Saab MY02 manual

Saab Model Year 2002 MY02 Product Information: Saab Way 2002 Self-study Guide for On-line Griffin Test Foreword This book is intended for use by all Saab Dealership Personnel, except technicians, as an introduction to the Model Year 2002 products. The information in this book is based on information from the Service Manual update with descriptions [...]

2 9-5 • Table of Contents 9-5 9-5 Introduction – Model Year 2002 9-5 Product Range….………………………………………………………….…… 5 VIN (Vehicle Identification Number) MY 2002 ………………………………...… 10 Service Notes ……………………………………………………………………?[...]

Table of Contents 9-3 9-3 Introduction – Model Year 2002 9-3 Product Range ………………………………………………………..…..…. 85 VIN (Vehicle Identification Number) MY2002 ……………………………...…. 89 Engine 9-3 E ngine Range, Model Year 2002 ………………………………………..….. 90 Cooling Sy[...]

4 9-5 General information Warning, Important and Note The headings Warning, Important and Note appear from time to time in this service manual. They are used to draw the attention of the reader to information of special interest and seriousness. The importance of the information is indicated by the three different headings and the difference betwee[...]

9-5 Product Overview 5 9- 5 9-5 - Introduction – Model Year 2002 Saab 9-5 Product Range - Model Year 2002 - US For model year 2002, the trim level of Saab 9-5 models will be designated by new form names. In the U.S., the 9-5 will be available in three models, each available as a sedan or wagon: • Linear 2.3t • Arc 3.0t • Aero 9-5 Linear 2.3[...]

6 9-5 Product Overview 9-5 9-5 Arc 3.0t The next model in the 9-5 lineup is the 9-5 Arc 3.0t. All 9-5 Arc 3.0t models in the U.S. will be equipped with the B308E V6 turbo engine with the new 5-speed automatic transmission. A manual transmission is not available on Arc models. 9-5 Arc 3.0t models have an extensive list of standard features: • Perf[...]

9-5 Product Overview 7 9-5 9-5 Aero The 9-5 Aero will be equipped with the B235R engine. Aero models are available with either manual or automatic transmissions. For model year 2002, the horsepower of B235R engine has been increased to 250 HP, while retaining the previous torque rating. Note that Aero models equipped with both automatic transmissio[...]

8 9-5 Product Overview 9-5 Brief Overview of Changes : 9-5 Saab 9-5 The following major revisions have been made on the Saab 9-5 for model year 2002: Engine Engine variants The following engine variants are available in the U.S. market for the Saab 9-5 model year 2002: • 2.3t Ecopower 185hp (207 ft. lbs. / 280Nm) B235E (Linear) • 3.0t Ecopower [...]

9-5 Product Overview 9 9-5 Diesel in the US? Many of the revisions under the skin to the MY2002 9-5 are as a result of the introduction of the diesel engine for the European markets. Several of these changes are improvements that carry over into gasoline vehicles and are a benefit to the U.S. specification vehicles as well. Diesel engines naturally[...]

10 9-5 Product Overview 9-5 Vehicle Identification Number (VIN) M2002 Example: YS3EF45C623008642 1 - Geographical area Y = Northern Europe 2 - Country S = Sweden 3 - Car manufacturer 3 = Saab Automobile AB 4 - Product line E = 9-5 5 - Model Series B = Saab 9-5 Linear 2.3t with driver and passenger airbag D = Saab 9-5 Arc 3.0t with driver and passen[...]

Service 11 9-5 Service Service Saab 9-5 Revisions • “No Charge Scheduled Maintenance” is included on all 9-5 models in the U.S. for 2002. (Also included on all 9-3 SE 5-door models with the “Premium Package”, all SE convertibles, and all Viggens.) • The customer can request the car to be programmed to an optional level of customization [...]

12 Engine 9-5 Engine Engine range, Saab 9-5 model year 2002 (US) Engine B235E (Linear) B235R (Aero) B308E (Arc) Compression ratios 9.3:1 9.3:1 9.5:1 Turbocharger make, type Garrett GT17 Mitsubishi TD04HL-15T Garrett GT15 Wastegate pre-stressing 2 mm 2 mm - Basic charging pressure 0.40 Bar ±0.03 0.45 Bar ±0.03 0.27 Bar ±0.03 Max. power, EEC 185hp[...]

Engine 13 9-5 Cooling system New coolant A new "Long-life" coolant is used in all Saab engines for model year 2002. The new coolant was actually introduced during late 2001 production. The coolant that is filled in production does not require changing throughout the service life of the car. The fluid is orange in color to distinguish it f[...]

