recommended that you have the spark plugs replaced by your Saab dealer. The spark plugs should be replaced ac- cording to the maintenance schedule in the “Saab Warranty and Service Record Booklet”. When disconnecting the spark plug cables, always grasp the spark plug cap, not the cables.
Make sure the cables are replaced
in the correct order.
B00365
1) Power steering pump pulley 2) Air conditioner compressor pulley 3) Crank pulley The alternator, power steering pump, and air conditioner compressor depend on drive belts. Satisfactory performance re- quires that belt tension be correct. To check belt tension, place a straight- edge (ruler) across two adjacent pulleys and apply a force of 22 lbs (98 N, 10 kg) midway between the pulleys by using a spring scale. Belt deflection should be the amount specified. If a belt is loose, cracked, or worn, contact your Saab deal- er.
A1910BE-A-GSAAB.book Page 19 Tuesday, September 6, 2005 8:37 AM
Deflection
New belt
0.28 – 0.35 (7.0 – 9.0)
0.30 – 0.33 (7.5 – 8.5)
Used belt
0.35 – 0.43 (9.0 – 11.0)
0.35 – 0.40 (9.0 – 10.0)
in (mm) Manual transmission oil
Maintenance and service 11-19
¢ Checking the oil level
B00465
B00469
Turbo model 1. Park the vehicle on a level surface and stop the engine. 2. Pull out the dipstick, wipe it clean, and insert it again.
Non-turbo model 1) Yellow handle
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A1910BE-A-GSAAB.book Page 20 Tuesday, September 6, 2005 8:37 AM
11-20 Maintenance and service
B00368
1) Upper level 2) Lower level 3. Pull out the dipstick again and check the oil level on it. If it is below the lower level, add oil through the dipstick hole to bring the level up to the upper level.
Be careful not to spill manual trans- mission oil when adding it. If oil touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. If oil gets on the exhaust pipe, be sure to wipe it off.
¢ Recommended grade and
viscosity
Each oil manufacturer has its own base oils and additives. Never use different brands together.
Oil grade:
API classification GL-5
-30 -20 -10
10
20
30
40
-20
20
40
60
80
100
90
85W
80W
75W/90
SAE viscosity no. and applicable tem- perature
B00032
Automatic transmission fluid ¢ Checking the fluid level The automatic transmission fluid expands largely as its temperature rises; the fluid level differs according to fluid tempera- ture. Therefore, there are two different scales for checking the level of hot fluid and cold fluid on the dipstick. Though the fluid level can be checked without warming up the fluid on the “COLD” range, we recommend checking the fluid level when the fluid is at operating temperature.
Be careful not to spill automatic transmission fluid when adding it. If automatic transmission fluid touch- es the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. If au- tomatic transmission fluid gets on the exhaust pipe, be sure to wipe it off.
q Checking the fluid level when the
fluid is hot
1. Drive the vehicle several miles to raise the temperature of the transmission fluid
A1910BE-A-GSAAB.book Page 21 Tuesday, September 6, 2005 8:37 AM
up to normal operating temperature; 158
to 176°F (70 to 80°C) is normal. 2. Park the vehicle on a level surface and set the parking brake. 3. First shift the selector lever in each po- sition. Then shift it in the “P” position, and run the engine at idling speed.B00471
1) Yellow handle
B00370
1) HOT range 2) COLD range 3) Upper level 4) Lower level 4. Pull out the dipstick and check the fluid level on the gauge. If it is below the lower level on the “HOT” range, add the recom- mended automatic transmission fluid up to the upper level. q Checking the fluid level when the
fluid is cold
When the fluid level has to be checked without time to warm up the automatic transmission, check to see that the fluid level is between the lower level and upper level on the “COLD” range. If it is below that range, add fluid up to the upper level. Be careful not to overfill.
