Saab 900 Convertible Manual
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Saab 900 Convertible Manual

Saab 900 Convertible Manual

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  • Page 2: Product Information

    Enclosed is the final version of this Troubleshooting Guide for your dealership’s service library. The information contained in this document is the latest and only information that should be referenced when working on a 1995- 900 Convertible. In conjunction with the publication of this Guide, several older bulletins have been supersed- ed.
  • Page 3 900 Convertible Top Troubleshooting Guide Table of Contents TOPIC PAGE Table of Contents How to determine if Updates & Campaigns have been performed Inoperative Top/Operational Problems/Unsatisfactory Performance Squeaks & Rattles Water Leaks SID Messages Miscellaneous Problems BULLETINS INCLUDED IN THIS GUIDE:...
  • Page 4 900 Convertible. Note that this is not a guarantee that all of the steps of a particular PSI or campaign have been performed.
  • Page 5 900 Convertible Top Troubleshooting Guide Inoperative Top/Operational Problems/Unsatisfactory Performance (Note that problems are listed in order of top operating sequence, beginning with top fully raised) PROBLEM ACTION POSSIBLE CAUSE See page 1 Nothing happens when attempting a. Top switch on center console...
  • Page 6 900 Convertible Top Troubleshooting Guide Inoperative Top/Operational Problems/Unsatisfactory Performance (Note that problems are listed in order of top operating sequence, beginning with top fully raised) ACTION PROBLEM POSSIBLE CAUSE See page 10 12 Top gets caught on interior trim Early interior trim panel not cut at...
  • Page 7 900 Convertible Top Troubleshooting Guide Inoperative Top/Operational Problems/Unsatisfactory Performance (Note that problems raised) are listed in order of top operating sequence, beginning with top fully See page 16 Top out of adjustment 23 First bow comes down on header crooked, straightens as 5th bow...
  • Page 8 900 Convertible Top Troubleshooting Guide Squeaks & Rattles ACTION PROBLEM POSSIBLE CAUSE See page 19 Clicking/snapping noise from the Loose bolts at front side rail 1st bow header Rattle from “pull down” handle at Incorrect fit See page 19 center of 1 st bow...
  • Page 9 900 Convertible Top Troubleshooting Guide Water Leaks PROBLEM ACTION POSSIBLE CAUSE Leaks from header while driving a. Water coming in between See page 22 (determine whether water comes header and front side rail seal in while driving only, or while sitting...
  • Page 10 900 Convertible Top Troubleshooting Guide Miscellaneous ACTION PROBLEM POSSIBLE CAUSE DTC B1605, top works O.K. See page 24 ACC does not switch to manual See page 24 SID misprogrammed mode when lowering top See page 24 ACC does not switch to automatic...
  • Page 11 900 Convertible Top Troubleshooting Guide Inoperative Top/Operational Problems/Unsatisfactory Performance: (Note that problems are listed in order of top operating sequence, beginning with top fully raised) 1. Nothing happens when attempting to lower top (no movement at all, no noises, etc.) a.
  • Page 12 900 Convertible Top Troubleshooting Guide b. 5th bow potentiometer “Check Soft Top” ap- will not reach high limit. pears on SID. Reprogram top according to PSI 04/97-0758. c. Tonneau motor disengaged? Remove the right taillight assembly to inspect the Tonneau motor. Check for proper engagement of Tonneau motor.
  • Page 13 900 Convertible Top Troubleshooting Guide c. Tonneau motor disengaged? (continued) There can be too much friction between the emergency release handle cable and the sheathing because of the way the sheathing/cable is positioned. Cut the ties securing the sheathing/cable to the body so that it finds a more natural Make sure that the release handle is pushed all the way to the rear of the car, and that the cable does not kink (see illustration).
  • Page 14 900 Convertible Top Troubleshooting Guide 4. Tonneau cover catches going up - “‘snaps” when opening Adjust striker and latch as per Service Manual 8:5 Cabriolet, pages 127-l 28. Make sure to check the Tonneau cover latch adjustment with top fully raised, because the 5th bow pushes the Tonneau cover down when the top is fully raised.
