brake SAAB 9-5 2003 Service Manual

199 Car care and technical information
Engine compartment, 4-cyl. engine
10
9
6
7
8
1
2
4
3
5
IB1773
Engine compartment, 4-cyl. engine 1 Engine-oil dipstick/filler cap
2 Reservoir, brake/clutch fluid
3 Fuse box
4 Expansion tank, coolant
5 Washer-fluid filler cap
6Battery
7 Dipstick, automatic transmission fluid
8 Turbo unit
9 Ignition discharge module
10 Reservoir, power-steering fluid
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200 Car care and technical informationEngine compartment, 6-cyl. (3.0t V6)
99
2
1
4
57
6
10
83
IB1774
Engine compartment, 6-cyl. (3.0t V6) 1 Engine-oil dipstick
2 Engine-oil filler cap
3 Reservoir, brake/clutch fluid
4 Fuse box
5 Expansion tank, coolant
6 Washer-fluid filler cap
7Battery
8 Dipstick, automatic transmission fluid
9 Ignition discharge module
10 Reservoir, power-steering fluid
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205 Car care and technical information
Transmission fluidManual transmission Check and top up the fluid in accordance
with the service program.
If original fluid cannot be obtained for top-
ping up (see page 264), automatic trans-
mission fluid Dexron III (synthetic oil) can be
used. If so, the car should be taken to an
authorized Saab dealer immediately to
have the reason for low fluid level corrected
and original fluid installed.Automatic transmission Check the fluid level as follows:
1 Stand the car on level ground and apply
the parking brake. The automatic trans-
mission fluid must be at normal running
temperature, approximately 175°F
(80°C). This can be achieved by driving
the car for about 30 min on the open
road.
2 With the engine idling, move the selector
lever to D and wait for at least
15 seconds. Next, move the selector
lever to R and wait for 15 seconds again.
Finally, move the selector lever to P. Let
the engine idle.
3 Wipe the dipstick clean with a lint-free
cloth and put it back.
4 With the fluid at normal temperature, the
level should be between the MAX and
MIN marks on the dipstick. Top up, as
necessary, with Saab 3309 automatic
transmission fluid (mineral oil-based),
adding it through the dipstick pipe. The distance between the MIN and MAX
marks on the dipstick corresponds to a
volume of approximately 0.4 qts
(0.4 liter).
If the outside temperature is below 50°F
(10°C), the fluid will not reach the specified
temperature of 175°F (80°C). In this case,
the correct fluid level may be 0.8 in (20 mm)
below the MAX mark.
WARNING
 Prolonged and repeated exposure of
the skin to engine oil can cause seri-
ous skin disorders.
 Avoid prolonged skin contact when-
ever possible. Wash the affected area
thoroughly with soap and water after
any contact.
 Keep oil out of reach of children.
 Do not touch the turbocharger or
manifold. These get very hot when the
engine has been running.
 Do not spill oil on hot parts of the
engine as this could cause a fire. Used
engine oil is particularly flammable.
 Protect the environment. Do not dis-
pose of oil in the ground or down a
drain. Dispose of all used oil and oil fil-
ters at an appropriate disposal facility.
NOTICEIf there is a smell of burning fluid or the
fluid is black, change the fluid.
IB1923
Dipstick for automatic-transmission fluid
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207 Car care and technical information
Brake and clutch fluid Checking the fluid level The combined brake and clutch-fluid reser-
voir is transparent to facilitate checking of
the fluid level.
The level should be between the MAX and
MIN marks. Top up, as necessary, with
DOT 4 fluid. Do
not
use DOT 5 brake fluid.
Use only new brake fluid from a sealed con-
tainer.
Check that there are no leaks in the brake
system.
The brake fluid level will fall somewhat as
the brake pads wear. The MAX level in the
reservoir corresponds to the amount of
brake fluid required with new brake pads. If
the fall in fluid level is moderate, due to
normal brake pad wear, topping up is not
necessary.
Changing of the brake fluid should be
carried out by an authorized Saab dealer.The vehicle´s regular braking system is
adjusted automatically, but the parking
brake has to be adjusted manually. This
work, involving adjustment of the parking
brake cables and brake pads, must only be
carried out by an authorized Saab dealer.
It is not possible to detect, through abnormal
pedal or parking brake-lever travel, whether
brake pads are worn and need replacing. It
is therefore essential that brake pads be
checked regularly, as specified in the ser-
vice program.
Brake pad wear indicators The outboard brake pads on the front
wheels incorporate pad-wear indicators.
When the lining is down to 0.11 in (3 mm),
the pad will produce a screeching, squeal-
ing or scraping noise when the brakes are
applied. New pads should be fitted without
delay.
Brake pads should only be changed by
an authorized Saab dealer. To ensure
optimum brake performance, use only
Saab original brake pads.