14 Electrical system 9-5 Electrical system Charging system Generator 1. Stator 2. Rotor with slip rings 3. Integrated fans 4. Rectifier 5. Regulator 6. Pulley The generator is an alternating current generator with integrated charge regulator. Maximum current is now 140 A, up from 130 A in 2001. The generator is driven by the engine through a multi-[...]

Electrical system 15 9-5 Battery and battery cooling A new style battery is introduced for model year 2002. It is a sealed, maintenance-free battery. The battery has a capacity of 70 Ah, and a cold cranking rating of 700 CCA. The battery has a level window to indicate whether there is sufficient electrolyte (battery fluid) in the battery. The windo[...]

16 Electrical system 9-5 Relay and Fuse Box Relay and fuse box A new relay and fuse box has been introduced on model year 2002. A new type of fuse, a microfuse, has been introduced. These fuses have the same function as earlier types, but are smaller in size.[...]

Electrical system 17 9-5 Brief description The headlight assembly contains a xenon lamp with ignition transformer, control module, beam length adjustment motor, halogen bulb and parking light bulb. The AHL (Automatic Headlight Levelling) control module governs the current/voltage supply to the xenon lamp. These lamps require very high voltages (app[...]

18 Electrical system 9-5 System overview • Halogen bulb (11) • Xenon headlight (11a) • Parking light bulb (13) • Headlight beam length adjustment motor (280) • Main instrument unit (540) • Headlamps (663FL/FR) • AHL control module (664) • Main beam damping solenoid (665) • Load angle sensor, front (704F) • Load angle sensor, rea[...]

Electrical system 19 9-5 Principal components 1. DICE control module (628) 2. Light switch (10) 3. Light switch (215) 4. Xenon lamp indicator (662) 5. Headlight filament monitor (228b) Main beam flasher relay (666) Dipped beam relay (8) Main beam relay (8a) 6. Load angle sensor, front (704F) 7. Load angle sensor, rear (704R) 8. Halogen bulb (11) 9.[...]

20 Electrical system 9-5 Description of operation General The headlight contains a xenon lamp with ignition transformer, control module, beam length adjustment motor, H7 halogen bulb and parking light bulb. A 70mm (2.75in) ellipsoid lens forms the light pattern together with the xenon lamp and reflector. The headlight is equipped with a clear plast[...]

Electrical system 21 9-5 Dip switch solenoid Xenon lamps always have the same brightness. The beam of light from a xenon lamp is limited for dipped beam (low beam) use by a screen, which is opened by a solenoid for main beam (high beam) use to give a brighter light.[...]

22 Electrical system 9-5 AHL control module, xenon There is a control module located inside the headlight housing that governs the supply of current/voltage to the xenon lamps. The control module also governs the stepping motors for the automatic beam length adjustment. The control module receives information on the angle of the car from the load a[...]

Electrical system 23 9-5 Automatic headlight beam adjustment Cars with the Bi-Xenon headlight system are equipped with automatic headlight beam adjustment. The control system ensures that the headlights are always at an optimum angle during acceleration, braking and at varying loads. When the front of the car lifts during fast acceleration, the hea[...]

24 Electrical system 9-5 Load angle sensors Cars with automatic headlight beam adjustment are fitted with a front and rear load angle sensor. The front sensor is fitted between the subframe and the wishbone and receives information on the wishbone movement in relation to the subframe. This information is sent on to the AHL control module as a pulse[...]

Electrical system 25 9-5 Bi-Xenon Headlight System - Electronic Calibration The Automatic Headlight Leveling system (AHL) must be calibrated after changing the headlamp, AHL control module or the front and rear load angle sensors. The system must also be calibrated after performing any work requiring dismantling of the front or rear load angle sens[...]

26 Electrical system 9-5 Description of operation, high pressure headlight washers All 9-5 models sold in the U.S. for model year 2002 will be equipped with the new “High Pressure Headlight Washer” system. (Including models not equipped with Bi-Xenon headlights.) There is a washer nozzle fitted on a cylinder in the spoiler in front of each head[...]

Electrical system 27 9-5 System overview, high pressure headlight washers • DICE control module (628) • Windshield wiper stalk switch (61) • Relay, high pressure headlight washer fluid pump (667) • Motor, high pressure headlight washer pump (668) • High pressure “pop-up” sprayer washers (A) (A) (A)[...]