Maintenance and service 11-21
¢ Recommended fluid
Use one of the following types of automat- ic transmission fluid. IDEMITSU ATF HP Castrol Transmax J Pennzoil ATF-J* * Available only in the USA (except Alaska and Hawaii)
NOTE Using any non-specified type of auto- matic transmission fluid could result in damage inside the transmission. When replacing the automatic transmission fluid, be sure to use a fluid of the types specified above.
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11-22 Maintenance and service
Front differential gear oil (AT vehicles) ¢ Checking the oil level
B00472
1) Yellow handle 1. Park the vehicle on a level surface and stop the engine. 2. Pull out the dipstick, wipe it clean, and insert it again.
¢ Recommended grade and
viscosity
Each oil manufacturer has its own base oils and additives. Never use different brands together.
Oil grade:
API classification GL-5
-30 -20 -10
10
20
30
40
-20
20
40
60
80
100
90
85W
80W
75W/90
SAE viscosity no. and applicable tem- perature
B00032
B00372
1) Upper level 2) Lower level 3. 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 up- per level.
Be careful not to spill front differen- tial gear oil when adding it. If oil touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. If oil gets on the exhaust pipe, be sure to wipe it off.
A1910BE-A-GSAAB.book Page 23 Tuesday, September 6, 2005 8:37 AM
Rear differential gear oil ¢ Checking the gear oil level Your vehicle may be equipped with a rear differential protector. The differential pro- tector provides protection to the rear dif- ferential assembly during off-road use. Removal of the rear differential protector is not required when checking the oil level.
B00434
1) Filler hole 2) Drain hole 3) Oil level Remove the plug from the filler hole and check the oil level. The oil level should be kept even with the bottom of the filler hole. If the oil level is below the bottom edge of the hole, add oil through the filler hole to raise the level.
B00373
1) Filler plug 2) Drain plug
Maintenance and service 11-23
Be careful not to spill rear differ- ential gear oil when adding it. If rear differential gear oil touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. If rear differential gear oil gets on the exhaust pipe, be sure to wipe it off.
If the vehicle requires frequent re- filling, there may be an oil leak. If you suspect a problem, have the vehicle checked at your Saab dealer.
¢ Recommended grade and
viscosity
Each oil manufacturer has its own base oils and additives. Never use different brands together.
Oil grade:
API classification GL-5
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11-24 Maintenance and service
-30 -20 -10
10
20
30
40
-20
20
40
60
80
100
Power steering fluid ¢ Checking the fluid level
90
85W
80W
75W/90
SAE viscosity no. and applicable tem- perature
B00032
B00376
B00375
1) Reservoir tank The power steering fluid expands greatly as its temperature rises; the fluid level dif- fers according to fluid temperature. There- fore, the reservoir tank has two different checking ranges for hot and cold fluids. Check the power steering fluid level monthly. 1. Park the vehicle on a level surface, and stop the engine.
1) Specified range 2. Check the fluid level of the reservoir tank. When the fluid is hot after the vehicle has been run: Check that the oil level is be- tween “HOT MIN” and “HOT MAX” on the surface of the reservoir tank. When the fluid is cool before the vehicle is run: Check that the oil level is between “COLD MIN” and “COLD MAX” on the sur- face of the reservoir tank. 3. If the fluid level is lower than the appli- cable “MIN” line, add the recommended fluid as necessary to bring the level be- tween the “MIN” and “MAX” line. If the fluid level is extreme low, it may indi- cate possible leakage. Consult your Saab dealer for an inspection.
A1910BE-A-GSAAB.book Page 25 Tuesday, September 6, 2005 8:37 AM
Be careful not to burn yourself be- cause the fluid may be hot.
When power steering fluid is be- ing added, use only clean fluid, and be careful not to allow any dirt into the tank. And never use dif- ferent brands together.
Avoid spilling fluid when adding it
in the tank.
Be careful not to spill power steer- ing fluid when adding it. If power steering fluid touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. If power steering fluid gets on the exhaust pipe, be sure to wipe it off.