  • Page 15 900 Convertible Top Troubleshooting Guide a. Missing 2nd bow drive link or 2nd bow binding on fabric? Perform Customer Satisfaction Campaign 428 if it has not been completed This problem can occur if the 2nd bow does not flip back, causing it to contact the front side rails.
  • Page 16 900 Convertible Top Troubleshooting Guide b. Programming? Reprogram top according to PSI 04/97-0758. Main motor or 5th bow potentiometer faulty? Monitor the “Main Motor Potentiometer” and “5 Bow Potentiometer” with Watch Tech 2 using the line graph function as you cycle the top completely.
  • Page 17 900 Convertible Top Troubleshooting Guide balance link usually bends here toward center of car 8. Rear window hits rear headrest when lowering top Reprogram top according to PSI 04/97-0758, paying particular attention to overlap values. If you still experience this problem, you can try lowering the 5th bow overlaps one unit at a time until the problem ceases.
  • Page 18 900 Convertible Top Troubleshooting Guide a. Programming Reprogram top according to PSI 04/97-0758. Pay special attention to the Tonneau motor high limit, b. Tonneau motor drive shaft twisted? cover hinges. If you think that this situation exisits, you may have to remove the u-joint at the end of the shaft to inspect it for a twist.
  • Page 19 900 Convertible Top Troubleshooting Guide The rear window may be catching on the 5th bow latch hooks as the top is being lowered. There are 3 different designs of “rear window stops” which have been used. ANY ONE OF THESE 3 STYLES IS ACCEPTABLE.
  • Page 20 900 Convertible Top Troubleshooting Guide 12. Top gets caught on interior trim panel on way down Cut panel - see illustration. front of car Remove shaded (left side shown)
  • Page 21 900 Convertible Top Troubleshooting Guide 13. Top won’t park low enough a. Main motor low limit not programmed correctly? Reprogram according to PSI 04/97-0758 Tighten screws as per Customer Satisfaction Campaign 428, item E, page 9 as well as the two noted in the illustration .below.
  • Page 22 900 Convertible Top Troubleshooting Guide 1. Determine which side is causing the problem 2. Remove the three 13mm nuts securing the top stack to the chassis 3. Raise the top assembly out of the boot slightly on one side. Sup- port it with a piece of wood.
  • Page 23 900 Convertible Top Troubleshooting Guide driving Install foam tape on underside of Tonneau cover. See illustration. 17. Tonneau cover catches going up - “snaps” when opening Adjust Tonneau latches according to Service Manual 8:5 Cabriolet, pages 127 & 128. Make sure to check the Tonneau latch adjustment with top fully raised, because the 5th bow pushes the Tonneau cover down when the top is fully raised.
  • Page 24 900 Convertible Top Troubleshooting Guide or hesitates when raising the top Open the top so that the front side rail is in a near vertical position. Note the angle of the 2nd bow flipper rod and compare it to the angle of the flipper rod on the other side of the car.
  • Page 25 900 Convertible Top Troubleshooting Guide Replace Tonneau motor assembly. Recheck cable adjustment. See pages 22-227 of Service Manual 8:5 and also Operational Problem #3 above for additional illustration. 20. Top does not go up (rise) evenly - one side rises quicker than the other Replace faulty motor and reprogram top.
  • Page 26 900 Convertible Tar, Troubleshooting Guide c. Does first bow need to be moved forward? There must be a small gap, but no more t h a n 5 m m , 1. Partially lower the top 2. Remove the front side rail seals on both sides 3.
  • Page 27 900 Convertible Top Troubleshooting Guide Tonneau cover catches on fabric when closing? Install rivets as per Customer Satisfaction Campaign 428, item F, page 11. Remove any stitching previously installed on the elastic straps per earlier PSI Tonneau cover latches not aligned properly? Readjust latches according to Service Manual 85, pages 127 &...
  • Page 28 900 Convertible Top Troubleshooting Guide won’t a. 5th bow latch motor jammed or inoperative? motor. See MI 811-1758. Use Tech 2 to “Activate&h Bow Latch Motor”. If motor does not operate cor- rectly, perform electrical tests. There may be a wiring fault.
  • Page 29 Squeaks & Rattles (Note: noise comes from the corner where the header meets the side rail. The noise disappears with the latch released.) Remove bolts, Loctite and retighten 3 bolts. page Tighten bolts as per Customer Satisfaction Campaign 428, item D, If these screws have been loose for some time, the pop rivet may have worked loose.
