Home Saab Repair Saab 900 16V 85-93 Part#0216861

Saab 900 16 Valve Official Service Manual: 1985-1993

Saab repair manual index:

A B C D E F G H I J K L M N O P Q R S T U V W X Y Z

Subjects are indexed by repair group number, followed by the page number(s) within the repair group where the subject can be found. For example 210-4 refers to repair group 210 Engine Disassembly and Assembly, page 4.

WARNING ?

  • Automotive service and repair is serious business. You must be alert, use common sense, and exercise good judgement to prevent personal injury and complete the work safely.
  • Before beginning any work on your vehicle, thoroughly read the safety notice, disclaimer, and all the Cautions and Warnings listed near the front of this manual.
  • Always read the complete procedure before you begin the work. Pay special attention to any Cautions and Warnings that accompany that procedure, or other information on a specific topic.

    A

    ABS unit
    installing 521-5
    removing 521-3
    wiring diagrams 371-8

    Accelerator and throttle linkage, lubricating 110-13

    A/C compressor
    See also Air conditioning
    testing 854-10

    AIC system
    See Automatic Idle Control (AIC) system

    AIC valve
    adjusting/removing 240-24

    Advice for the beginner 100-10
    bolt torque 100-10
    cleaning 100-11
    cleanliness 100-10
    general information 100-12
    getting started 100-8

    Air bag system
    See Supplemental Restraint System (SRS)

    Air conditioning (A/C) 854-7
    component replacement 854-9
    discharging and recharging 854-7
    electrical tests 854-9
    general 854-1
    safety switches, testing 854-11
    system description 854-7
    technical data 028-1
    troubleshooting 854-2
    wiring diagrams 371-13

    Air distribution control switch 854-5

    Air filter element replacing 110-12

    Air mass meter 240-13
    removing 240-22
    testing 240-14

    Alignment
    See Front wheel alignment

    Alternator
    brushes, replacing 321-3
    removing 321-2
    testing 321-1

    Alternator and charging system
    wiring diagrams 371-19

    Antenna, electric 851-4
    replacing/testing 851-4

    Antifreeze
    See Coolant

    Anti-lock braking system (ABS) 500-2
    See also ABS

    ABS wheel speed sensor
    replacing 500-3
    warning indicator 100-20

    Anti-roll bar
    See Rear Suspension

    Automatic Performance Control (APC)
    See Turbocharger

    ATF
    See Automatic transmission fluid

    Automatic Idle Control (AIC) system
    testing 240-17
    wiring diagrams 371-23

    Automatic transmission 110-14, 400-2
    gear selector cable 444-1
    gear system, planetary 400-4
    general 472-1
    governor, removing 444-4
    hydraulic system 400-5
    pan (sump) gasket 472-1
    pressure test 400-8
    removing 201-9
    stall speed test 400-7
    troubleshooting 400-6

    Automatic transmission final drive 110-16

    Automatic transmission fluid (ATF)
    ATF cooler, replacing 472-2
    ATF pump 400-4
    replacing fluid/filter 110-15

    Axle, rear
    See Rear suspension

    Axle, front
    See Drive axle

    B

    Back-up light switch 364-4

    Back-up lights
    wiring diagrams 371-26

    Ball joints
    checking and replacing 631-1

    Ball joints, steering joints (tie rod ends) 110-19

    Battery
    charging 311-2
    general 311-1
    service 110-13
    testing 311-1
    voltage 200-10

    Belts
    See Drive belts

    Body
    general 100-7, 800-1
    maintenance 110-20
    technical data 028-1

    Boost pressure (turbo) 291-4
    See also Turbocharger

    Brake calipers 523-1
    front, removing 523-1
    rear, removing 523-2

    Brake discs
    general 516-1
    inspecting and replacing 516-1
    removing 516-2

    Brake fluid
    bleeding and changing 520-1

    Brake fluid level warning light 100-20

    Brake fluid warning lamp switch 364-6

    Brake lights
    wiring diagrams 371-28

    Brake lines and hoses 522-1
    replacing 522-1

    Brake master cylinder
    removing 521-2

    Brake pads
    general 517-1
    inspecting 517-1
    replacing 517-1

    Brake pedal
    general 524-1
    removing 524-1

    Brake system
    general 520-1

    Brake system bleeding
    cars with ABS 520-2
    cars without ABS 520-1
    general 110-18

    Brakes 110-17
    See also Anti-lock Braking System (ABS)
    general 100-6, 500-1
    technical data 025-1
    troubleshooting 500-5