¢ Recommended fluid
“Dexron III” Type Automatic Transmis- sion Fluid
Brake fluid ¢ Checking the fluid level
MAX
MINMIN
B00473
1) “MAX” level mark 2) “MIN” level mark Check the fluid level monthly. Check the fluid level on the outside of the reservoir. If the level is below “MIN”, add the recommended brake fluid to “MAX”. Use only brake fluid from a sealed con- tainer.
Maintenance and service 11-25
Never let brake fluid contact your eyes because brake fluid can be harmful to your eyes. If brake fluid gets in your eyes, immediately flush them thoroughly with clean water. For safety, when perform- ing this work, wearing eye protec- tion is advisable.
Brake fluid absorbs moisture from the air. Any absorbed moisture can cause a dangerous loss of braking performance.
If the vehicle requires frequent re- filling, there may be a leak. If you suspect a problem, have the vehi- cle checked at your Saab dealer.
Never use different brands of brake fluid together. Also, avoid mixing DOT 3 and DOT 4 brake flu- ids even if they are of the same brand.
When adding brake fluid, be care- ful not to allow any dirt into the reservoir.
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A1910BE-A-GSAAB.book Page 26 Tuesday, September 6, 2005 8:37 AM
11-26 Maintenance and service
Never splash the brake fluid over painted surfaces or rubber parts. Alcohol contained in the brake flu- id may damage them.
Be careful not to spill brake fluid when adding it. If brake fluid touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. If brake fluid gets on the ex- haust pipe, be sure to wipe it off.
¢ Recommended brake fluid
FMVSS No. 116, fresh DOT 3 or DOT 4
brake fluidClutch fluid (MT vehicles) ¢ Checking the fluid level
B00126
Check the fluid level on the outside of the reservoir. If the level is below “MIN” level mark, add the recommended clutch fluid to “MAX” level mark. Use only clutch fluid from a sealed con- tainer.Never let clutch fluid contact your eyes because clutch fluid can be harmful to your eyes. If clutch fluid gets in your eyes, immediately flush them thoroughly with clean water. For safety, when performing this work, wearing eye protection is ad- visable.
Clutch fluid absorbs moisture from the air. Any absorbed mois- ture can cause improper clutch operation.
If the vehicle requires frequent re- filling, there may be a leak. If you suspect a problem, have the vehi- cle checked at your Saab dealer. Never use different brands of
clutch fluid together.
When clutch fluid is added, be careful not to allow any dirt into the tank.
Never splash the clutch fluid over painted surfaces or rubber parts. Alcohol contained in the clutch fluid may damage them.
A1910BE-A-GSAAB.book Page 27 Tuesday, September 6, 2005 8:37 AM
Be careful not to spill clutch fluid when adding it. If clutch fluid touches the exhaust pipe, it may cause a bad smell, smoke, and/or a fire. If clutch fluid gets on the ex- haust pipe, be sure to wipe it off.
¢ Recommended clutch fluid
FMVSS No. 116, fresh DOT 3 or 4 brake flu- id
Avoid mixing DOT 3 and DOT 4
brake fluids even if they are of the same brand.Brake booster If the brake booster does not operate as described in the following, have it checked by your Saab dealer. 1. With the engine off, depress the brake pedal several times, applying the same pedal force each time. The distance the pedal travels should not vary. 2. With the brake pedal depressed, start the engine. The pedal should move slight- ly down to the floor. 3. With the brake pedal depressed, stop the engine and keep the pedal depressed for 30 seconds. The pedal height should not change. 4. Start the engine again and run for ap- proximately one minute then turn it off. Depress the brake pedal several times to check the brake booster. The brake boost- er operates properly if the pedal stroke de- creases with each depression.
Maintenance and service 11-27
Brake pedal Check the brake pedal free play and re- serve distance according to the mainte- nance schedule in the “Saab Warranty and Service Record Booklet”.
¢ Checking the brake pedal free
play
B00377
1) 0.04 – 0.12 in (1.0 – 3.0 mm) Stop the engine and firmly depress the brake pedal several times. Lightly press the brake pedal down with one finger to check the free play with a force of less than 2 lbs (10 N, 1 kg). If the free play is not within proper specifi- cation, contact your Saab dealer.