28 Electrical system 9-5 Main components, high pressure headlight washers 1. DICE control module (628) 2. Windshield wiper stalk switch (61) 3. Relay, high pressure headlight washer fluid pump (667) 4. Motor, high pressure headlight washer pump (668)[...]

Electrical system 29 9-5 8 3 6 1 E 36 3 D 0 2 6 6 4 9 6 5 0 Rain Sensing Wipers (Available on Arc and Aero) Brief description • Stalk switch (61) • Rain sensor (649) • Relay (83 and 650) Windshield wipers with rain sensor The windshield wiper unit is located under the cover below the windshield and comprises a motor, arm system and two wiper [...]

30 Electrical system 9-5 System overview • Rain sensor (649) • Relay, rain sensor (650) • Relay, headlamp washer fluid pump (667) • Windshield wiper stalk switch (61,618) • Windshield wiper motor (62F) • Washer fluid motor, windshield (63a, 63b) • Washer fluid motor, headlamps (668) • Relay, intermittent wiper (83) • DICE (628) ?[...]

Electrical system 31 9-5 5 4 667 10 E363D046 1 2 3 1 3 2 8 9 10 9 6 7 8 4, 5, 6 7 (668) (649) (61/618) (62F) (63B) (541) (628) 83 650 Principal components 1. Rain sensor (649) 2. Windshield wiper stalk switch (61,618) 3. Windshield wiper motor (62F) 4. Relay, rain sensor (650) 5. Relay, intermittent wiper (83) 6. Relay, headlamp wsher fluid pump (6[...]

32 Electrical system 9-5 1 2 3 4 , 0 E 36 3 D 0 2 9 Activating positions Wipers are activated with the stalk switch in the following positions: 1. Automatic mode The rain sensor controls the wiper motor from intermittent to high speed. 2. Low speed The wiper motor is activated at low speed without the assistance of the rain sensor. 3. High speed Th[...]

Electrical system 33 9-5 E 363 D 0 28 Rain sensor The rain sensor is a control module with its own logic. It is NOT connected to the bus and, therefore, will not generate fault codes or communicate with Tech 2. The sensor is located on the windshield in front of the rear-view mirror. It is pressed against the inside of the windshield and secured wi[...]

34 Electrical system 9-5 Main instrument unit, MIU A new main instrument unit with several modifications has been introduced on the Saab 9-5. All the electronics and other components are now combined on one circuit board, thus reducing the depth and weight of the main instrument unit. Instrument lighting comprises only LEDs, which provide a more ag[...]

Electrical system 35 9-5 New warning and indicator lamps • ESP (Electronic Stability Program) indicator. The lamp is available on cars equipped with ESP and comes on when it is active. TC/ABS is included in the ESP system and the TCS lamp has been replaced with a new symbol on cars with optional ESP or TC/ABS. • ESP OFF or TCS OFF indicator. Th[...]

36 Electrical system 9-5 Saab Parking Assistance, SPA (Available on Arc and Aero) Brief description To facilitate reversing and parking, the Saab 9-5 (Sedans and SportWagons) can be equipped with Saab Parking Assistance (SPA) . SPA will be available in an option package on Arc and Aero models in the U.S. market for model year 2002. SPA measures and[...]

Electrical system 37 9-5 System overview • Ultrasound distance sensors: • Right-hand outer sensor (631RR) • Right-hand center sensor (631RRC) • Left-hand center sensor (631RLC) • Left-hand outer sensor (631RL) • SPA control module (630) • SID control module (541) • DICE control module (628) • TWICE control module (632) • TCM con[...]

38 Electrical system 9-5 Main components 1. SPA control module (630) 2. Distance sensor, LH outer (631RL) 3. Distance sensor, LH center (631RLC) 4. Distance sensor, RH center (631RRC) 5. Distance sensor, RH outer (631RR) 6. SID (541) 7. DICE control module (628)[...]

Electrical system 39 9-5 Turning off SPA If you wish to turn off the SPA, for example, when towing a trailer, press the CLEAR button on the SID when “PARK ASSIST” is displayed until ”PARK ASSIST OFF” appears, approx. 1-2 seconds. If you wish to reactivate the SPA there are two methods: • Press CLEAR until the SID text changes (the text is[...]

40 Electrical system 9-5 Distance measurement and indication The control module receives information from the DICE when reverse gear is selected. The control module accordingly activates the distance sensors. The sensors emit and receive ultrasound signals, sent in a preset pattern, see Distance sensors. The control module processes continuous data[...]