    Brake fluid bleeding
    See Brake system bleeding

    Brake fluid specifications 520-2

    Bumpers
    removing and installing 860-1

    Burglar alarm
    wiring diagrams 371-3

    C

    Camshaft
    checking 215-1
    general 200-1, 215-1
    reconditioning 214-11
    removing and installing 214-5
    technical data 022-5

    Cam followers
    See Hydraulic cam followers

    Camshaft timing chain
    checking and replacing 215-1

    Camshaft valve cover
    See Cylinder head

    Carbon deposits
    See Driveability and engine management

    Carpets 851-2
    removing 851-2

    Cautions
    general 100-7

    Central locking
    locking motors, removing 830-10
    wiring diagrams 371-40

    Charging system
    general 321-1
    quick-check 321-1
    testing 321-1
    troubleshooting 321-1
    wiring 371-19

    Chassis service 110-17

    Check Engine light 200-5, 240-5, 340-3

    Cigarette lighter
    wiring diagrams 371-75

    Clutch
    controls 412-1
    disc, pressure plate, release bearing replacing 411-1
    general 400-2, 411-1
    master and slave cylinders
    bleeding 412-2
    replacing 412-1

    Coil springs
    See Front Suspension or Rear Suspension

    Combined instruments
    removing 853-3
    wiring diagrams 371-44

    Connecting rods
    general 212-1
    See also Pistons

    Continuity, checking for 300-7

    Control arms
    removing and installing 632-2

    Control arm bushings
    replacing 632-1

    Convertible top
    adjustments 812-1
    general 812-1
    hydraulic system 812-3
    wiring diagrams 371-49

    Coolant (antifreeze) and cooling system

    Coolant pump 261-1
    replacing 261-6

    Coolant temperature gauge
    sender 261-4

    Coolant temperature sensor (LH fuel injection) 240-12
    removing 240-22

    Cooling system 022-8
    draining and filling 261-5
    general description 200-2
    hoses, replacing 261-5
    maintenance 110-7
    troubleshooting 261-3

    Crankcase ventilation hoses 110-11

    Crankshaft 216-1
    general 200-2
    inspecting/reconditioning 216-1
    removing/installing 210-1
    technical data 022-6

    Crankshaft oil seals
    See Cylinder block oil seals

    Cruise control
    component locations 368-1
    control switch, checking 368-3
    electrical tests 368-2
    general 368-1
    pedal switches 368-2
    vacuum pump, checking 368-3
    wiring diagrams 371-51

    CV joint
    See Drive axle

    Cylinder block
    clearances (piston/cylinder) 212-3
    disassembly 210-2
    general 200-1, 210-1
    reconditioning 212-2
    technical data 022-3

    Cylinder block oil seals
    replacing 216-3

    Cylinder head
    See also Valve train
    disassembly and assembly 214-9
    general 200-1
    reconditioning 214-11
    removal/installation 211-1, 211-3
    technical data 022-4
    valve cover, removing 214-4

    Cylinders (engine)
    See Cylinder block

    D

    Dashboard and consoles
    general 853-1

    Dashpot (LH 2.2)
    See Fuel Injection (LH)

    Differential and final drive 400-5

    Directional indicators
    wiring diagrams 371-55

    Distributor
    cap and rotor, replacing 340-11

    Distributor cap, rotor, and spark plugs
    general 110-10

    Doors
    adjusting fit 830-2
    general 830-1
    interior panel, removing 830-3
    lock and handle mechanism 830-8
    See also Central Locking
    removing and installing 830-1

    Drive axle
    general 774-1
    joint boots, inspecting 110-17
    replacing 774-5

    Drive belts 110-8

    Drive plate (automatic trans.) 216-3

    Driveability and engine management
    basic adjustments 200-8
    carbon deposits 200-7
    mechanical condition 200-7
    troubleshooting 200-4
    warnings and cautions 200-7
    wiring and harness connectors 200-10

    E

    EGR
    See Exhaust gas recirculation system (EGR)

    Electric controls and switches
    extra gauges 364-6
    general 364-1

    Electrical system
    components, connectors and ground locations (list) 371-6
    general 100-4, 300-1
    safety precautions 300-1
    switches, engine 364-5
    service 110-13
    short circuits, checking for 300-7
    technical data 023-1
    test equipment 300-2
    testing, general 100-11
    troubleshooting 300-4
    wiring diagrams 371-1

    Emergencies 100-18

    Engine
    general 100-2, 201-1
    maintenance schedules 110-5
    mechanical troubleshooting 200-4
    removing and installing 201-1
    removing from transmission 201-9
    technical data 022-1