WARNING
Brake fluid deteriorates as it becomes
old. Because it is hygroscopic, it absorbs
water from the air and, in time, could allow
vapor to form in the brake system, thus
reducing its performance. It is therefore
important that brake fluid be changed reg-
ularly, as specified in the service pro-
gram.
NOTICEAvoid spilling brake fluid onto paintwork,
since it can cause the paint to bubble and
lift. If any brake fluid is spilled, the area
should be flushed with large quantities of
water as quickly as possible.
IB1188
Brake and clutch-fluid reservoir
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219 Car care and technical information
Rear light cluster, 9-5 SedanThe bulbs for the lamps in the rear light clus-
ter are accessed from the luggage compart-
ment.
1 Lower the flap (secured with catches).
2 Squeeze the two plastic lugs and
remove the bulb holder.
3 The bulb has a bayonet fitting. Press in
the bulb and twist it counterclockwise.
4 Change the bulb.
Trunk lid light and taillights,
9-5 SedanBefore changing bulbs in the trunk, you
must first release the trim at the foot of the
trunk. This involves removing the handle
and the three trim fasteners (studs).
1 Unscrew the handle on the inside of the
tailgate.
2 Using the peg in the top of the screw-
driver handle, push in the button in the
center of the studs.
3 Remove the studs.
Changing bulbs
1 Squeeze together the silver plastic lug
and the electrical connection and with-
draw the lamp holder.
IB1791
12
3
2
3
5
6
4
1
4
Rear light clusters 1 Direction indicators
2 Taillights
3 Stop lights and taillights
4 Reversing lights
5 Rear fog light
6 High-mounted brake light
IB516
IB1792
1
1
2
3
2
6
4
4
52
2
3
IB1877
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228 Car care and technical informationFuse panel in instrument panel
# Amp Function
A 30 Trailer lights
B 10 Automatic transmission
C 7,5 Electric door mirrors; DICE: manual beam length
adjustment
115Brake lights
2 15 Reversing lights
3 10 Parking lights, left
4 10 Parking lights, right
5 7,5 DICE / TWICE
6 30 Electric windows, right; trailer charging
6B 5 Brake lights, trailer
7 10 Engine injectors
8 15 Trunk lighting; trunk lock; door lighting, circulation
pump; parking assistant; SID
9 15 Audio System; CD changer
10 15 Heating, rear seat; sunroof
11 30 Electrically adjusted passenger seat
12 7,5 Automatic transmission
13 20 Audio System, amplifier
14 30 Ignition system, engine
15 20 Fuel pump
16 20 DICE (direction indicators)
16B – –
17 20 Engine-management system; main instrument;
DICE/TWICE
18 40 Door-mirror heating; rear-window heating
19 10 OnStar; Telematics
20 15 ACC; interior lighting; rear fog light; high beam flasher
21 10 Audio System; rear-view mirror; load angle sensor
(cars with xenon); navigation (accessory); Cruise
Control
22 40 Interior fan
23 15 Central locking; navigation (accessory); door mirror
memory
24 40 Air pump (3.0t V6 only)
25 30 Electrically adjustable driver’s seat; fuel-filler flap
26 7,5 Driver seat memory; mirrors memory; sunroof; park-
ing assistant; seatbelt reminder
IB2439
BC123456 A
14
121110987
13
6B
1516
2324
222120191817
16B25262728293031
3635343332
393837
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237 Car care and technical information
Changing a wheel
WARNING
 The car jack is designed solely for use
in changing a wheel or fitting snow
chains. It must not be used to sup-
port the car during repair work or
servicing.
Never crawl under a car that is
supported only by a jack.
 Special care must be taken if the car is
on a slope – use wheel chocks!
 Position chocks, one ahead and one
behind, the wheel that is diagonally
opposite to the one to be changed.
 Switch on the hazard warning lights if
the car is on a road.
 Apply the parking brake and leave the
car in gear (1st or reverse). Automatic
transmission: move selector to the
P position.
 Ensure that everybody is out of the car
before jacking it up.
 Never start the engine while the car is
jacked up.
 The jack must stand on a firm, level
surface.
 Stow the jack in the place provided for
it under the panel in the floor of the
trunk. Secure it properly to avoid injury
to passengers in the event of a crash.
 Do not use the jack for any purpose
other than for jacking up the car.
 Grit, salt and rust can clog the inner
threads of the wheel bolts if the car has
been driven for several years exclu-
sively with alloy wheels.
If steel wheels are now fitted, the bolt
hole threads in the brake hubs should
be cleaned before the thinner steel
wheels are fitted. It may otherwise not
be possible to achieve the required
clamping force despite tightening the
bolts to the correct torque.