T ransmission 41 9-5 Transmission 5-Speed automatic transmission (Available on Linear and Aero, Standard on Arc) Brief description A new 5-speed automatic transmission has been introduced on the 9-5 engines. The new transmission is based on the tried and tested 4-speed Aisin-AW that has been fitted on the 9-5 since its introduction. Special advanta[...]

42 Transmission 9-5 Another new feature is the Hall sensor used for the input and output shaft speed sensors that have previously been of the inductive type. This change in sensor has been made because Hall sensors are more precise, they supply a clear square wave at speeds as low as 20 rpm where the earlier inductive sensors required at least 50 r[...]

T ransmission 43 9-5 System overview[...]

44 Transmission 9-5 Principal components The automatic transmission consists of the following principal components: 1. Gearbox 2. Control module, (TCM) 502 3. Gearshift solenoid valves, (S1-S5) 531 4. Lock Up solenoid valve, (SLU) 531 5. System pressure solenoid valve, (SLT) 531 6. Clutch disc pressure solenoid valve (SLS) 531 7. Input shaft speed [...]

T ransmission 45 9-5 Control modules The transmission control module primarily controls • Shift points • System pressure • Lock-up engagement (fixed or slipping) The control module has two 38-pin connections and is located behind the glove box in the passenger compartment. It is programmed for one of the engine variants B235E/R or B308E and i[...]

46 Transmission 9-5 Electronic overspeed protection In order to prevent the engine from overspeeding, the transmission control module is programmed with an electronic overspeed protection function. This means that it is not possible to gear down until the vehicle speed is below the relevant limit. Gear changing Max speed km/h Max speed mph 5-4 175 [...]

T ransmission 47 9-5 Electronic reverse gear detent When changing to R from D, 4, 3 or L while the vehicle speed exceeds 7 km/h (4.3 mph), the control module will energize the S1 solenoid to prevent reverse gear from being engaged (brake B3 released). The electronic reverse gear detent is disengaged when the speed of the car is below 7 km/h (4.3 mp[...]

48 Transmission 9-5 Limp-home In case of a major system error, such as a mechanical fault with the system input or output functions, or an internal fault in the control module, all the control module functions will be deactivated at the same time as the control module sends the bus message "CHECK GEARBOX unit ON" to turn on the indicator [...]

Brakes 49 9-5 Brakes Brake system System revisions A number of revisions and adaptations have been made on the Saab 9-5 to give more space in the engine compartment – mostly as a result of the introduction of the new V6 diesel engine in some markets. Other improvements include better flow capacity to the hydraulic unit for the ESP stabilizing sys[...]

50 Brakes 9-5 Front brake system A number of modifications have been made at the front. With the new steering swivel member, the wheel sensors are now screwed directly into the steering swivel member. 9-5 models with the 3.0t V6 engines will be equipped with larger front discs, previously fitted only on 9-5 Aero models (306mm / 12.05in). In the U.S[...]

Brakes 51 9-5 Brake servo and master cylinder Master cylinder 1. Pushrod with primary piston 2. Pressure chamber, primary circuit 3. Central valves 4. Secondary piston 5. Pressure chamber, secondary circuit 6. Return spring 7. Stop pin 8. Stop pin 9. Seals The brake servo and brake fluid reservoir are new and adapted to the new master cylinders. Th[...]

52 Brakes 9-5 Brake system, rear The rear brakes have been changed and now have larger, ventilated brake discs on engine models B235R ( Aero) and B308E (Arc). A new carrier has been introduced and the brake caliper has been redesigned to better suit the large diameter brakes discs, 300mm (11.8in) compared with the standard 278mm (10.9in), and the 2[...]

Brakes 53 9-5 Electronic Stability Program, ESP (Available on Linear, Standard on Arc and Aero) Brief description, ESP ESP (Electronic Stability Program) is a system that regulates the engine torque and braking to assist the driver with stabilizing the vehicle during unexpected situations that would otherwise be difficult to handle. ESP also includ[...]

54 Brakes 9-5 System overview • Hydraulic unit with control module (671) • Yaw rate sensor, side acceleration sensor (658) • Steering angle sensor (657) • Brake pressure sensor (659) • Wheel sensor (298) • ESP switch (660) • ESP indicator lamp (47x) • ESP OFF indicator lamp (47y)[...]

Brakes 55 9-5 Principal components 1. Brake unit including control module, valve body and pump (671) 2. ABS warning lamp. TCS and ESP indicator lamp. TCS OFF and ESP OFF indicator lamp (540) 3. Front left wheel sensor (298FL) 4. Front right wheel sensor (298FR) 5. Rear left wheel sensor (298RL) 6. Rear right wheel sensor (298RR) 7. ESP/TCS ON/OFF s[...]