    Engine oil and oil filter 110-5

    Evaporative loss control device (ELCD) 110-11, 254-1

    Exhaust emission control
    general 254-1

    Exhaust manifold
    removing and installing 252-4

    Exhaust gas recirculation system (EGR) 254-2
    checking operation 254-3
    temperature sensor, testing 254-4
    valve testing 254-3

    Exhaust system
    general 110-13, 252-1
    removing and installing 252-1

    Exhaust valves
    See Valve train

    EZK ignition system
    See also Ignition system general 340-1
    knock sensor 340-2
    replacing 340-14
    system testing 340-8
    wiring diagrams 371-83

    F

    Fan belts
    See Drive belts

    Fasteners
    non-reusable fasteners 100-10
    tightening 100-10

    Fault code memory (LH fuel injection)
    canceling 240-7

    Fault diagnosis 240-4

    Feeler gauges 100-17

    Flywheel (manual transmission) 216-3

    Foglamps
    wiring diagrams 371-58

    Front Suspension
    coil springs 731-2
    checking 731-4
    removing 731-2
    general 731-1
    shock absorbers
    general 110-3
    removing/installing 731-1
    technical data 027-1
    troubleshooting 700-2

    Front wheel bearings
    See wheel bearings

    Fuel filter, replacing 110-13

    Fuel gauge sender unit
    removing and installing 234-15

    Fuel injection (LH)
    basic requirements 240-4
    component replacement 240-22
    component testing 240-10
    fault codes 240-5
    fault tracing 240-4
    fuel injectors 240-14
    removing 240-23
    testing 240-15
    general 100-3, 240-1
    LH control unit, removing 240-22
    LH variants 240-3
    oxygen sensor
    See Oxygen sensor
    safety precautions 240-3
    system adjustments 240-24
    technical data 022-7

    Fuel lines 234-16
    replacing 234-16

    Fuel pressure regulator 240-9
    removing 240-23

    Fuel pressure tests 240-8

    Fuel pump 234-6
    delivery pressure 240-10
    delivery rate 234-6
    electrical tests 234-6
    noise 234-4
    operating pump for tests 234-4
    screen (filter), replacing 234-13 replacing pump
    roller-type 234-8
    rotor-type 234-10
    safety precautions 234-2
    testing 234-7
    troubleshooting 234-3
    variants 234-1
    wiring diagrams 371-60

    Fuel pump check valve
    replacing 234-13

    Fuel pump relay, testing 234-7

    Fuel supply 200-2, 200-11

    Fuel system
    See Fuel Injection (LH)

    Fuel tank
    general 234-1
    removing and installing 234-14
    rollover valve, replacing 234-15

    Fuse and relay locations, main 371-1

    G

    Gaskets
    general information 100-11

    Gauges
    See Electric controls and switches or instrument cluster

    Gear lever housing
    See Manual transmission

    Gear shift lever
    See Manual transmission

    Glovebox lighting
    wiring diagrams 371-71

    Ground
    connections 200-10, 300-1, 371-6

    H

    Hall sensor 340-12
    replacing 340-13

    Hall ignition system 340-1
    See also Ignition system
    testing 340-6
    wiring diagrams 371-83

    Handbrake warning lamp switch 364-4

    Hatchback and trunk lid 830-11
    lock mechanism, replacing 830-9
    See also Central Locking
    removing/installing 830-11

    Headlight wiper motor
    removing 363-2

    Headlights
    replacing 351-1
    wipers and washers 363-2
    wiring diagrams 371-73

    Heated rear window
    wiring diagrams 371-75

    Heater and controls 854-3

    Heater core and heater valve 854-3
    replacing 854-3

    Hood
    alignment and adjustment 820-3
    general 820-1
    release cable 820-2

    Horns
    wiring diagrams 371-81

    How to use this manual 100-7

    Hydraulic cam followers 214-1
    checking and replacing 214-2

    I

    Idle speed (LH 2.2) 240-24

    Ignition lock cylinder
    installing 432-3
    removing 432-2

    Ignition switch, replacing 432-2

    Ignition timing 340-14
    checking and adjusting 340-15

    Ignition switch
    wiring information 371-7

    Ignition system
    component removal and replacement 340-11
    disabling ignition system 340-3
    electrical tests and fault tracing 340-5
    general 100-4, 340-1
    quick-check of system 340-4
    test equipment 340-3
    troubleshooting 340-2
    visual inspection 340-4, 5
    wiring diagrams 371-83

    Injectors
    See Fuel injection (LH)