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240 Car care and technical information1 Put the car in 1st gear (automatic trans-
mission: move selector to the P position)
and apply the parking brake.
2 Wind the jack up to a suitable height
before placing it under the recess in the
sill.
Make sure that the jack fully engages
the recess in the sill and that the base of
the jack is steady and flat on the ground.
3 Remove the wheel cover (where appli-
cable).
Loosen the wheel bolts by half a turn.
4 Wind the jack to raise the wheel clear of
the ground. Remove the wheel bolts and
lift off the wheel.
5 Clean any rust or dirt from the contact
surfaces between the wheel and brake disc. Do not wipe away the grease in the
hub.
6 Fit the wheel and screw in the bolts in the
sequence shown (opposite pairs).
Tighten the bolts enough for the bolts
and wheel to be seated correctly.
7 Lower the car and tighten the wheel
bolts to the correct torque in the
sequence shown (opposite pairs).
Tightening torqueLight-alloy wheels: 80 ft.lbs. (110 Nm)
Steel wheels: 80 ft.lbs. (110 Nm)
Do not overtighten the bolts using an
impact wrench: not only can this
damage the wheels but it can also make
it impossible to undo the bolts using the
wheel wrench in the car’s toolkit.
8 Check-tighten the wheel bolts after a
few miles.Tightening torqueLight-alloy wheels: 80 ft.lbs. (110 Nm)
Steel wheels: 80 ft.lbs. (110 Nm)NOTICE When refitting wheel covers (where
applicable), make sure that the valve
protrudes through the marked hole in
the wheel cover.
 Do not overtighten the bolts using an
impact wrench: not only can this
damage the wheels but it can also
make it impossible to undo the bolts
using the wheel wrench in the car’s
toolkit.
Clean any rust or dirt from the contact sur-
faces between the wheel and brake disc.
IB2428
Do not wipe away the grease in the hub.
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241 Car care and technical information
Flat spottingAll tires get hot, especially on long journeys
or when the car is driven hard. After the car
has been parked with hot tires and the tires
have cooled down, a flat spot can appear in
the tire, where it is in contact with the
ground. The same can occur if the car has
not been moved for a long time.
Flat spots can give rise to vibration that can
be felt through the steering wheel, similar to
that experienced when the wheels need bal-
ancing. Flat spots of this type disappear
once the tires get hot again, usually after
10–15 miles (20–25 km) of driving at cruis-
ing speed.
WARNING
Grit, salt and rust can clog the inner
threads if the car has been driven for sev-
eral years exclusively with alloy wheels.
If steel wheels are now fitted, the bolt hole
threads in the brake hubs should be
cleaned before the thinner steel wheels
are fitted. It may otherwise not be possi-
ble to achieve the required clamping force
despite tightening the bolts to the correct
torque.
IB539
Tightening sequence, wheel bolts
IB1800IB1800
Removing the wheel cover
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244 Car care and technical informationWashing the carThe bodywork must be washed frequently.
When the car is new, the body should be
washed by hand using plain cold water and
a clean, soft brush, or in a brushless car-
wash that uses mild detergent. Automatic
car washes with brushes should be avoided
when the car is new. Do not use automatic
car washes for the first five or six months,
before the paintwork has hardened prop-
erly. Thereafter, use a high quality car wash
soap added to lukewarm water.
Do not use a pressure washer at close
range on stone chip damage, scratches or
other damage to the paintwork. The paint
can otherwise start to flake.
Remove any bird droppings without delay,
as these can discolor the paintwork and
prove difficult to polish out.
Use a soft cloth moistened with methyl alco-
hol to remove splashes of tar or asphalt. Do
not use strong cleaners, as these can dry
out the paintwork.
The underside of the car also needs wash-
ing regularly, and this should be done extra
thoroughly at the end of winter. Clean the
underside of the car by hand if the car is usu-
ally washed in an automatic car wash with-
out special facilities for underbody cleaning.
Never wash or leave the car to dry in the
sun, but wipe it dry with a chamois leather
immediately after washing to avoid smears
and streaks.
Clean the window glass inside and out using
a high quality window cleaner. This is partic-
ularly important when the car is new, as
upholstery and trim have a tendency to
sweat a little at first.
Keep the glass well cleaned, as this helps to
prevent misting.

NOTICEAvoid using any alcohol-based cleaners
on the front and rear light clusters, as
these can cause cracking of the lenses.
NOTICE The door mirrors must be fully
retracted before the car enters an
automatic car wash.
 Remove fixed antennas, e.g. for
mobile phone, before putting car
through an automatic car wash.
 Try your brakes on leaving a car wash.
Wet brake discs may reduce the per-
formance of the brakes.
 Cars with Saab Parking Assistance:
Do not spray the sensors or closer
than 20 cm to the sensors with a pres-
sure washer, as this can damage
them.
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