56 Brakes 9-5 Control module The control module is integrated in the ESP unit and has a 31-pin connector. The control module also governs the coordinated functions of ABS, EBD and TCS. The ESP function reduces engine torque and handles the braking on all four wheels. Torque reduction takes place after the ESP control module sends a bus message requ[...]

Brakes 57 9-5 Yaw Rate / Side Acceleration Sensor This sensor consists of a combined micro- mechanical yaw rate sensor and a side acceleration sensor. It is located on a bracket on the exhaust tunnel in front of the gear lever. This location positions the sensor as close to the car's center of gravity and center -line (X-axis) as possible. Its[...]

58 Brakes 9-5 Function, side acceleration sensor The side acceleration sensor registers the lateral forces that arise during cornering. It provides the ESP control module with information on the magnitude of the lateral forces that are trying to make the car change direction. It sends this ACTUAL VALUE to the ESP control module, which compares it w[...]

Brakes 59 9-5 ESP switch A spring-loaded switch is located on the dashboard to the right of the steering wheel for turning the ESP function ON/OFF. The TCS function will also be turned off when the ESP function is turned off. The ESP OFF lamp in the main instrument unit will come on. The switch can be used to disengage ESP and TCS at speeds below 6[...]

60 Brakes 9-5 ESP function ESP is a stabilization system that helps to keep the vehicle on the right course when cornering, taking evasive action, braking and accelerating. The stabilizing effect of the ESP system is based on calculations made by the control module, which evaluates information sent from the various system sensors: • Wheel speed s[...]

Brakes 61 9-5 Engine torque regulation Engine torque regulation takes place after bus communication with the engine control module. The ESP control module requests an engine torque between -100 and +400 Nm. This is achieved through ignition retardation and throttle control, i.e. by changing the throttle angle and the boost pressure (air mass/combus[...]

62 Brakes 9-5 ESP valve block The hydraulic unit comprises 12 solenoid valves that govern the brake pressure to the brake units during ABS, TCS or ESP regulation. The pressure-increase and pressure-reducing valves in the TC/ABS unit are similar in their design and operation. In order to enable ESP regulation, the valves are connected to the rear wh[...]

Brakes 63 9-5 Braking phases Phase 1. Pressure build up on all four wheels (filling pulse and pressure retention) Driver not braking Filler p ulse Regulation starts with a filler pulse. This means that a slight, equal pressure build up takes place in all the wheel cylinders, irrespective of the wheel to be regulated during braking. The pump starts,[...]

64 Steering assembly 9-5 Steering assembly Steering System overview The steering system now has a number of new components that have been replaced and modified due to adaptation to the new V6 diesel engine and to lower the gross weight of the chassis. All 9-5 models benefit from these changes. Steering swivel member The steering swivel member is ca[...]

Suspension 65 9-5 Suspension Suspension A number of modifications have been made to the Saab 9-5 to increase safety and adapt it to the new V6 diesel engine. These modifications have meant that the chassis has been given sportier characteristics. It has become even more balanced and remains stable when negotiating tight turns on dry asphalt. The ca[...]

66 Suspension 9-5 The following parts and modifications are unique to the 2002 model and affect its characteristics: • Front subframe is approximately 20% stiffer. • Changes to the front strut thrust bearing have increased the car's lateral stiffness. • Steering swivel member has an integrated hub and new wheel bearings. • Anti-roll ba[...]

Body 67 9-5 Body Body colors Two new body colors have been introduced and one shade has been discontinued: • Polar White (283), a base solid paint, replaces Cirrus White. Note that Cosmic Blue (264) is once again available in the U.S. market. • Hazelnut (286) is a new metallic paint. Color code Color Paint type Note 9-5 Linear/Arc 9-5 Aero 170 [...]

68 Body 9-5 Exterior Front bumper The front bumper consists of a cellular plastic core and a shell of painted plastic in which the grille is an integral part. There is a three-piece removable decor strip inset in the shell, two outer pieces and one center piece. The covers for the headlight washer nozzles are also in the shell. The bumper shell is [...]

Body 69 9-5 Emblem Sedan Emblems on the hood and trunk lid are attached with double-sided adhesive tape. The 9-5 emblem is affixed to the left-hand side of the trunk lid and the emblem showing the engine variant is on the right-hand side.[...]