    Instruments (cluster) 853-2
    removing 853-3
    wiring diagrams 371-44

    Instrument center console 800-2

    Instrument cluster switch panel
    removing 364-1

    Instrument pad, lower
    removing 851-3

    Instrument panel 853-1

    Interior switches 364-3

    J

    Jack stands, using 100-16

    Jump-starting 100-18

    L

    Lambda Sensor
    See Oxygen Sensor

    LH fuel injection
    See Fuel injection (LH)

    Lighting for controls
    wiring diagrams 371-98

    Lights
    backup
    wiring diagrams 371-26
    direction indicators light bulbs,
    replacing 351-3
    general 351-1
    hazard warning light bulbs, replacing
    headlights
    see Headlights
    interior bulbs, replacing 351-4
    parking light bulbs, replacing 351-3
    side marker and side reversing light
    bulbs, replacing 351-3
    stop light bulbs, replacing 351-3
    wiring diagrams 371-55
    time delay relay 351-5

    Lifting the car 100-8
    raising the car safely 100-9

    Locks, handles, and latch mechanisms 830-7
    See also Central locking

    Lubrication and maintenance
    quick data 010-2

    Lubrication system 022-6, 220-1
    See also Oil pump
    general description 200-2

    Luggage compartment lighting
    wiring diagrams 371-102

    M

    Maintenance program
    Saab recommended 110-2

    Manual transmission 110-16, 400-1
    gear selector rod, removing 432-3
    gear shift control 432-1
    gear shift lever, adjusting 432-6
    removing 201-9
    troubleshooting 400-5

    Manual transmission control 432-1

    Master cylinder
    See Brakes

    Mercury switch (convertible) 364-5

    Mirrors, power
    wiring diagrams 371 -110

    Modulating valve
    See EGR
    testing 254-5

    N

    Notes, general 100-7

    O

    Oil
    excessive consumption 200-5

    Oil and filter
    changing 110-6

    Oil change equipment 100-16

    Oil cooler (turbo models only) 220-5
    removing 220-5

    Oil pressure
    relief valve 220-4
    testing 220-4
    warning circuit 220-5
    warning systems 220-4

    Oil pressure warning light 100-20

    Oil pump
    removing and installing 220-1

    On-board diagnostics (EZK ignition only) 340-3

    On-board diagnostics (LH 2.4 and LH 2.4.2 only) 240-5

    Overheating 100-19

    Oxygen sensor 110-11, 200-8, 240-16
    testing 240-16

    P

    Panhard rod
    See Rear suspension

    Parking brake 110-18
    adjusting 551-3
    general 551-1

    Parking brake cables
    removing/installing 551-1

    Parking lights
    wiring diagrams 371-104

    Parts
    buying 100-12
    genuine Saab parts 100-12
    non-returnable parts 100-14
    spare parts kit 100-20

    Pistons 212-1
    technical data 022-3

    Piston rings 022-3, 212-4

    Piston-to-cylinder clearance
    See Cylinder Block

    Power steering fluid 110-18

    Power steering system 644-1
    pump and lines 644-4
    removing/installing 644-1

    Pressure plate
    See Clutch

    R

    Radiator
    pressure test 261-3
    removing 261-8

    Radiator and expansion tank
    general 261-1

    Radiator cooling fan thermoswitch
    replacing 261-8

    Radiator cooling fans 261-8
    general 261-1
    quick-check 261-4
    removing 261-9
    wiring diagrams 371-118

    Radio wiring diagrams 371-120

    Radio antenna
    See Antenna
    rear axle, removing 732-7

    Rear Suspension 732-1
    bump stop 732-10
    coil spring link, removing 732-5
    coil springs 732-2
    panhard rod, removing 732-9
    shock absorbers 732-1
    torque arm, removing 732-9

    Refrigerant charge
    checking 854-7

    Regulator brushes
    See Alternator

    Relay positions 371-5

    Release bearing
    See Clutch

    Residual fuel pressure
    See Fuel injection (LH)

    Road test 110-20

    Rubber bump stop
    See Rear suspension

    S

    Saab turbo with APC
    general description 100-2

    Safety 100-8

    Seals 100-11

    Seat belt and ignition key warning
    wiring diagrams 371-125

    Seats
    heated, wiring diagrams 371-77
    removing, front 851-1
    removing, rear 851-2

    Seatbelts 851-1
    general 800-1
    passive (motorized)
    wiring diagrams 371-107
    removing 851-2

    Shift-up indicator
    fifth gear lockout switch 364-5
    temperature switch 364-5
    throttle switch 364-5
    wiring diagrams 371-128

    Shock absorbers
    See Front suspension or Rear suspension

    Short circuits, checking for 300-7
    using a voltmeter 300-8
    using an ohmmeter 300-7