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11-28 Maintenance and service
¢ Checking the brake pedal re-
serve distance
B00378
1) More than 2.56 in (65 mm) Depress the pedal with a force of approxi- mately 66 lbs (294 N, 30 kg) and measure the distance between the upper surface of the pedal pad and the floor. When the measurement is smaller than the specification, or when the pedal does not operate smoothly, contact with your Saab dealer.
Clutch pedal (MT vehicles) Check the clutch pedal free play and re- serve distance according to the mainte- nance schedule in the “Saab Warranty and Service Record Booklet”.
¢ Checking the clutch function Check the clutch engagement and disen- gagement. 1. With the engine idling, check that there are no abnormal noises when the clutch pedal is depressed, and that shifting into 1st or reverse feels smooth. 2. Start the vehicle by releasing the pedal slowly to check that the engine and trans- mission smoothly couple without any sign of slippage.
¢ Checking the clutch pedal
free play
B00377
1) 0.16 – 0.51 in (4.0 –13.0 mm) Lightly press the clutch pedal down with your finger until you feel resistance, and check the free play. If the free play is not within proper specifi- cation, contact your Saab dealer.
A1910BE-A-GSAAB.book Page 29 Tuesday, September 6, 2005 8:37 AM
Replacement of brake pad and lining
If you continue to drive despite the scraping noise from the audible brake pad wear indicator, it will re- sult in the need for costly brake ro- tor repair or replacement.
700040
The right front disc brake and the right rear disc brake have audible wear indicators on the brake pads. If the brake pads wear close to their service limit, the wear indica- tor makes a very audible scraping noise when the brake pedal is applied. If you hear this scraping noise each time you apply the brake pedal, have the brake pads serviced by your Saab dealer as soon as possible.¢ Breaking-in of new brake
pads and linings
When replacing the brake pad or lining, use only genuine Saab parts. After re- placement, the new parts must be broken in as follows: q Brake pad and lining While maintaining a speed of 30 to 40 mph (50 to 65 km/h), step on the brake pedal lightly. Repeat this five or more times. q Parking brake lining 1. Drive the vehicle at a speed of approx- imately 22 mph (35 km/h). 2. With the parking brake release button pushed in, pull the parking brake lever SLOWLY and GENTLY. (Pulling with a force of approximately 33 lbs [147 N, 15
kg].) 3. Drive the vehicle for approximately 220
yards (200 meters) in this condition. 4. Wait 5 to 10 minutes for the parkingMaintenance and service 11-29
brake to cool down. Repeat this proce- dure. 5. Check the parking brake stroke. If the parking brake stroke is out of the specified range, adjust it by turning the adjusting nut located on the parking brake lever.
Parking brake stroke:
7 – 8 notches / 44 lbs (196 N, 20 kg)
A safe location and situation should be selected for break-in driving.
Pulling the parking brake lever too forcefully may cause rear wheels to lock. To avoid this, be cer- tain to pull the lever up slowly and gently.
the
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11-30 Maintenance and service
Parking brake stroke
B00379
Check the parking brake stroke according to the maintenance schedule in the “Saab Warranty and Service Record Booklet”. When the parking brake is properly adjust- ed, braking power is fully applied by pull- ing the lever up seven to eight notches gently but firmly (approximately 44 lbs [196 N, 20 kg]). If the parking brake lever stroke is not within the specified range, have the brake system checked and ad- justed at your Saab dealer.Tires and wheels ¢ Types of tires You should be familiar with type of tires present on your vehicle. The factory-fitted tires are all-season tires except for the 17-inch tires that are option- al on the Aero (those are summer tires). q All season tires All season tires are designed to provide an adequate measure of traction, handling and braking performance in year-round driving including snowy and icy road con- ditions. However all season tires do not of- fer as much traction performance as win- ter (snow) tires in heavy or loose snow or on icy roads. All season tires are identified by “ALL SEASON” and/or “M+S” (Mud & Snow) on the tire sidewall. q Summer tires Summer tires are high-speed capability tires best suited for highway driving under dry conditions. Summer tires are inadequate for driving on slippery roads such as on snow-cov- ered or icy roads. If you drive your vehicle on snow-covered or icy roads, we strongly recommend the use of winter (snow) tires.