70 Body 9-5 SportWagon The emblems on the Saab 9-5 SportWagon are affixed in the same way as the 9-5 Sedan, with double-sided adhesive tape. The emblems are affixed in the same location as on the Sedan model with the 9-5 emblem on the left-hand side of the tailgate and the emblem showing the engine variant on the right-hand side. Decor panel There [...]

Body 71 9-5 Body modifications Body modifications have been made for three reasons: • Improved impact characteristics • Exterior modifications • Engine modifications Enhanced impact characteristics In order to enhance impact characteristics in case of head-on collisions, the Saab 9-5 now has a new bumper member of press-hardened steel with ne[...]

72 Body 9-5 Interior equipment Energy absorber for improved head protection in case of impact. The joints between the A-pillars and the roof and the C-pillars and the roof now have energy absorbers to increase internal safety. The absorbers are fixed to the top of the headlining, which means that the entire headlining must be replaced if there is a[...]

Body 73 9-5 ISO-fix mounting for child seat “ISO-fix” is an international standard for child safety seat mounting. ISO-fix brackets are now fitted as standard on the rear floor of the 9-5, between the seat and the backrest (seat back). The child seat bracket is intended to provide a simple and safe child seat installation, and good protection t[...]

74 Body 9-5 Dashboard • Linear The classy and simple model of the Saab 9-5 range. Includes new style wood inserts in the dashboard (a lighter shade of walnut). • Arc The elegant touring model in the Saab 9-5 range. Includes new style wood inserts in the dashboard (a lighter shade of walnut). • Aero The top of the line model, exuding sporty fe[...]

Body 75 9-5 Airbag (SRS) Brief description The airbag system has been further developed to provide optimum personal protection through differentiated protective features that take into account the seat position, whether the person is buckled up, and the force of the impact. The side impact sensor has also been improved with a new accelerometer in t[...]

76 Body 9-5 System overview • Dual-stage airbag, driver (333D) • Dual-stage airbag, passenger (333P) • Seat position sensor (669D, 669P) • Seat-belt buckle (70D, 70P) • Front impact sensor (332FL, 332FR) • Contact roller (336a) • Side airbags (333Db, 333Pb) • Side impact sensors (328D, 328P) • Seat-belt tensioners (236LH, 236RH) ?[...]

Body 77 9-5 Principal components 1. Airbag control module (331) 2. Side impact sensors (328D, 328P) 3. Dual-stage airbag, driver (333D) 4. Dual-stage airbag, passenger (333P) 5. Side impact airbags (333Db, 333Pb) 6. Seat-belt tensioners (236LH, 236RH) 7. Knee shield, driver, 3-piece 8. Knee shield, passenger 9. Front impact sensor (332FL, 332FR) 10[...]

78 Body 9-5 Control modules The main task of the control module is to recognize the situation arising from a collision and inflate the airbag with the correct force and/or ignite the correct seat-belt tensioner. The control module contains two accelerometers, a microprocessor, a reserve power source and a voltage converter. The control module has t[...]

Body 79 9-5 Conditions for Airbag Activation If the control module detects a high collision force and the seat is more than 30% from its front position, the front airbags will be inflated in two stages with a 5 to 20 ms delay between the deployment of the two stages. If the collision force is low, only stage 1 will be activated. If the seat positio[...]

80 Body 9-5 Front impact sensor The front impact sensor is used to detect collision forces at an early stage and send information to the control module. The system has two front impact sensors. They are located on the bumper rail at the same height as the detachable grille on the front of the car. The two sensors are identical and both have two lea[...]

Body 81 9-5 Driver airbag The driver airbag is mounted inside the steering wheel. The driver airbag is a dual-stage type. This means that it can be inflated in two stages at different pressures depending on the force of the impact and the position of the seat. If the seat is in a forward position, i.e. less than 30% ( approx 65mm / 2.56in) from its[...]

82 Body 9-5 Passenger airbag The passenger airbag is standard on all Saab 9-5 models in all markets. The passenger airbag is dual-stage type. This means that it can be inflated in two stages at different pressures depending on the force of the impact and the position of the seat. If the seat is in a forward position, i.e. less than 30% from its fro[...]

Body 83 9-5 Airbag warning lamp A new feature this year is that the airbag warning lamp is turned on by a bus message that is sent by the airbag control module "Airbag warning lamp: Off/On". If the airbag control module does not send this message, the lamp will be turned on by the MIU. Previous models do have an SRS warning lamp, but this[...]

