SAAB 900 1986 Repair Manual

Downloaded from www.Manualslib.com manuals search engine Top assembly 812-37
7 Rsmove the pin{eraininq ctip (sph pin)
trom the piston rod on €iher side. Nole
lhe positions ol the washers and spacers
and wilhdraq the clsvice pin on eifier
close lhe bypass valve. switch on h€
,gnition and. by means ot lh. switch tor
the lop, lully .etract th€ pislons. switch ofi
undo Lhe s€cu.i.o bolrs lor the setoo
Laft lhe setuo pump oil ils sealing andplug lhe co.. nectors lroh the relays.

Downloaded from www.Manualslib.com manuals search engine 812-38 Top assembly
11 label lhe conneclors and disconnecl lhe
l€ads lrom lhe pump
12 Bemove lhe mosture batrior on eilher
lhrough the apenures in
I3
Pass lhe cylinder on the FH side undeF
neah the tuellines and handbrako cable
Lill out rh€ hydraulic syslefr complet€.
Label rhe braclel lor each cyrrnder (lgrrl
I lefi) and pulrhem ro ono 3ide

Downloaded from www.Manualslib.com manuals search engine Top assembly 812-39
To tlt
1 Bleed the hydrautic system lo expsl a0 ai.(eee Page 312-44) This must be done
belore ft6 system is insta0ed in the car
Ensure lhalhe p'stons.re ru y relacled.
Pass lhe RH s€rvo cylinder and bypassvarve und6r lhe handbrake cabte and tuel
Plug in lhe pump connectors, noling lhemaikrngs to ensure that lhe ioht conneclors are plugged togelher

Downloaded from www.Manualslib.com manuals search engine 812-40 Top assembly
Pluo the connectors onto rhe reays Pass
lhe pump undernealh lhe handbrake cab e
and press lhe rubbe. bushes on lrre puhp
Mount the brackel tor the BH cy 'nder onlo
the cyinder. ensu.ing lhal lhe hose con.
nedions are Iowafds the rea. ol the car
Pass lhe cyinder through lhe apenu.e n
Pul lhe cvlinder 'nto posrtron and tghren
lh€ se.urin9 bolrs g.ininq a(cess rhrodoh
lhe apedure in lhe panel
\
0p

Downloaded from www.Manualslib.com manuals search engine Top asssmbly 812-41
Mount lhe bracket on the oher cylinder,
agaln €nsuing lhat lhe hose oonnections
are towards the rea. ot lhe car
Pass the cylinde. lhrough lhe rear aper
Note lhat lhe hydraulc hos€s should nol
90 lndernealh lhe handbrake cable.
Put the cylinder inlo posilion and righbn
lhe secu nq bolls, gaininq access lhrolgh
$e apenure in the panel.
1o
12 Pul back fte moislure bariers on €ilhef
13Pass lhe bypass valve throuqh lhe ape.
lu.e in lhe rear sido panel and secure il in
Secure the hydraulc hoses in lheirclips.
15 Release lhe lalchng handles lor lhe lop,
lo tacililate adiushent ol lhe seruo cyin.

Downloaded from www.Manualslib.com manuals search engine 812-42 Top assembly
16 operale lhe pump lo bring lhe pistons into
$e lully e{ended position.
Aeconnect $6 rods by insarlng the
crev'ce pin and securinq wilh lhe spll prn
worh on one piston al a ime
17 Felil lhe side tim (s€6 page 351,2).
13 Fi he backest (soe page 3s2.2)
1S Fn lhe sear cushion (see page 3s2.1).
20 close lhe ratching handtes ror thebp
Servo pump
Rehovelhe hydraulic systBm kom lhe car
Labd ba hose conn€clions to indicab
which is towards th€ lront and which is
lowards lhe r€ar, and remove he pump.
To ilt
Reconnect the hoses lo ben respectve
litlings on the new pump
5.1 - 6.2 Nm (3,3- 4,5lbl fr)
F€inslall ihe hydraulic system in rhe car
Hydraulic hoses
1 Renove the hydraulic syslem lrom Ihe car
Nole and mark $e position ot the hoses
and lhen dlsconnecl lhem ifom the cytm

Downloaded from www.Manualslib.com manuals search engine Top assembty 8i2-43
T
When faplacing the AH set ot hoses the
bypass valve must be rranstefted trom lhe
To ll
1 Bsconnecr |he hoses to lheir respec ve
lnings on the pump and cyt]nder
5-1 .6,2 Nm (3.8- 4.s lbt tt)
Reinslall the hydraurc syslem in the car
Servo cylinders
1 Remove the hydraoic sysrem trom the car
2 Disconnect the cyinder trom lhe hoses.
1 Roconnecl fte hoses lo rhe cytnder. Theliohler cololred hose shoutd be connecr
ed lo the titting nearerlhe pisron rod
5,1 - 6.2 Nm (3.3 - 4.5 brn)
2 Reinstatl lhe hydrauic syslem in the car
Eypass valve
I
Remove the hydraur,c system tron the car
Femove lhe bypass vatve
fit
Fil lhe new bypass varve
s.1 - 6.2 Nm (3,3 - 4.5 bt n)
Feinslall the hydrautrc syslem in th6 car

Downloaded from www.Manualslib.com manuals search engine 812-44 Top assombly
Bleeding tho hydreullc ayatem
To .void possible danage lo painMoA o.
lpholslory. [|. hydraulic sysiem musr be br6d
Removo lh€ hydrauhc ayslem lrom the car
Prac6 $€ pump on lh. rcrkbench.nd lho
.yllnders inslde a kay on $e lloor.
Filllhelluid resetooir,l€aving lhe pluq oll.
us€ sp€ciar hydrauric fiuid. pan no. (45)
3014694.
Olsconnect one ol the hoses lrofr on6 ol
lh€ cylinders. Allow lhe fluid lo,un out unil
lhe hose is lull. Aecon.ecl the hose io hs
F€p€al th€ pr@€dlre lot lhe oth€r hoses,
lopping up lhe.eseNon as necessary.
I

Downloaded from www.Manualslib.com manuals search engine Top assembly 812-45
3
I
Conneot a power suppry to the pump and
run to bing lhe pislons lo lh€k end ot
Keep lhe .eseryoir topped up with ttuid lo
ensure thal lhe lluid never r6.ches the
Fun lhe pistons to lhe opposinq end ol
Fepeatlhe procedure untilthe sysl6h has
a smarr amoud ol an in the system wil
nol afiecl operalion oilhe lop.
Checklhe levelin rho r.setuoirand top up
as necessary Fil the plug.
Retorque all hose iininqs lhat have been
3,3 - 4.5 Nm (5.1 .5,2 |bl n)
Wipe clean the hoses and hose fininOs.
Operata $e pislons a number ol limes
and check thalfiere are no leaks

Downloaded from www.Manualslib.com manuals search engine 812-46 Top assembly
13 R6lum the pislons to the lutty ret.aeted
14 Reinslall lhe hydraulic syslem in the car
Measurlng tho hydraullc pressure
Hydraulrc lluid mlst nol be allowod lo come
with upholslery or painlvork.
Release lha handbrake (to pul slack in lhe
cable over lhe setoo pump).
Femove lhe rcaFseat cushion (see page
852-1).
check the level ot hyd.aullc tluld in the
sysl€m and top up as necessary.
Check to see whethe. lhere is an
€xcessive amounl ol air in the system It
so. lhe syslem musl be bled belore the
pressure can he freasured (see paqe