When installing winter tires, be sure to re- place all four tires. q Winter (snow) tires Winter tires are best suited for driving on snow-covered and icy roads. However winter tires do not perform as well as sum- mer tires and all season tires on roads oth- er than snow-covered and icy roads.
¢ Tire inspection Check on a daily basis that the tires are free from serious damage, nails, and stones. At the same time, check the tires for abnormal wear. Contact your Saab dealer immediately if you find any problem. NOTE When the wheels and tires strike curbs or are subjected to harsh treat- ment as when the vehicle is driven on a rough surface, they can suffer damage that cannot be seen with the naked eye. This type of damage does not become evident until time has passed. Try not to drive over curbs, potholes or on oth- er rough surfaces. If doing so is un- avoidable, keep the vehicle’s speed down to a walking pace or less, and ap- proach the curbs as squarely as possi- ble. Also, make sure the tires are not
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pressed against the curb when you park the vehicle. If you feel unusual vibration while driving or find it difficult to steer the ve- hicle in a straight line, one of the tires and/or wheels may be damaged. Drive slowly to the nearest authorized Saab dealer and have the vehicle inspected.
¢ Tire pressures and wear Maintaining the correct tire pressures helps to maximize the tires’ service lives and is essential for good running perfor- mance. Check and, if necessary, adjust the pressure of each tire (including the spare) at least once a month (for example, during a fuel stop) and before any long journey.
Check the tire pressures when the tires are cold. Use a pressure gauge to adjust the tire pressures to the values shown on the tire label. The tire label is located on the door pillar on the driver’s side. Driving even a short distance warms up the tires and increases the tire pressures. Also, the tire pressures are affected by the outside temperature. It is best to check tire pressure outdoors before driving the vehi- cle. When a tire becomes warm, the air inside it expands, causing the tire pressure to in- crease. Be careful not to mistakenly re- lease air from a warm tire to reduce its pressure. NOTE The air pressure in a tire increases by approximately 4.3 psi (30 kPa, 0.3
kgf/cm2) when the tire becomes warm. The tires are considered cold when the vehicle has been parked for at least three hours or has been driven less than one mile (1.6 km).Maintenance and service 11-31
Incorrect tire pressures detract from con- trollability and ride comfort, and they cause the tires to wear abnormally. Correct tire pressure (tread worn evenly)
B00050
Roadholding is good, and steering is re- sponsive. Rolling resistance is low, so fuel consumption is also lower.11
D00120
Do not let air out of warm tires to ad- just pressure. Doing so will result in low tire pressure.
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11-32 Maintenance and service
Abnormally low tire pressure (tread worn at shoulders)
Abnormally high tire pressure (tread worn in center)
B00051
Rolling resistance is high, so fuel con- sumption is also higher.B00052
Ride comfort is poor. Also, the tire magni- fies the effects of road-surface bumps and dips, possibly resulting in vehicle damage. If the label shows tire pressures for the ve- hicle when fully loaded and for the vehicle when towing a trailer, adjust the tire pres- sures to the values that match current loading conditions.Driving at high speeds with exces- sively low tire pressures can cause the tires to deform severely and to rapidly become hot. A sharp in- crease in temperature could cause tread separation, and destruction of the tires. The resulting loss of vehi- cle control could lead to an acci- dent.