84 Body 9-5 Doors and locks Trunk lid lock cylinder, Sedan The lock cylinder in the trunk lid of the Sedans has been removed. The trunk lid can now be opened by pressing the trunk lid button on the remote control or the switch located in the driver's door. Emergency opening of trunk lid There is a luminous handle on the inside of the tailgate [...]

9-3 Product Overview 85 9-3 9-3 - Introduction – Model Year 2002 Saab 9-3 product range - model year 2002 - U.S. In the U.S. for 2002, the Saab 9-3 will be available in two models: • SE (5 door & convertible only) • Viggen (3 door, 5 door, and convertible) 9-3 SE 5 Door For 2002 in the U.S., the 9-3 SE will be available as a 5-door model [...]

86 9-3 Product Overview 9-3 9-3 SE Convertible As mentioned on the previous page, all 9-3 SE models in the U.S. (including the SE convertible ), will be equipped with the B205R engine. Standard equipment on 9-3 SE convertible models include: • Power memory driver’s seat • Power passenger’s seat • Woodgrain dash • Leather seats • Leath[...]

9-3 Product Overview 87 9-3 9-3 Viggen 3D/5D/Convertible The Viggen will only be available in the CA/US market. The Viggen will be available as a 3- door, 5-door or convertible. The Viggen will be equipped with the B235R engine and manual transmission only. The Viggen is equipped with all of the standard features found on SE models. In addition, th[...]

88 Product Overview 9-3 Brief Overview of Changes : 9-3 9-3 The following major revisions have been made on the Saab 9-3, model year 2002: Engine The 2.0t 185hp engine (B205R) will no longer be offered in the U.S. market. Cooling System New “Long-life” coolant. Electrical system Main instrument unit New compact and lighter main instrument unit [...]

P roduct Overview 89 9-3 Vehicle Identification Number (VIN) M2002 Example: YS3EF45C623008642 1 - Geographical area Y = Northern Europe 2 - Country S = Sweden 3 - Car manufacturer 3 = Saab Automobile AB 4 - Product line D = 9-3 5 - Model Series F = Saab 9-3 SE with driver and passenger airbag P = Saab 9-3 Viggen with driver and passenger airbag 6 -[...]

90 Engine 9-3 Engine Engine range, Saab 9-3 model year 2002 Engine B205R (SE) B235R ( Viggen) Compression r a tios 8.8:1 9.3:1 Turbocharger make, type Mitsubishi TD04HL-15T Mitsubishi TD04HL-15T Wastegate prestressing 2mm 2mm Basic charging pressure 0.45 bar +/- 0.03 0.45 bar +/- 0.03 Max. power, EEC 205hp/151kW at 5500 rpm (man) 5750 rpm ( aut) 23[...]

Engine 91 9-3 Cooling system A new “Long-life” coolant will be used in all Saab engines for model year 2002. The new coolant was actually introduced during late 2001 production. The coolant that is filled in production does not require changing throughout the service life of the car. The fluid is orange in color to distinguish it from earlier t[...]

92 Electrical system 9-3 Main instrument unit, MIU A new main instrument unit with several modifications has been introduced on the Saab 9-3. All the electronics and other components are now combined on one circuit board, thus reducing the depth and weight of the main instrument unit. Instrument lighting comprises only LEDs, which provide less hars[...]

Electrical system 93 9-3 New warning and indicator lamps • TCS indicator lamp. The lamp comes on when TCS is active. • TCS/ABS OFF lamp. The lamp comes on when TCS is disengaged and also in case of a fault in TCS. Functional changes • The miles graduation is more compressed in the higher speeds. km/hr instrument shown[...]

94 9-3 Body 9-3 Body Body color range Two new colors have been introduced: • Hazelnut (286) • Polar White (283), a base solid paint, replaces Cirrus White. Note that Cosmic Blue (264) is once again available in the U.S. market. Color code Color Paint type Note 9-3 SE 9-3 Viggen 170 Black Base solid X X 278 Laser Red Base solid X X 283 Polar Whi[...]

Body 95 9-3 Exterior/interior The following features are new for the 9-3 model year 2002: • Upgraded interior • New 16in 5-spoke alloy wheels • Body colored skirting on all SE models • New color options • ISO-fix mounting for child seat To mark the occasion of Saab’s 25 years using turbo technology, the word “Turbo” will be embossed[...]

96 Body 9-3 Doors and Locks Emergency opening of tailgate (US/CA) There is a luminous handle on the inside of the tailgate in case someone gets trapped in the luggage compartment. The handle can be pulled down towards the floor in order to release the lock so that the luggage compartment can be opened from the inside.[...]

