gearbox SAAB 9-3 2002 Owners Manual

6Engine bayWarning labels ___________ 7
V.I.N. number __________ 243
Engine number _________ 243
Gearbox number ________ 243
Color coding ___________ 243Ignition system _________ 240
Drive belt ______________ 197
Alternator _____________ 197
Spark plugs ____________ 240
Catalytic converter ______ 150
Simple fault tracing
(A/C, ACC) ____________ 226Turbo-compressor ________ 67
Pressure gauge __________ 67
Important considerations
for driving _____________ 148
Technical data: engine ___ 237Manual transmission __________ 191
Automatic transmission ________ 191
Transmission oil ______________ 191
Gearbox: technical data ________ 240
Battery _____________________ 195
Battery charge _______________ 195
Jump starting ________________ 181IB1624
Engine: description ____________ 188
Engine oil, level control
and topping up _______________ 190
Engine oil: changing ___________ 190
Oil grade_____________________ 237
Washer fluid ___________ 199
Topping up with fluid _____ 199
Washer jets ___________ 199
Wiper/washer control stalk _ 78
Steering servo _______________ 195
Fluid checking
and topping up ______________ 195
Coolant, checking
and topping up ________ 192
Coolant _______________ 192
Temperature gauge ______ 67
Driving in hot weather ____ 173
Driving in cold weather ___ 171Fuse panels ___________ 206
Changing a fuse ________ 206
Table of fuses __________ 208
Relays _______________ 210
Brake system ________________ 241
Brake fluid __________________ 194
Brake pads __________________ 194
ABS brakes _________________ 164
ProCarManuals.com

146 Starting and drivingIgnition switchThe single lock used for both the ignition
and gear/selector lever is in the center con-
sole located between the front seats. Before
you can remove the key, the car must be in
reverse gear (manual gearbox cars) or the
Parking (P) position (cars with automatic
transmission).
The key for this lock also fits all other locks
in the car. The key number is on a small
plastic tag delivered together with the keys.
Be sure to save this plastic tab since it has
the key number on it.
IB862
LOCK position
Put the gear lever in reverse and turn the ignition key to the LOCK posi-
tion.
For cars with automatic transmission, select the Parking (P) position
and turn the ignition key to the LOCK position.
The gear lever is now locked. The key can only be removed when the
gear lever is in this position.
The parking lights, the hazard warning lights and the interior lighting can
still be illuminated.
OFF position
Gear lever is not locked (manual transmission).
Automatic transmission: gear lever is locked until brake pedal is
depressed.
ON position
The entire electrical system is operative. Do not leave the key in the
ON position while the engine is not running. Turn the key to the
LOCK position to disconnect the electrical system.
When you turn the key to the ON position, the warnings and indicators
in the main instrument light so that you can check to see that they are
functioning properly. They are extinguished after approx. 3 seconds.
Start position (ST)
The starter motor operates in this position. When you release the key,
it springs back to the ON position. Restarting the starter motor is pre-
vented. If starting is unsuccessful, you must turn the key back to a posi-
tion between OFF and LOCK before you can turn it to the start (ST)
position again.
ProCarManuals.com