¢ Wheel balance Each wheel was correctly balanced when your vehicle was new, but the wheels will become unbalanced as the tires become worn during use. Wheel imbalance caus- es the steering wheel to vibrate slightly at certain vehicle speeds and detracts from the vehicle’s straight-line stability. It can also cause steering and suspension sys- tem problems and abnormal tire wear. If you suspect that the wheels are not cor- rectly balanced, have them checked and adjusted by your Saab dealer. Also have them adjusted after tire repairs and after tire rotation. NOTE Loss of correct wheel alignment* caus- es the tires to wear on one side and re- duces the vehicle’s running stability.
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Contact your Saab dealer if you notice abnormal tire wear. *: The suspension system is designed to hold each wheel at a certain alignment (relative to the other wheels and to the road) for optimum straight-line stability and cornering perfor- mance.
¢ Wear indicators
B00327
1) New tread 2) Worn tread 3) Tread wear indicator Each tire incorporates a tread wear indica- tor, which becomes visible when the depth of the tread grooves decreases to 0.063 in (1.6 mm). A tire must be replaced when the tread wear indicator appears as a solid band across the tread.
When a tire’s tread wear indicator becomes visible, the tire is worn be- yond the acceptable limit and must be replaced immediately. With a tire in this condition, driving at high speeds in wet weather can cause the vehicle to hydroplane. The re- sulting loss of vehicle control can lead to an accident. NOTE For safety, inspect tire tread regularly and replace the tires before their tread wear indicators become visible.
¢ Tire rotation
B00054
Maintenance and service 11-33
Tire wear varies from wheel to wheel. To maximize the life of each tire and ensure that the tires wear uniformly, it is best to rotate the tires every 7,500 miles (12,500
km). Rotating the tires involves switching the front and rear tires on the right-hand side of the vehicle and similarly switching the front and rear tires on the left-hand side of the vehicle. (Each tire must be kept on its original side of the vehicle.) Replace any damaged or unevenly worn tire at the time of rotation. After tire rota- tion, adjust the tire pressures and make sure the wheel nuts are correctly tight- ened. After driving approximately 600 miles (1,000 km), check the wheel nuts again and retighten any nut that has become loose.¢ Tire replacement The wheels and tires are important and in- tegral parts of your vehicle’s design; they cannot be changed arbitrarily. The tires fit- ted as standard equipment are optimally matched to the characteristics of the vehi- cle and were selected to give the best pos- sible combination of running performance, ride comfort, and service life. It is essential for every tire to have a size and construc- tion matching those shown on the tire la-
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11-34 Maintenance and service
bel and to have a speed symbol and load index matching those shown on the tire la- bel. Using tires of a non-specified size detracts from controllability, ride comfort, braking performance, speedometer accuracy and odometer accuracy. It also creates incor- rect body-to-tire clearances and inappro- priately changes the vehicle’s ground clearance. All four tires must be the same in terms of manufacturer, brand (tread pattern), con- struction, and size. You are advised to re- place the tires with new ones that are identical to those fitted as standard equip- ment. For safe vehicle operation, Saab recom- mends replacing all four tires at the same time.
NOTE
B00480
Unidirectional tires: Some tires have a specified direction of rotation. A tire of this type has an arrow or other mark on its side wall to indicate the direction of rotation. Install it so that the direction of rotation is correct when the vehicle is driven forward. All four tires must be the same in terms of manufacturer, brand (tread pattern), construction, de- gree of wear, speed symbol, load index and size. Mixing tires of dif- ferent types, sizes or degrees of wear can result in damage to vehi- cle’s power train. Use of different types or sizes of tires can also dangerously reduce controllabili- ty and braking performance and can lead to an accident.
Use only radial tires. Do not use radial tires together with belted bias tires and/or bias-ply tires. Do- ing so can dangerously reduce controllability, resulting in an ac- cident.
¢ Wheel replacement When replacing wheels due, for example, to damage, make sure the replacement wheels match the specifications of the wheels that are fitted as standard equip- ment. Replacement wheels are available from Saab dealers.
