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 of the most important changes and additions to the Saab 9-5 and 9-3. This publication presents new features in terms to help you describe them to your customers.
• 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 …………………………………………………………………………….….. 11 Engine 9-5 Engine Range, Model Year 2002 ……………………………………………. 12 Cooling system …………………………………...………………………………… 13 Electrical system Charging System ……………………………………..................………………… 14 Bi-Xenon Headlights …………………………….............………………………… 17 High Pressure Headlight Washers ……….
Table of Contents 9-3 9-3 Introduction – Model Year 2002 9-3 Product Range ………………………………………………………..…..…. VIN (Vehicle Identification Number) MY2002 ……………………………...…. 85 89 Engine 9-3 Engine Range, Model Year 2002 ………………………………………..….. 90 Cooling System.........................…………………………………………….....… 91 Electrical System Main Instrument Unit, MIU .…………………………………………………..….. 92 Body Body Colors ……………………………………………………………………….. 94 Exterior/Interior ...........................……………………………………………...
General information Warning, Important and Note Market codes 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 between them is explained below. The codes refer to market specifications.
9-5 Product Overview 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 2.3t The Saab 9-5 Linear 2.3t is the entry-level model in the 9-5 lineup. 9-5 Linear 2.
9-5 Product Overview 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.
9-5 Product Overview 7 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.
9-5 Product Overview 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 200 hp (229 ft. lbs. / 310 Nm) B308E (Arc) • 2.3T Ecopower 250hp (258 ft. lbs./350Nm) B235R (Aero) Note B235R and B308E must be run on high-octane fuel (min.
-5 Product Overview 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 produce soot or Particulate Matter (PM).
9-5 Product Overview 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.
Service 11 Service Service Saab 9-5 Revisions • A maintenance-free battery has been introduced together with cooling box and new generator. These additions will greatly increase battery life expectancy and reduce evaporation. • “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.
Engine 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/136kW at 5500 rpm 250hp/183kW at 5500 rpm 200hp/147kW at 5000 rpm Max, torque, EEC 207 ft. lbs. (280 Nm) at 1800-3500 rpm 258 ft. lbs.
Engine 13 Cooling system New coolant Note Do not top up with the earlier type of coolant (blue-green), as this will impair the corrosion protection properties. 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 orange coolant will also be discolored by the blue-green coolant and may appear to be contaminated with engine oil, etc.
Electrical system 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-groove V-belt from the crankshaft belt pulley. The drive ratio is 1:2.85.
Electrical system 15 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 window should normally be dark/black when the level is sufficient. If it is shiny like a mirror, the battery should be changed as the level is too low.
Electrical system 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 Bi-Xenon Headlights (Available on Arc & Aero) Brief description There is a halogen bulb mounted in the headlight assembly housing. When the headlight flashers are used while the low beam is turned off, only the halogen bulb lights up (sometimes called the “flash to pass” function). The headlight assembly contains a xenon lamp with ignition transformer, control module, beam length adjustment motor, halogen bulb and parking light bulb.
Electrical system System overview • Headlamps (663FL/FR) • Halogen bulb (11) • AHL control module (664) • Xenon headlight (11a) • Main beam damping solenoid (665) • Parking light bulb (13) • Load angle sensor, front (704F) • Headlight (280) • Load angle sensor, rear (704R) • Main instrument unit (540) beam length adjustment motor 9-5
Electrical system 19 Principal components 1. DICE control module (628) 8. Halogen bulb (11) 2. Light switch (10) 9. Headlight beam length adjustment motor (280) 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) 10. Xenon headlight (11a) 11. Main beam damping solenoid (665) 12. Parking light bulb (13) 13.
Electrical system Description of operation General Xenon lamp The headlight contains a xenon lamp with ignition transformer, control module, beam length adjustment motor, H7 halogen bulb and parking light bulb. The xenon lamp is a gas discharge lamp and therefore does not have a filament. The light is generated by an electrical discharge between two electrodes. The igniter is the capsule in which the discharge takes place and is filled with xenon gas and metal halogens under high pressure.