  • Page 30 900 Convertible Top Troubleshooting Guide Rattle at 2nd bow (above driver’s or passenger’s head) a. Incorrect cut at ends of 2nd bow? The end of the 2nd bow must have a flat surface at least 5mm wide which rests on the stop block when the top is fully raised. If there is less than 5mm, replace 2nd bow.
  • Page 31 900 Convertible Top Troubleshooting Guide Remove bolts, Loctite and retighten 2 bolts each side. Tighten bolts as per Customer Satisfaction Campaign item E, page 9. 6. Rattle in rear side trim area by rear speaker (only 1995 V/N up to Wrap pretensioner in felt tape.
  • Page 32 900 Convertible Top Troubleshooting Guide Water Leaks (Note: Determine whether water comes in while driving only, or while Sit- ting still) Leaks from header while driving a. Water coming in between header and front side rail seal? Replace windshield header seal and side rail seals as per Water Leak PSI b.
  • Page 33 Additional information regarding SID messages in Service Manual 85 Cabri- can be found olet, page 40. 1. “Check Soft Top” while top is operating, top works O.K. a. Check for DTC’s Follow appropriate fault tracing procedure in Service Manual 85 Cabriolet. b.
  • Page 34 900 Convertible Top Troubleshooting Guide Miscellaneous Operate top and recheck for DTC’s. If DTC’s do not reoccur, ignore this DTC. (Note that this DTC is frequently a “phantom” code and can be ignored if no operation problems are experienced.) 2. ACC does not switch to manual mode when lowering top Reprogram SID to “hood”.
  • Page 35 900 Convertible Top Troubleshooting Guide 5. Side rail seal drooping continued Secure seal to seal retainer with Velcro strips inside seal as shown. FRONT SIDE RAIL SEAL CENTER SIDE RAIL SEAL Attach the “soft side” of velcro tape to seal retainers.
  • Page 36 900 Convertible Top Troubleshooting Guide release button inoperative a. Incorrect programming? eration of the trunk motor because it cannot determine if the trunk lid will lide with the Tonneau cover, The customer usually complains of some other top operation problem at the same time. Reprogramming can correct both problems.
  • Page 37 Parts: technicians, NOT a “do-it-yourself&‘. Saab Cars USA, Inc. Service bulletins are intended for use by prOfeSSiOnal They are written to inform these technicians of conditions that may occur on some vehicles, or t0 provide information that could. assist in the proper service of a vehicle, properly trained technicians have the equipment, tools, safety instructlons, and !c-row+ow to do a lob~properfy and safely.
  • Page 38 PSI 04/97-0753 See Page 3 of PSI 04/97-0754: Customer Satisfaction Campaign 428 (Section 8, Pm 135). See Page 2 of PSI 04/97-0755: Addressing Customer Complaints of Water Leaks (Section 8, p. 136).
  • Page 39 PSI 04/97 - 0753 lf side trim molding is distorted, or a customer complaint is registered regarding these moldings, change the left- and right-hand side trim moldings as needed, following the directions below. Parts: LH side trim molding 45 58 219 RH side trim molding 45 58 227 Figure 2.
  • Page 40 PSI 04/97 - 0753 Improving the operation of 2nd Bow. Also see Step C of Customer Satisfaction Campaign 420. Parts: Rubber plug (2) 46 96 175 3. Gluing rubber plug Figure 1. Glue the rubber plug, P/N 46 96 175, to the head of the pop rivet securing the second bow’s stop. See Fig- ure 3.C.
  • Page 41 Fit a protective plate by the 5th bow motor on the right hand side to eliminate the risk of the toothed segment damaging the wiring conriected to the 5th bow’s potentiometer. Parts: Protective plate 59 951 Loctite Thread-Locking Adhesive Screw (if necessary) 45 55 710 4.
  • Page 42 PSI 04/97 - 0753 Checking whether the cover on the front rail is secure Parts: Flat black paint Figure 5. Checking front rail cover Remove any loose front rail covers and touch up with flat black paint as needed. The Factory has deter- mined that these covers are not necessary.