148 Starting and drivingStarting the engine The engine has an automatic choke and
should be started as follows:
Cars with manual gearbox
To start the engine the clutch pedal must
be fully depressed.
1 Depress the clutch pedal but do not
touch the accelerator.
2 Start the engine. Let the ignition key
spring back as soon as the engine has
started and is running smoothly – at very
low temperatures, you may need to run
the starter for up to 50 seconds.
Let the engine idle for about 10 seconds. Do
not open the throttle wide for at least
2-3 minutes after starting.
Cars with automatic transmission
The selector lever must be in the P or N
position.
1 Keep your foot on the brake pedal.
2 Start the engine. Let the ignition key
spring back as soon as the engine has
started and is running smoothly – at very
low temperatures, you may need to run
the starter for up to 50 seconds.
Let the engine idle for about 10 seconds. Do
not open the throttle wide for at least
2–3 minutes after starting.
Useful tips on cold climate startingIf the engine has failed to start after several
attempts in very cold weather, press and
hold the accelerator down to the floor and
run the starter for 5–10 seconds. This will
prevent the engine being flooded (exces-
sively rich fuel-air mixture).
Now start the engine in the normal way – do
not touch the accelerator.
If the engine stalls immediately after starting
(e.g. if the clutch was released too quickly),
do not touch the accelerator when restarting
the engine.
Every time the engine is switched off the
spark plugs are automatically cleaned. If
your attempt to start nevertheless fails, let
go of the ignition key and allow it to spring
back. This initiates more vigorous cleaning
of the sparking plugs which goes on for
about 5 seconds. Then start in the ordinary
way. Do not touch the accelerator; if the
accelerator is pressed to the floor the fuel
supply is shut off.
Important
considerations for
drivingThe engine-management system in the
Saab 9-3 is called Saab Trionic T7. The
system manages the ignition, fuel injection
and turbo boost pressure.
The Trionic T7 system developed by Saab
is an intelligent engine-management
system designed to achieve optimum drive-
ability under differing driving conditions.
The system makes adjustments automati-
cally, for instance, if the car is being driven
at altitude (oxygen-deficient air), for differ-
ent grades of fuel (AON 87–93) and for dif-
ferent load conditions.
1 Starting and driving
 Refrain from using full throttle before
the engine has warmed up (before
needle is in the mid-range on tempera-
ture gauge) to avoid unnecessary
wear. If the needle of the pressure
gauge repeatedly enters the red zone
the engine may suddenly lose power,
owing to the intervention of a monitor-
ing system which curtails the charging
pressure. Get in touch with an autho-
rized Saab dealer at once.
 A safety function prevents the engine
from reving faster than 6,200 rpm by
temporarily shutting of the fuel injec-
tors.
ProCarManuals.com

150 Starting and driving
Important considerations with cata-
lytic convertersThe catalytic converter is an emission-con-
trol device incorporated in the car’s exhaust
system. It consists of a metal canister with a
honeycomb insert, the cells of which have
walls coated in a catalytic layer (mixture of
precious metals).
To ensure that the catalytic converter con-
tinues to function properly, and also to avoid
damage to the converter and its associated
components, the following points must be
observed:
 Have the car serviced regularly in accor-
dance with the service program. The fuel
and ignition systems are particularly
important in this context.
 Always be alert to any misfiring of the
engine (not running on all cylinders) and
any loss of power or performance. At the
first sign of a malfunction, reduce speed
and take the car to an authorized Saab
dealer as soon as possible. If the engine fails to start (in very cold
weather or if the battery is dead), the car
can be push started (manual gearbox
only) or started using jumper cables to a
donor battery. However, as soon as you
have started the engine, it is important
that it runs on all cylinders. If it is misfiring,
allow it to idle for up to five minutes to give
it time to settle and run smoothly. If, after
this time, the engine still fails to run prop-
erly, turn off the engine and get in touch
with an authorized Saab dealer for
advice.
NOTEIf the CHECK ENGINE warning light
starts to flash, ease off the accelerator
slightly. If the light does not cease to flash
within 5 seconds, stop the car in a suita-
ble place as soon as possible and turn off
the engine. The car must be towed to an
authorized Saab dealer.
If the CHECK ENGINE warning light
flashes, it indicates that the engine is
misfiring which can result in damage to
the catalytic converter.
NOTEUse only unleaded gasoline. Leaded gas-
oline is detrimental to the catalyst and
oxygen sensor and will seriously impair
the function of the catalytic converter.
IB1315
Engine-management system with catalytic
converter 1 Engine control module
2 Oxygen sensor (lambda probe)
3 Catalytic converter
ProCarManuals.com

155 Starting and driving
Engine Break-in PeriodPistons, cylinder bores and bearings need
time to obtain uniform, wear-resistant sur-
faces.
If a new engine is driven too hard, this grad-
ual process of bedding-in will not be possi-
ble and the life of the engine will be short-
ened.
During the first 1,200 miles (2,000 km), do
not exceed 5,000 rpm.
In addition, refrain from driving the car at full
throttle, other than for brief instances,
during the first 1,800 miles (3,000 km).Wearing in new brake padsNew brake pads take time to bed in, about
90 miles (150 km) if the car is driven largely
under stop-and-go conditions or about
300 miles (500 km) of highway driving.
To extend the useful life of the pads, avoid
hard braking as much as possible.
Manual transmissionTo start the engine the clutch pedal must
be fully depressed.
The gear positions are marked on the gear
lever. Before reverse (R) can be engaged,
you must lift the ring underneath the
gear-lever knob.
To change gear, fully depress the clutch
pedal and then release it smoothly. It is
inadvisable to drive with your hand resting
on the gear lever, as this can increase the
wear on the gearbox.
When shifting down from 5th to 4th gear,
ease the gear lever straight back, without
applying any lateral pressure. This will pre-
vent 2nd gear being engaged by mistake,
which can result in overreving and possible
damage to the engine.
Shift-up indicator for improved fuel
economy
(U.S. models only except Viggen)Cars equipped with a manual transmission
have a "Shift-up" light on the instrument
panel. The light begins to work after the
vehicle is warmed up and provides you with
a good indication when to shift to a higher
gear.
It is not necessary or recommended to
follow the shift-up recommendations in all
driving conditions, for example, when driv-
ing in heavy urban traffic or steep downhill
grades.
However, shifting with the light should result
in improved fuel economy. Therefore, for
reduced fuel consumption and better
energy conservation, you should make a
habit of shifting before or when the shift-up
light comes on.
NOTEWhen the reverse gear is to be engaged
the car must be at a standstill with the
accelerator fully released. Lift the reverse
lock-out collar and push the gear lever
firmly to the right in neutral before easing
it into reverse.
IB864
ProCarManuals.com