Electrical system 21 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.
Electrical system 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 angle sensors and regulates the angle of the headlamps based on that information.
Electrical system 23 Automatic headlight beam adjustment Headlight beam adjustment motor 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 headlights will be angled down and during heavy braking when the front of the car dips, they will be angled up.
Electrical system 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 width modulated signal.
Electrical system 25 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 sensor.
Electrical system Wash/wipe systems (Standard on all 9-5 Models) Description of operation, high pressure headlight washers Note 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 headlamp. The washer nozzles are covered in the spoiler when not in operation.
Electrical system 27 (A) (A) 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) 9-5
Electrical system 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.
Electrical system 29 Rain Sensing Wipers (Available on Arc and Aero) 61 64 9 65 0 83 E 36 3D 02 6 Brief description • • • Stalk switch (61) Rain sensor (649) Relay (83 and 650) The rain sensor assumes the DICE functions regarding windshield wipers. 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 arms with wiper blades. The function is controlled by the rain sensor via two wiper relays.
Electrical system 649 541 61,618 62F 667 83 650 628 63b 668 E363D045 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) • SID (541) 9-5
Electrical system 31 1 (649) 2 (61/618) 4, 5, 6 83 667 3 (62F) 7 (63B) 650 8 8 (668) 9 (541) 5 7 4 6 3 10 (628) 9 10 2 1 E363D046 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 (667) 7. Washer fluid motor (63b) 8. Washer fluid motor (668) 9. SID (541) 10.
Electrical system 1 4, 0 2 3 E 3 63 D 0 29 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 The wiper motor is activated at high speed with the assistance of the rain sensor. 4.
Electrical system 33 E3 6 3 D 0 28 Rain sensor The light sensors generate infrared light that is refracted at a certain angle in the surface layer of the windshield if there is no snow or rain on the windscreen. When there are raindrops or snowflakes on the area that the sensors cover, the light will refract at a different angle. 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.
Electrical system 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 agreeable light and are very reliable. The following changes have also been carried out: • Only one 22-pin connector.
Electrical system 35 km/hr instrument shown New warning and indicator lamps Functional changes • • The miles graduation is more compressed in the higher speeds. • The airbag lamp is now governed via bus information from SRS to the main instrument unit. The main instrument unit uses the information to turn the lamp on/off. ESP (Electronic Stability Program) indicator. The lamp is available on cars equipped with ESP and comes on when it is active.
Electrical system 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 indicates the distance to the closest object behind the vehicle.
Electrical system 37 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 control module (502) 9-5
Electrical system 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.
Electrical system 39 Turning off SPA The text message is stored in English, Swedish, German, Spanish, French and Italian in the SPA unit. It is sent via the I bus to the SID, where it is displayed. 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.
Electrical system 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 input from the sensors in order to send the correct signal to the SID, and, in turn, to the driver.
Transmission 41 Transmission 5-Speed automatic transmission (Available on Linear and Aero, Standard on Arc) Brief description position, inside the cabin between the glove box and the bulkhead. A new 5-speed automatic transmission has been introduced on the 9-5 engines. The TCM self-diagnosis continuously monitors all the functions of the system and sets DTC’s if necessary. 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.
Transmission 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 rpm to supply a sine wave that changed with respect to frequency and amplitude. The valve body now contains 5 "on-off" solenoids and 3 PWM solenoids.
Transmission 43 System overview 9-5
Transmission Principal components The automatic transmission consists of the following principal components: 6. Clutch disc pressure solenoid valve (SLS) 531 Control module, (TCM) 502 7. Input shaft speed sensor, 532 3. Gearshift solenoid valves, (S1-S5) 531 8. Output shaft speed sensor, 533 4. Lock Up solenoid valve, (SLU) 531 9. Transmission fluid temperature sensor, 535 5. System pressure solenoid valve, (SLT) 531 10. Gear selector position sensor, 245 1. Gearbox 2.