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Use only those wheels that are specified for your vehicle. Wheels not meeting specifications could in- terfere with brake caliper operation and may cause the tires to rub against the wheel well housing dur- ing turns. The resulting loss of vehi- cle control could lead to an acci- dent. NOTE When any of the wheels is removed and replaced for tire rotation or to change a flat tire, always check the tightness of the wheel nuts after driv- ing approximately 600 miles (1,000
km). If any nut is loose, tighten it to the specified torque.Aluminum wheels Aluminum wheels can be scratched and damaged easily. Handle them carefully to maintain their appearance, performance, and safety. When any of the wheels is removed and replaced for tire rotation or to change a flat, always check the tightness of the wheel nuts after driving approximately 600
miles (1,000 km). If any nut is loose, tight- en it to the specified torque. Never apply oil to the threaded parts, wheel nuts, or tapered surface of the wheel. Never let the wheel rub against sharp protrusions or curbs. Be sure to fit tire chains on uniformly and completely around the tire, otherwise the chains may scratch the wheel. When wheel nuts, balance weights, or the center cap is replaced, be sure to re- place them with genuine Saab parts de- signed for aluminum wheels.Maintenance and service 11-35
Windshield washer fluid
300523
If you spray washer fluid on the windshield but the supply of washer fluid appears to diminish, check the level of washer fluid in the tank.11
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11-36 Maintenance and service
id until it reaches the “Hi” level on the level gauge or the “Full” mark on the tank. Use windshield washer fluid. If windshield washer fluid is unavailable use clean wa- ter. In areas where water freezes in winter, use an anti-freeze type windshield washer fluid. If you fill the reservoir tank with a fluid with a different concentration from the one used previously, purge the old fluid from the piping between the reservoir tank and washer nozzles by operating the washer for a certain period of time. Otherwise, if the concentration of the fluid remaining in the piping is too low for the outside tem- perature, it may freeze and block the noz- zles.
Adjust the washer fluid concen- tration appropriately for the out- side temperature. If the concen- tration is inappropriate, sprayed washer fluid may freeze on the windshield and obstruct your view, and the fluid may freeze in the reservoir tank.
Never use engine coolant as washer fluid because it could cause paint damage.
Hi
Low
300172
Washer fluid level gauge
FULL
300524
Remove the washer tank filler cap, then check the fluid level indicated by the level gauge (attached to the inside of the cap). If the level is near the “Low” mark, add flu-Replacement of wiper blades Grease, wax, insects, or other material on the windshield or the wiper blade results in jerky wiper operation and streaking on the glass. If you cannot remove the streaks af- ter operating the windshield washer or if the wiper operation is jerky, clean the out- er surface of the windshield (or rear win- dow) and the wiper blades using a sponge or soft cloth with a neutral detergent or mild-abrasive cleaner. After cleaning, rinse the windshield and wiper blades with clean water. The windshield is clean if beads do not form when you rinse the windshield with water.
Do not clean the wiper blades with gasoline or a solvent, such as paint thinner or benzene. This will cause deterioration of the wiper blades. If you cannot eliminate the streaking even after following this method, replace the wiper blades using the following proce- dures:
¢ Windshield wiper blades as-
sembly
1. Raise the wiper arm off the windshield.
A1910BE-A-GSAAB.book Page 37 Tuesday, September 6, 2005 8:37 AM
¢ Windshield wiper blade rub-
ber
B00330
1) Metal support 1. Grasp the locked end of the blade rub- ber assembly and pull it firmly until the stoppers on the rubber are free of the met- al support.
Maintenance and service 11-37
B00504
1) Metal spines 2. If the new blade rubber is not provided with two metal spines, remove the metal spines from the old blade rubber and in- stall them in the new blade rubber.
B00380
1) Stopper 2. Remove the wiper blade assembly by holding its pivot area and pushing it in the direction shown by the arrow while de- pressing the wiper blade stopper. 3. Install the wiper blade assembly to the wiper arm. Make sure that it locks in place. 4. Hold the wiper arm by hand and slowly lower it in position.
11
B00059
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11-38 Maintenance and service
3. Align the claws of the metal support with the grooves in the rubber and slide the blade rubber assembly into the metal support until it locks.