Signat ure Technologies 97 9-3 Signature Technologies Saab Active Head Restraint (SAHR) Neck injuries are one of the most common results of rear-end collisions, and the majority occur during low-speed collisions. In fact, statistics indicate that 25% of automobile accidents with injuries involve rear-end collisions and 75% of those result in neck i[...]

98 Signature Technologies 9-3 Triple Load Paths The body of the 9-5 is designed to maintain a survival area for the occupants in the event of a collision. Basically, the energy caused by a collision is directed along designated paths to avoid an intrusion into the passenger compartment. U-shaped beams are placed in the front and rear of the vehicle[...]

Signat ure Technologies 99 9-3 Turbocharger The basics of why a turbocharger works The Ideal Gas Law states that gas temperature, pressure, and volume are all related. Compress a gas (reduce the volume) and pressure and temperature goes up. Let it expand, and temperature and pressure go down. Increase the temperature, and the pressure goes up (in a[...]

100 Signature Technologies 9-3 Why use Turbocharging? Turbocharging is a typical Swedish concept. The use of 4-cylinder engines provides far better fuel economy than 6 or 8-cylinder engine. The fact that we can achieve ample power out of the smaller 4-cylinder engines is a testament to our ingenuity. There are also tax implications in Europe, which[...]

Signat ure Technologies 101 9-3 The Saab Trionic is an adaptive system, meaning that it “learns” about different driving conditions, storing this information for use when similar driving conditions reoccur. It makes instantaneous adjustments to fuel injection, ignition and boost pressure parameters, depending on external conditions. Precise man[...]

102 Signature Technologies 9-3 Night Panel When activated, the night panel mode can assist nighttime driving by extinguishing most instruments and displays as long as the information is non-essential. The night panel feature not only turns off the associated lights to the gauges, but the gauges themselves (this can be seen by activating it during t[...]

Signat ure Technologies 103 9-3 Saab Real Life Safety “My beautiful 9-3 Convertible was totaled and I got out with only a scratch on my thumb. The car’s engineering, the seat belt, and the reinforced roof saved my life.” -- Marsha Metzger, North Caldwell, NJ ”I was in a head-on collision with my Saab, I opened the door and walked out. I lov[...]

104 Signature Technologies 9-3 sudden allergic reaction to an avocado dip appetizer. Trabolsy found himself hurtling down M-32 at 90 mph, trying to find a hospital in Alpena. “I can’t ...breathe,” he remembers his wife gasping, her head half out of the open passenger window. Fluid poured out of her eyes and ears. Her throat was swelling shut.[...]

Signat ure Technologies 105 9-3 Here are the facts: -For the period from October, 1996 through May, 2000, a driver was on the phone at the time of a crash severe enough to deploy the vehicle’s air bags during only two of the 8.1 million embedded cell phone calls placed to an OnStar Call Center -In six other cases, it was determined that the drive[...]

106 Signature Technologies 9-3 Enrolling Customers at Dedicated Delivery It is recommended that you pre-register a customer car prior to the customer picking up their new Saab. This can be done by calling the OnStar enrollment center at 888-ONSTAR1 (888-667-8271). Be sure to have the customer’s name, customer’s address, the make, model, color a[...]

Glossary 107 9-3 Glossary ABS Anti-lock Brake System – The system that monitors the amount of brake pressure and individual wheel speed to assist in a hard braking situation. ABS essentially pumps the brakes for you to prevent wheel lock-up, which keeps the vehicle under control. Aero – The high performance meets high-end luxury form. Aero for [...]

108 Glossary 9-3 Fuse – Conducts electricity to a component to enable it to work. If a fuse is pulled or blown, the feature will not operate properly. A fuse protects a circuit from a short-circuit or or an overloaded circuit. Hp Horsepower – The amount of stamina power that a vehicle has in order to maintain a desired speed. More aerodynamic v[...]

Glossary 109 9-3 Understeer – The front of the vehicle tends to continue straight ahead in a turn as the steering wheel is being turned in the intended direction. VIN Vehicle Identification Number – A number assigned to each individual vehicle that is manufactured. Each VIN is unique to its vehicle. Viggen – Swedish for “Thunderbolt.” YRS[...]

110 Glossary 9-3 Notes[...]

2002 Griffin Society Product Test Page 111 IMPORTANT - Test Instructions!! • The 2002 Griffin Society Product Test, S02T, must be taken on-line at www.saab-edu.com . * * This only applies to those employees still needing to take the test. If you already completed a written version of S02T, you do not have to retake this test using the eLearning v[...]