  • Page 43 and creaking complaints. Lubricate once and let it dry. Lubricate a second time before eleasing vehicle to customer. ‘arts: 3634770: obtain from GM Dealer cars) Figure 6. Lubricating weatherseals Operate the top using the “ROOF” switch until it is halfway raised and the Tonneau cover is fully upright. The side windows should be raised and the door windows lowered.
  • Page 44 PSI 04/97-0753 Check the wiring connected to the 5th bow’s potentiometer to make certain it is not too taut or too slack. Adjust as necessary. Parts: Cable ties (as required) 79 71 880 (head of Alien bolt that holds the gear) a ’...
  • Page 45 Fit chafing guards wear on the top over the 5th bow’s latch fittings to minimize the risk of fabric when the top is down. Parts: LH Chafing Guard 45 59 431 RH Chafing Guard 45 59 456 Figure 8. Fitting Chafing Guards to 5th Bow Latch Operate the top using the “ROOF”...
  • Page 46 PSI 04/97- 0753 prevent false messages from appearing on SID, connector HIO-15 for the 5th bow mi- croswitch must be rewired. Parts: Female connecting sleeve 91 20 957 Male connecting pin 41 15077 Cable tie 79 71 880 Connecting pin removal tool 85 80 110* *Issued as M94 Essential tool.
  • Page 47 PSI 04/97-0753 Car’s rear wiring harness: Withdraw the green lead with female pin from position 3 in the male part of connector HlO-15. connector H10-15. the yellow/white lead with female pin from position 4 in the male part of strain on harness after Cut Off the pins from both leads and strip them (leave wire as long as possible to avoid repair).
  • Page 48 PSI 04/97 - 0753 16. Snip the cable tie holding the connector in position 17. Unplug the connector. See Figure 11 .C. 18. Remove and scrap the existing microswitch. 19. Cover open end of connector with a piece of tape to protect end of pins. 20.
  • Page 49 Check the lock washers located at the main potentiometer for brittleness. Parts: Lock washer (as necessary) 45 56 098 Figure 12. Checking lock washers Operate the top using the “ROOF” switch until it is in the position shown above. The top, 5th bow and Ton- neau cover should be fully raised.
  • Page 50 PSI 04/97-0753 See Service Manual 85 Cabriolet, page 215. Figure 13. Checking torque of cam bolt Tighten cam bolts to 23Nm. Page 14 of 24...
  • Page 51 PSI 04/97 - 0753 NOTE: On later cars the wiring has been routed behind the antenna bracket. Fit a chafing guard on the antenna bracket to reduce the risk of damage to the wiring. NOTE Subjects #14,15 and 16 should be done at the same time in the trunk. Parts: Chafing guard 82 78 558...
  • Page 52 PSI 04/97 - 0753 Press the chafing guard in place on the antenna bracket as shown in Figure 14.A above. Wrap duct tape around the tube of the antenna mast to prevent the trunk light from shorting against it. Do not refit the trim and scuff plate until repair steps 14,15 and 16 have been completed. Change the Tonneau cover potentiometer.
  • Page 53 PSI 04/97-0753 securing the luggage compartment trim on the RH side. luggage Detach the compartment weatherseal on the RH side and fold down the trim. Remove the right-hand rear light cluster. This will enable the Tonneau cover drive mechanism to be seen while in operation.
  • Page 54 13. Refit the luggage compartment weather-seal on the RH side. 14. Do not refit the trim and scuff plate until repair step 16 has been completed. Check with Tech 2 or ISAT for the version of the TSAS ECM. If it is a version lower than 0402, replace it.
  • Page 55 Remove the clip securing the luggage compartment weatherseal on the LH side. See Figure 18.B below. Detach the luggage compartment weatherseal on the LH side. See Figure 18.C below. Unplug the luggage compartment lighting connectors and fold down the trim. See Figure 18.D below. Unplug the three ECM connectors.
  • Page 56 Programming the SID: Connect page 72 of 1995900 Owner3 Manual or Page 7 in 1995 900 Convertible Owner’s Manual. Select PROGRAMMING in ISAT’s SAAB INFO DISPLAY menu. Proceed to the programming phase or end. Enter SID type -SID 2/3 .

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1995 900 convertible

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