¢ Rear window wiper blade rub-
ber
B00061
2. Turn the wiper blade assembly coun- terclockwise.700017
1. Pull out the end of the blade rubber as- sembly to unlock it from the plastic sup- port.
B00332
1) Stopper 4. Be sure to position the claws at the end of the metal support between the stoppers on the rubber as shown. If the rubber is not retained properly, the wiper blade may scratch the windshield.
¢ Rear window wiper blade as-
sembly
1. Raise the wiper arm off the rear win- dow.
B00062
3. Pull the wiper blade assembly toward you to remove it from the wiper arm.B00064
A1910BE-A-GSAAB.book Page 39 Tuesday, September 6, 2005 8:37 AM
2. Pull the blade rubber assembly out of the plastic support.
Maintenance and service 11-39
ends. If the rubber is not retained properly, the wiper may scratch the rear window glass. 5. Install the wiper blade assembly to the wiper arm. Make sure that it locks in place. 6. Hold the wiper arm by hand and slowly lower it in position.
B00505
1) Metal spines 3. If the new blade rubber is not provided with two metal spines, remove the metal spines from the old blade rubber and in- stall them in the new blade rubber.
B00066
4. Align the claws of the plastic support with the grooves in the blade rubber as- sembly, then slide the blade rubber as- sembly into place.B00067
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11-40 Maintenance and service
Battery
Before beginning work on or near any battery, be sure to extinguish all cigarettes, matches, and light- ers. Never expose a battery to an open flame or electric sparks. Bat- teries give off a gas which is high- ly flammable and explosive.
For safety, in case an explosion does occur, wear eye protection or shield your eyes when working near any battery. Never lean over a battery.
Do not let battery fluid contact eyes, skin, fabrics, or paint be- cause battery fluid is a corrosive acid. If battery fluid gets on your skin or in your eyes, immediately flush the area with water thor- oughly. Seek medical help imme- diately if acid has entered the eyes. If battery fluid is accidentally swallowed, immediately drink a large amount of milk or water, and seek medical attention immediate- ly.
To lessen the risk of sparks, re- move rings, metal watchbands, and other metal jewelry. Never al- low metal tools to contact the pos- itive battery terminal and anything connected to it WHILE you are at the same time in contact with any other metallic portion of the vehi- cle because a short circuit will re- sult.
Keep everyone including children
away from the battery.
Charge the battery in a well-venti-
lated area.
compounds,
Battery posts, terminals and relat- ed accessories contain lead and lead chemicals known to the State of California to cause cancer and reproductive harm. Batteries also contain other chemicals known to the State of California to cause cancer. Wash hands after handling.
U P P E R L E V E L L O W E R L E V E L L O W E R L E V E L
B00382
1) Cap 2) Upper level 3) Lower level It is unnecessary to periodically check the battery fluid level or periodically refill with distilled water. However, if the battery fluid level is below the lower level, remove the cap. Fill to the upper level with distilled water.
Never use more than 10 amperes when charging the battery because it will shorten battery life.
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Maintenance and service 11-41
Fuses
Never replace a fuse with one hav- ing a higher rating or with material other than a fuse because serious damage or a fire could result. The fuses are designed to melt during an overload to prevent damage to the wiring harness and electrical equipment. The fuses are located in two fuse boxes.
B00173
B00476
To remove the coin tray, open the cover and pull the coin tray out.
The spare fuses are stored in the main fuse box cover in the engine compart- ment.
B00172
One is located under the instrument panel behind the coin tray on the driver’s seat side.B00481
The other one is housed in the engine compartment.11
The fuse puller is stored in the main fuse box in the engine compartment.
B00477
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11-42 Maintenance and service
Main fuse
600160
4. Pull out the fuse with the fuse puller. 5. Inspect the fuse. If it has blown, re- place it with a spare fuse of the same rat- ing. 6. If the same fuse blows again, this indi- cates that its system has a problem. Con- tact your Saab dealer for repairs.B00338
1) Good