172 Starting and driving Check the anti-freeze in the engine cool-
ant, see page 192.
The car´s trip computer will warn you when
there is a risk of slippery conditions. For fur-
ther information on this function, see page
69.
The car is equipped with tires designed to
provide optimum grip on both wet and dry
roads, although this has been achieved at
the expense of somewhat reduced grip on
snow and ice. For regular driving on snow
and ice, we therefore recommend that
winter (snow) tires be fitted.
Winter (snow) tires, particularly studded
tires (where use is legally permitted), gener-
ally make driving safer on snow and ice. Acquaint yourself with the legal provi-
sions governing the use of different
types of winter tires and snow chains.
Studded tires are not allowed in some
countries.
If winter tires are installed, the same type
must be installed on all wheels. Your Saab
dealer will be pleased to advise you on the
best tires for your car.
Remember that tires age. It may therefore
be necessary to change them before they
reach the legal wear limit, as they gradually
lose their friction properties. Date code, see
page 214.
The best response if the car gets into a
front-wheel skid is to freewheel (manual
gearbox only), i.e. disengage the clutch (so
that the wheels are neither driven nor
braked by the engine) and carefully steer
the wheels in the direction you want to go.
If the car has an automatic transmission you
should lift off the accelerator somewhat and
carefully steer the wheels in the direction
you want to go.
In a rear-wheel skid, steer into the skid, i.e.
in the same direction as that in which the
back is sliding.
Tire chainsIf you want to fit tire chains (where legally
permitted) they should only be installed to
the tires recommended under ”Technical
data” (see page 242).
Consult your Saab dealer for details about
approved tire chains.
WARNING
 Do not exceed 30 mph (50 km/h)
when tire chains are fitted.
 Tire chains can reduce the directional
stability of the car.
 Tire chains must not be used on the
rear wheels.NOTE Check the links frequently for wear.
 Check that the chains do not contact
the wheel-arch liner at full lock.
 See section "Technical data", page
242, for information on allowable
wheel dimensions for the fitting of tire
chains.
ProCarManuals.com

180 Starting and driving
Saab 9-3 ViggenThe front towing eye is stored in a storage
bag beside the spare wheel. Remove the
plastic cover with a screwdriver from the
car’s toolkit, and screw in the towing eye.
Towing a car with manual gearboxThe gear lever must be in neutral. Switch
hazard lights on.
Drive carefully and do not exceed the
speed limit for vehicles in tow.
Always try to keep the towrope taut by
gently applying the brake as necessary.
This will avoid the towrope being jerked vio-
lently.
NOTEThe design of the underside of the rear
bumper means that the rear towing eye
must not be used. This is to prevent dam-
aging the bumper.
NOTEIf the car is to be towed with the front
wheels off the ground, make sure the
parking brake is off, as this acts on the
rear wheels.
IB885
Rear towing eye
IB1331
Front towing eye, Saab 9-3 Viggen
ProCarManuals.com