    Slave cylinder
    See Clutch

    Solenoid
    See starter motor

    Spark plugs 010-2, 110-10

    Speedometer cable
    replacing 853-3

    Spoiler
    assembly 812-6
    removing 812-6

    Spring link bushings
    replacing 732-5

    Starter
    removing 331-2
    solenoid, replacing 331-2
    troubleshooting 331-1
    wiring diagrams 371-130

    Steering 600-1
    general 100-6, 600-1
    technical data 026-1
    troubleshooting 600-2

    Steering column
    assembly, removing 641-2
    general 641-1

    Steering column switches and horn switch (1985-1989 models) 364-3

    Steering swivel member
    removing and installing 774-1

    Steering wheel
    removing 641-1

    Storage console
    removing 853-2

    Sunroof 830-12
    removing/installing 830-12

    Supplemental restraint system (SRS) 110-20
    wiring diagrams 371-133

    Suspension
    See Front Suspension or Rear Suspension

    System line pressure
    See Fuel injection (LH)

    System relay
    See Fuel injection (LH)

    T

    Technical data
    general 010-1

    Temperature gauge sender
    replacing 261-4
    quick-check 261-4

    Thermostat 261-6
    quick-check 261-5
    replacing 261-6

    Thermostatic valve (EGR)
    testing 254-4

    Thermoswitch, cooling fan
    See Radiator

    Throttle position sensor 240-12
    removing 240-22

    Throttle position sensor (LH 2.2 and LH 2.4)
    adjusting 240-26

    Throw-out bearing
    See Clutch

    Tie rod end
    general 643-1
    removing 643-1

    Tires 110-19
    changing 100-18

    Tools 100-14
    basic requirements 100-14
    Saab special tools 100-17
    torque wrench 100-17

    Torque arm
    See Rear suspension

    Torque converter 400-4

    Towing 100-20

    Transmission
    See also Automatic transmission or Manual transmission
    technical data 024-1

    Transmission and drive train
    gear selector cable 444-1
    general 100-5
    service 110-14
    throttle cable 444-2
    transmission controls 444-1

    Trim, interior body 851-3
    headliner, removing 851-3
    interior side trim, removing 851-4

    Trunk lid lock mechanism
    replacing 830-8

    Trunk lid or hatchback lid lock cylinder
    replacing 830-10

    Tune-up and preventive maintenance 200-8

    Tune-up quick data 010-2

    Turbocharger
    Automatic Performance Control (APC)
    APC bypass valve, testing 291-8
    APC knock sensor, testing 291-7
    APC pressure sensor, testing 291-8
    APC solenoid valve, testing 291-6
    general 291-1
    replacing 291-9
    technical data 022-8
    testing 291-1

    Turbo boost pressure 291-3
    Turbocharger and APC troubleshooting 291-2

    Turn signals
    See Directional indicators

    V

    Vacuum booster
    general 541-1
    replacing 541-1

    Vacuum servos and air flaps testing 854-6

    Valve cover
    removing and installing 214-4

    Valve train 214-4
    disassembling 214-9
    exhaust valves
    sodium filled, scrapping 214-14, 15
    general 214-1
    reconditioning 214-1
    valve guides, replacing 214-12
    valve seats 214-13
    valve springs 214-15
    valve stem oil seals 214-7

    Vehicle Identification codes and specifications 400-5

    Ventilation blower
    removing and installing 854-5

    Ventilation fan (blower)
    wiring diagrams 371-136

    Volt-ohm meter (vom) or multimeter 100-17

    Voltage
    checking for at the fuel pump 234-7
    measuring 300-6

    Voltage and ground, checking for 300-4, 371-1

    Voltage and polarity 300-1

    Voltage drop, checking for 300-6

    W

    Warnings, cautions and notes 100-7

    Warnings and cautions 261-1

    Wheel alignment 600-1
    general 600-1
    specifications 601-1
    troubleshooting 600-2

    Wheel bearings
    front, replacing 774-9
    rear, replacing 774-9

    Wheel studs, replacing 774-9

    Window regulator,
    front
    manual, removing/installing 830-6
    power, removing/installing 830-4
    rear
    manual, removing/installing 830-7
    power, removing/installing 830-5

    Windows 830-3

    Windows, power
    wiring diagrams 371-112

    Windshield
    removing assembly 363-1
    wipers and washers 363-1

    Windshield washer fluid 110-19

    Wipers and washers
    wiring diagrams 371-138

    Wire repairs 100-12

    Wiring diagrams 300-2, 371-1
    codes and abbreviations 300-2
    using 300-4

    Wiring, fuses, and relays 300-1

    Working safely under a car 100-9