Transmission 45 Control modules The transmission controls control module When the ignition switch is turned to the ON position, the control module will be activated and turn on the CHECK GEARBOX lamp as a function check. If no faults are found, TCM will turn off the lamp after three seconds. primarily • Shift points • System pressure • Lock-up engagement (fixed or slipping) In the event of a fault in any of the inputs/outputs, the transmission will go into Limp-home mode.
Transmission 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.
Transmission 47 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 mph) or the selector lever is moved to a position other than R.
Transmission 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 lamp in the main instrument unit. A fault code will also be stored. The transmission will now be controlled solely by the hydraulic system.
Brakes 49 Brakes Brake system System revisions The following are new: 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 system and modifications to the brake disks that will provide better braking performance on 9-5 models with 2.3 Turbo (Aero) and 3.0t V6 engines.
Brakes Front brake system ABS/ESP (Available on Arc and Aero) 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. A number of changes have been made in the engine bay and, because of this, the ABS unit has been located on a new bracket closest to the bulkhead. 9-5 models with the 3.
Brakes 51 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 new master cylinders allow a greater flow of fluid between the ESP hydraulic unit and the master cylinders. Brake fluid pulses at a much greater extent than was necessary for TC/ABS.
Brakes 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 20mm (0.78in) thick disc compared with the standard single brake disc of 12mm (0.47in).
Brakes 53 Electronic Stability Program, ESP (Available on Linear, Standard on Arc and Aero) Brief description, ESP In the U.S. market, ESP will be standard equipment on the Aero and Arc models. ESP will be optional on the Linear model. 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.
Brakes System overview • Hydraulic unit with control module (671) • Yaw rate sensor, side acceleration sensor (658) • Wheel sensor (298) • ESP switch (660) • Steering angle sensor (657) • ESP indicator lamp (47x) • Brake pressure sensor (659) • ESP OFF indicator lamp (47y) 9-5
Brakes 55 Principal components 1. 2. Brake unit including control module, valve body and pump (671) 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 switch (660) 8. Steering angle sensor (657) 9. Yaw rate sensor, side acceleration sensor (658) 10.
Brakes 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. Programming 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 requesting a certain engine torque. The engine control module uses this request to regulate the air mass/combustion.
Brakes 57 Yaw Rate / Side Acceleration Sensor Function, micro-mechanical yaw rate sensor This sensor consists of a combined micromechanical 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. This sensor measures the rotational movement around an optional axis.
Brakes Brake pressure sensor 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 with the DESIRED VALUE given by the steering angle sensor.
Brakes 59 ESP indicator lamp If the ESP or TCS function is activated while driving, a symbol in the main instrument unit will light up and go out again when the function is deactivated. The lamp is turned on/off by a bus message (ON/OFF) from the ESP control module to the main instrument unit. The lamp only comes on if engine torque is reduced and the brakes are applied.
Brakes 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 sensors • Steering wheel angel sensor • Yaw rate sensor • Side acceleration sensor • Brake pressure sensor 2.
Brakes 61 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/combustion). Using engine torque regulation means that the brakes need not be applied as often, resulting in a higher degree of smoothness.
Brakes ESP valve block Brake application The hydraulic unit comprises 12 solenoid valves that govern the brake pressure to the brake units during ABS, TCS or ESP regulation. For ESP regulation, the control module starts the pump, which continues during the entire regulating process, at the same time as the pressure-reducing valve is closed to enable a build up of pressure. Pressure is built up by opening the pressure-increase valve to supply the pump with brake fluid.
Brakes 63 Brake fluid is returned from the wheel outlet valve through the pressure-reducing valve to the master cylinder. The pump is running. Braking phases Phase 1. Pressure build up on all four wheels (filling pulse and pressure retention) Driver not braking Driver applying the brakes, see phases 1-3 If the driver applies the brakes while ESP regulation is active, the brake pressure sensor will inform the control module of the input brake pressure in the hydraulic unit.
Steering assembly Steering assembly arrangement for steering wheel adjustment. Steering System overview Miscellaneous 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.
Suspension 65 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 front subframe has been modified at several points to further improve impact characteristics.