184 Starting and drivingDriving considerations
with compact spare
wheel/tire fitted The following should be observed when the
compact spare wheel (T115/70 R16) is
installed:
The compact spare is light and easy to
handle when changing the wheel. Do not
drive farther than necessary with the com-
pact spare fitted – the maximum life of the
wheel is only just over 2000 miles
(3,500 km). Have the standard wheel
repaired and reinstalled as soon as possi-
ble.Points to bear in mind when driving with a
compact spare wheel:
 The car’s ground clearance is reduced
with the compact spare fitted.
 Only one compact spare wheel may be
used at any time.
 Take care not to hit the curb.
 Do not fit snow chains.
 Leave the wheel cover off, so that the
warning text is readily visible.
For long tripsBefore starting off on a long journey, it is
advisable to have your car inspected by
your Saab dealer.
Obtain a few important items to take along
on your journey such as spare bulbs, wiper
blades, fuses, a Poly-V belt and the like.
You can check some points yourself before-
hand:
 Make sure that the engine is in good con-
dition.
 Check that no oil or fuel leaks out of the
engine or gearbox/transmission.
 Check the coolant and power steering
fluid levels. Check also for leaks.
 Inspect the Poly-V belt and replace it if it
shows any signs of wear.
 Check the battery charge.
 Check the tires for tread pattern and air
pressure, including the compact spare
wheel.
 Take an extra car key/remote control and
keep it separate, see also page 36.
 Check the brakes.
 Check all bulbs.
 Check for the presence of the tool kit and
the jack in the car.
WARNING
Do not exceed 50 mph (80 km/h) as the
tire can overheat and adversely affect the
handling of the car.
The tire should be inflated to 60 psi
(420 kPa).
NOTETo avoid damaging a punctured alloy
wheel this can be placed outside up in the
spare-wheel well but only while driving to
the closest dealer.
A general rule is that all heavy loads must
be well secured in the luggage compart-
ment, see page 142.
ProCarManuals.com

188 Car careEngineThe engine is a transverse four-cylinder
in-line engine with twin overhead camshafts
and 16 valves.
The engine is equipped with two balance
shafts that reduce engine vibration to a min-
mimum.
The balance shafts are chain-driven and
rotate at twice the speed of the crankshaft.
They produce forces and torques that are
opposed to those generated by the pistons
and connecting rods. The effect occurs
twice in each revolution of the engine, coun-
teracting the vibration from its moving parts,
and at the same time reducing unwanted
engine noise.
The gearbox, located on the right (viewed
from the front), is integrated with the engine.
Engine familiesSaab cars imported into the United States
and Canada meet all applicable emission
control standards. The engine family and
appropriate tune-up specifications are iden-
tified on a label affixed to the left front inner
fender.
These engine families meet applicable EPA
Federal Standards, California State Stan-
dards and Canadian Federal Standards and
are equipped with the following systems:
• Sequential multiport fuel injection system.
 Three way catalytic converter.
 Crankcase emissions control system.
 Evaporative emission system.
Emission control
systemsThe systems for controlling emissions to the
atmosphere require regular checking and
adjustment at the intervals specified in the
service program.
In addition to meeting the exhaust emission
regulations and thereby helping to keep the
environment clean, a correctly tuned engine
will also give maximum fuel economy.
ProCarManuals.com

240 Technical dataElectrical system
Drive belts

Manual transmission
Automatic transmission
Voltage ___________________________ 12 V
Battery capacity ____________________ 60 Ah
Starter motor ______________________ 1.4 kW
Alternator rating ____________________ 130 A/14 V
Firing order ________________________ 1-3-4-2
Spark plugs:
2.0 Turbo 185 bhp__________________ NGK PFR 6H-10
2.0 Turbo 205 bhp __________________ NGK PFR 6H-10
Viggen __________________________ NGK PFR 6H-10
Electrode gap ______________________ 0.95 mm
(0.03740”)
Outside lengthCars with A/C compressor ____________ 2345 mm
Cars without A/C compressor __________ 1805 mmDrive belt
IB929
Type _____________________________ 5-speed, fully
synchronized with
final-drive gear and
differential
Oil type (for topping-up) ______________ Saab synthetic man-
ual gearbox oil
Oil capacity _______________________ 1.8 qts. (1.8 l)
Speed (mph/km/h) at 1000 rpm in 5th gear 26/42
Type _____________________________ Electronically con-
trolled 4-speed with
torque converter
and differential
Gear selector positions ______________ P R N D 3 2 1
Oil quantity, total ___________________ 7.4 qts. (7.2 litres)
Oil volume (on changing) _____________ 3.4 qts. (3.25 litres)
Oil type ___________________________ Texaco Texamatic
Dextron III, mineral
oil based
Clutch type ________________________ Hydraulically-oper-
ated plate clutches,
brake bands and
one-way clutches
Speed (mph/km/h) at 1000 rpm in 4th gear 25/40
ProCarManuals.com