brake SAAB 9-5 2004 Service Manual

201 Car care and technical information
Engine compartment
10
9
6
7
8
1
2
4
3
5
IB1773
Engine compartment1 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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206 Car care and technical informationTransmission 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 276), 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.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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208 Car care and technical informationBrake 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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220 Car care and technical informationRear 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
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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229 Car care and technical information
Fuse 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 7.5 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, remote control receiver
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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238 Car care and technical informationWheel Alignment and Tire Balance
The wheels on your vehicle were aligned
and balanced carefully at the factory to give
you the longest tire life and best overall per-
formance.
Scheduled wheel alignment and wheel bal-
ancing are not needed. However, if you
notice unusual tire wear or your vehicle pull-
ing one way or the other, the alignment may
need to be reset. If you notice your vehicle
vibrating when driving on a smooth road,
your wheels may need to be rebalanced.
Wheel Replacement
Replace any wheel that is bent, cracked or
badly rusted or corroded. If wheel nuts keep
coming loose, the wheel, wheel bolts and
wheel nuts should be replaced. If the wheel
leaks air, replace it (except some aluminum
wheels, which can sometimes be repaired).
See your dealer if any of these conditions
exist.
Your dealer will know the kind of wheel you
need.
Each new wheel should have the same
load-carrying capacity, diameter, width,
offset and be mounted the same way as the
one it replaces.
If you need to replace any of your wheels,
wheel bolts or wheel nuts, replace them only
with new Saab original equipment parts.
This way, you will be sure to have the right
wheel, wheel bolts and wheel nuts for your
vehicle.
Notice:
The wrong wheel can also cause
problems with bearing life, brake cool-
ing, speedometer or odometer calibra-
tion, headlamp aim, bumper height, vehi-
cle ground clearance and tire or tire
chain clearance to the body and chassis.
See “Changing a wheel” on page 247.Used Replacement Wheels
WARNING
Using the wrong replacement wheels,
wheel bolts or wheel nuts on your vehicle
can be dangerous. It could affect the
braking and handling of your vehicle,
make your tires lose air and make you
lose control. You could have a collision in
which you or others could be injured.
Always use the correct wheel, wheel bolts
and wheel nuts for replacement.
WARNING
When fitting just one new pair of tires,
these should be fitted to the rear wheels,
as these are more critical to the direc-
tional stability of the car (e.g. on braking
or in a skid). The existing rear wheels
should therefore be moved to the front.
WARNING
Putting a used wheel on your vehicle is
dangerous. You can’t know how it’s been
used or how far it’s been driven. It could
fail suddenly and cause a crash. If you
have to replace a wheel, use a new GM
original equipment wheel.
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239 Car care and technical information
Tire Chains
Notice:
If your vehicle does not have
P225/45R17 size tires, use tire chains
only where legal and only when you
must. Use only SAE Class ²S² type
chains that are the proper size for your
tires. Install them on the front tires and
tighten them as tightly as possible with
the ends securely fastened. Drive slowly
and follow the chain manufacturer’s
instructions. If you can hear the chains
contacting your vehicle, stop and
retighten them. If the contact continues,
slow down until it stops. Driving too fast
or spinning the wheels with chains on
will damage your vehicle.If a Tire Goes Flat
It’s unusual for a tire to “blowout” while
you’re driving, especially if you maintain
your tires properly. If air goes out of a tire,
it’s much more likely to leak out slowly. But
if you should ever have a “blowout”, here are
a few tips about what to expect and what to
do:
If a front tire fails, the flat tire will create a
drag that pulls the vehicle toward that side.
Take your foot off the accelerator pedal and
grip the steering wheel firmly. Steer to main-
tain lane position, and then gently brake to
a stop well out of the traffic lane.
A rear blowout, particularly on a curve, acts
much like a skid and may require the same
correction you’d use in a skid. In any rear
blowout, remove your foot from the acceler-
ator pedal. Get the vehicle under control by
steering the way you want the vehicle to go.
It may be very bumpy and noisy, but you can
still steer. Gently brake to a stop – well off
the road if possible.
If a tire goes flat, the next part shows how to
use your jacking equipment to change a flat
tire safely.
WARNING
If your vehicle has P225/45 R17 size tires,
don’t use tire chains, there’s not enough
clearance.
Tire chains used on a vehicle without the
proper amount of clearance can cause
damage to the brakes, suspension or
other vehicle parts. The area damaged by
the tire chains could cause you to lose
control of your vehicle and you or others
may be injured in a crash.
Use another type of traction device only if
its manufacturer recommends it for use
on your vehicle and tire size combination
and road conditions. Follow that manu-
facturer’s instructions. To help avoid
damage to your vehicle, drive slowly,
readjust or remove the device if it’s con-
tacting your vehicle, and don’t spin your
wheels.
If you do find traction devices that will fit,
install them on the front tires.
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242 Car care and technical informationLoading Your VehicleThis is an example of what your vehicle´s
Tire-Loading Information/Certification label
might look like. It is located on the B-pillar
and shows how much weight your vehicle
may properly carry. The label tells you the
proper size, and recommended inflation
pressures for the tires on your vehicle. It
also gives you important information about
the number of people that can be in your
vehicle and the total weight that you can
carry. This weight is called the Vehicle
Capacity Weight, and includes the weight of
all occupants, cargo and all nonfac-
tory-installed options.
Tire Terminology and DefinitionsAir Pressure: The amount of air inside the
tire pressing outward on each square inch of
the tire. Air pressure is expressed in pounds
per square inch (psi) or kilopascal (kPa).
Accessory Weight: This means the com-
bined weight of optional accessories, for
example, automatic transmission, power
steering, power brakes, power windows,
power seats, radio and air conditioning.
Aspect Ratio: The relationship of a tire´s
height to its width.
Belt: A rubber coated layer of cords that is
located between the plies and the tread.
Cords may be made from steel or other rein-
forcecing materials.
Bias Ply Tire: A pneumatic tire in which the
ply cords that extend to the beads are laid at
alternate angles substantially less than 90
degrees to the centerline of the tread.
Cold Inflation Pressure: The amount of air
pressure in a tire, measured in pounds per
square inch (psi) or kilopascal (kPa), before
a tire have built up heat from driving. See
“Inflation - Tire Pressure” on page 233.
Curb weight: This means the weight of a
motor vehicle with standard and optional
equipment including the maximum capacity
of fuel, oil and coolant, without passengers
and cargo.DOT Markings: A code molded into the
sidewall of a tire signifying that the tire is in
compliance with the U.S. Department of
Transportation motor vehicle safety stan-
dards. The DOT code includes the Tire
Identification Number (TIN), an alphanu-
meric designator which can also indentify
the tire manufacturer, production plant,
brand and date of production.
GVWR: Gross Vehicle Weight Rating see
“Loading Your Vehicle” on page 242.
GAWR FRT: Gross Axle Weight Rating for
the front axle, see “Loading Your Vehicle”
on page 242.
GAWR RR: Gross Axle Weight Rating for
the rear axle, see “Loading Your Vehicle” on
page 242.
Intended Outboard Sidewall: The side of
an asymmetrical tire that must always face
outward when mounted on a vehicle.
Kilopascal (kPa): The metric unit for air
pressure. There are 6.9 kPa to one psi.
Light Truck (LT-Metric) Tire: A tire used
on light duty trucks and some multipurpose
passenger vehicles.
Load Index: An assigned number ranging
from 1 to 279 that corresponds to the load
carrying capacity of a tire.
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247 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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250 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 torque
Light-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 torque
Light-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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