Suspension 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 bar with 21mm / 0.83in diameter (20mm / 0.79in earlier) on sports chassis and 20mm / 0.79in (19mm / 0.75in earlier) on standard chassis.
Body 67 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. • Hazelnut (286) is a new metallic paint. Color code Color Note that Cosmic Blue (264) is once again available in the U.S. market.
Body Exterior Front bumper Rear 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 rear bumper comprises an aluminum rail, a core of cellular plastic and a painted plastic shell with integrated corner covers.
Body 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.
Body 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 is a decor panel mounted in the space for the licence plate on the trunk lid or tailgate.
Body 71 Body modifications Body modifications three reasons: have been • Improved impact characteristics • Exterior modifications • Engine modifications made for Exterior modifications and engine modifications New support sections around the headlight housing are included in the exterior adaptations. Engine modifications include adaptations of the engine mounting near the battery. The battery bracket is new with a longitudinally mounted battery and a plastic battery tray.
Body 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 any damage. The new courtesy handles are also part of the improved internal safety features as they protect the head in case of impact.
Body 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 to children inside the car in case of a collision. It also offers a comfortable ride for the children.
Body 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 features with high performance. Very high equipment level with “Aluminum-look” dashboard.
Body 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 the control module that measures the lateral acceleration forces.
Body System overview • Side impact sensors (328D, 328P) • Dual-stage airbag, driver (333D) • Seat-belt tensioners (236LH, 236RH) • Dual-stage airbag, passenger (333P) • • Airbag warning lamp in main instrument unit (540-47t) Seat position sensor (669D, 669P) • Seat-belt buckle (70D, 70P) • SRS control module (331) • Front impact sensor (332FL, 332FR) • TWICE control module (632) • Contact roller (336a) • DICE control module (628) • Side airbags (333Db, 333Pb) • Data link con
Body Principal components 1. Airbag control module (331) 7. Knee shield, driver, 3-piece 2. Side impact sensors (328D, 328P) 8. Knee shield, passenger 3. Dual-stage airbag, driver (333D) 9. Front impact sensor (332FL, 332FR) 4. Dual-stage airbag, passenger (333P) 10. Seat-belt buckle (70D, 70P) 5. Side impact airbags (333Db, 333Pb) 11. Seat position sensor (669D, 669P) 6. Seat-belt tensioners (236LH, 236RH) 12.
Body Control modules The control module receives its information from the two front impact sensors. The sensors are located on the car's bumper member so that collision forces can be detected as early as possible. 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.
Body 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 position sensor indicates that the seat is less than 30% from its front position, stage 1 will be activated.
Body Front impact sensor Side impact sensor The front impact sensor is used to detect collision forces at an early stage and send information to the control module. The pressure from the side impact sensors is compared by the control module with the lateral value from the accelerometer before it activates the side airbag. This is the same side impact sensor used previously, but the control unit has new software. The system has two front impact sensors.
Body 81 Driver airbag The driver airbag is mounted inside the steering wheel. After an activation command, the control module will apply a current to ignite the driver charges. The driver charges generate a gas when they burn. The filter cools the gas and removes any particles before it passes to the airbag. 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.
Body The passenger airbag consists of a gas generator and an airbag. It has a volume of approx. 120 l (4.2 cu.ft.). The airbag is screwed to the dashboard and held in place with fabric foil. The wiring harness is connected to a 4-pin connector that branches off to two 2-pin connectors on each igniter.
Body 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 function was not communicated using the bus. A system fault will be indicated by the airbag warning lamp in the main instrument unit coming on.
Body Doors and locks Trunk lid lock cylinder, Sedan Tailgate lock cylinder, SportWagon 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. The tailgate lock cylinder remains on the SportWagon, but is protected by a cover (see illustration, above right).
9-3 Product Overview 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 Options available on 9-3 SE 5 door include: For 2002 in the U.S., the 9-3 SE will be available as a 5-door model and also as a convertible. All 9-3 SE models in the U.S. will be equipped with the B205R engine.
9-3 Product Overview 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.
9-3 Product Overview 87 9-3 Viggen 3D/5D/Convertible The Viggen will only be available in the CA/US market. The Viggen will be available as a 3door, 5-door or convertible. For M2002, the Viggen will be available in Black, Silver, Laser Red, and Steel Gray. The interior will be available in black leather with charcoal inserts, or sand beige leather. The seats are Viggen-embossed, bolstered leather. The Viggen will be equipped with the B235R engine and manual transmission only.
Product Overview 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 with several enhancements, such as LEDs instead of bulbs, has been introduced.
Product Overview 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- Body type 3 = 3-door 5 = 5-door 7 = 2-door (convertible) 7- Gearbox 5 = Manual 5-speed 8 = Automatic 4-speed 8- Engine variant K = 2.
Engine Engine Engine range, Saab 9-3 model year 2002 Engine B205R (SE) B235R (Viggen) Compression ratios 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) 230hp/169kW at 5500 rpm 5750 rpm (aut) Max torque, EEC 205 ft.lb. (280Nm at) 2200-5000 rpm (man) 258 ft.lb.
Engine Cooling system Note 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. Do not top up with the earlier type of coolant (blue-green), as this will impair the corrosion protection properties. 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 types of coolant that were blue-green.
Electrical system 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 harsh light and are very reliable. The following changes have also been made: • Only one 22-pin connector. • All lamp bulbs have been replaced with LEDs.
Electrical system km/hr instrument shown 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.
9-3 Body Body Body color range Two new colors have been introduced: • Hazelnut (286) • Polar White (283), a base solid paint, replaces Cirrus White. Color code Color Paint type 170 Black 278 Note that Cosmic Blue (264) is once again available in the U.S. market.
Body 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 on all outboard seats of the SE models.
Body 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.
Signature Technologies 97 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 injuries.
Signature Technologies Triple Load Paths Pendulum B-Pillar 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.
Signature Technologies 99 Turbocharger high pressure and very high heat exists, which means the gas has a very high energy level. 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 an enclosed space) or the volume goes up (it expands).
Signature Technologies Trionic Engine Management 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 are more favorable if you own a vehicle that has a lower displacement engine.
Signature Technologies 101 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.
Signature Technologies Night Panel Console-Mounted Ignition 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 the day).
Signature Technologies 103 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 “On December 26, 2000, while driving in Clearwater, Florida, I suffered a stroke (I’m only 48 years old). I had a cell phone with me but was rapidly losing the vision in my eye and was becoming paralyzed on the right side.
Signature Technologies 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. Hands-free Telephone New York recently passed a law banning the use of hand-held telephones in automobiles. OnStar’s hands-free embedded cellular phone meets the demands of the NY law that went into effect on November 1, 2001.
Signature Technologies 105 customer lives. On occasion the process may take what seems to be a very long time to generate a new number. At this point OnStar is competing for telephone numbers in the customer’s area along with every other phone company, cellular service or pager company.Once a new number is generated, your customer’s number is then downloaded into every cellular tower in the country so that when a call is made the system will recognize the caller as having authorization to make the call.
Signature Technologies 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 and license plate number of the new Saab. An OnStar advisor will provide this information to emergency workers to help them locate and identify the car.
Glossary 107 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. Convertibles do not have a B-Pillar, and therefore do not have a Pendulum B-Pillar. CCA Cold Cranking Amp – A rating used to classify the strength of a battery in cold weather conditions. It is measured at 32 degrees Fahrenheit.
Glossary 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. Sensor – A device used to provide information to the various ECMs. Many different types of sensors are used on our vehicles. Some main components act as sensors to provide information (e.g. spark plugs for the T7 Trionic Engine Management system).
Glossary 109 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 Yaw Rate Sensor – The sensor used with ESP to measure side acceleration, vehicle speed and the steering angle of the vehicle.
Glossary Notes 9-3
2002 Griffin Society Product Test 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 version. • Detailed test instructions are provided at www.saab-edu.com. Just click on How to Take an Online Test. • When you are ready to take the test, go to www.