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Saab MY02 Automobile User Manual

1. 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 types of coolant that were blue green Saab original Long life Coolant must be used in order to obtain the desired coolant properties The normal mixture of 50 coolant still applies The earlier blue green type and the new orange type will both be available as spare parts Technical Data Saab Original Long Life Coolant Type Ethylene glycol Color Orange Mixing 50 Part Number 200 I drum available later 4 can 02 86 542 Engine 91 Note Do not top up with the earlier type of coolant blue green as this will impair the corrosion protection properties The orange coolant will also be discolored by the blue green coolant and may appear to be contaminated with engine oil etc In an emergency conventional blue green coolant can be mixed with the Long life orange coolant However once the conventional coolant has been added the Long life properties are lost and the coolant must be changed at normal intervals For this reason care must be taken when topping off a vehicle with Long life coolant to be sure contamination does not result Adding any conventional coola
2. An intercooler simply places the airflow stream between the turbo compressor outlet and the combustion chamber through a radiator The more you can cool the airflow the better because compressed or cooler air allows for more air particles to be burned once it reaches the combustion chamber The intercooler using air and water allows for two stages of cooling to take place in one area to be more effective in the cooling process of turbocharging Oil is used on the moving parts within the turbocharger as a cooling agent as well 99 100 Signature Technologies 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 The process also has its use in aircraft technology which we find relevant to implement into our vehicles as a cornerstone of our brand Trionic Engine Management The Trionic system is called Tri because it originally simultaneously controlled three engine functions ignition timing fuel injection and boost pressure beginning with the 1999 9 5 and 2000 9 3 Trionic also controls the electronic throttle One clear benefit of controlling these functions is reduced emissions w
3. If the temperature still rises above 155 C 311 F for longer than 10 seconds or 140 C 284 F for longer than 60 seconds at speeds above 180 km h 111 mph DTC P0218 will be set A bus message TRANSMISSION OVERHEATING will be sent from the TCM to the SID display and the transmission will go into limp home mode only 5th gear 2nd gear and reverse will be available Transmission 43 System overview E440b 072 9 5 44 Transmission Principal components The automatic transmission consists of the following principal components 6 Clutch disc pressure solenoid valve SLS 1 Gearbox 531 2 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 9 5 Transmission Control modules The transmission control module controls primarily e Shift points e System pressure e 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 is only to be used in the Saab 9 5 together with the relevant engine variant The control module is delivered unprogrammed when purchased as a Spare part and must therefore be pro
4. Brakes Brake System REVISION S 28202 cciciort ceri E A EAT a 49 Electronic Stability Program ESP sic canccdoovscooss eer auras 53 Steering Assembly Steering Modifications sssaaa noina I Ann A De Ende 64 Suspension Suspension Modifications 5 25 sevesieeeedescewevecceab suena ssa seceewaecceaysseaseoziated 65 Body BOdYSG OOM S ak a cenit pat ser tae wie ted a aE SE Nanette NTE iaia 67 EXE OR Ga cee re EEN a AE OEE a Aa S eae 00 Interior Equipment scx siertsncccdeebiniee seen ieee hemeeoedeu mse cece vecenwad teceabeeexeeaaerlee 72 Airbag SRS jedan e E EE AEE aAA nes AA ORDES et cneee ex 75 9 5 Table of Contents 9 3 9 3 Introduction Model Year 2002 9 3 Product Range eie iaee a aa aa Aaa aeaa EA ole ne eiaa 85 VIN Vehicle Identification Number MY2002 W sssseeeeeeeee ener nerne 89 Engine 9 3 Engine ne Model Year 2002 ia csuccacramencusenwsestinneencomnaumeacseunees 90 Cooling System mo SEE E E E E N Ol Electrical System Main Instrument Unit MIU cs titans cuca danen ov ectunudlslacany dwnkwlasse dude Mevieeneiauacsd 92 Body BOOV GOlOIS sareren e a T E a cerned ER 94 Ext rior INterlOtes A E E EE E E EE E E E l Saab Signature Technologies 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
5. This location positions the sensor as close to the car s center of gravity and center line X axis as possible Its housing is hermetically sealed and filled with nitrogen to protect the components from being affected by the environment The sensor is used to measure the physical forces of the yaw rate and the side acceleration of the vehicle Brakes 57 E5210085 Function micro mechanical yaw rate sensor This sensor measures the rotational movement around an optional axis The yaw rate sensor is used to detect and register all the rotational movement around the car s vertical axis i e whether the car is turning The sensor sends this ACTUAL VALUE to the ESP control module which compares it with a DESIRED VALUE given by the steering angle sensor The yaw rate is calculated as the car rotates around its own axis and is expressed in degrees seconds Yaw rate can also be calculated by measuring side acceleration vehicle speed and steering angle If these three values correspond with the value measured by the Yaw Rate Sensor YRS then the system will assume that the car is stable The main components in the YRS are two flexible oscillator elements 58 Brakes 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 directio
6. prices and different emission testing standards 9 5 Product Overview 9 10 9 5 Product Overview Vehicle Identification Number VIN M2002 Example YS3EF45C623008642 Y Northern Europe Country S Sweden 3 3 Saab Automobile AB 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 passenger airbag H Saab 9 5 Aero with driver and passenger airbag Body type 4 4 door ak 5 5 door SportWagon Gearbox 5 Manual 5 speed a asa 9 Automatic 5 speed Engine variant E 2 3t G 2 3 Turbo High Output Z 3 0t V6 9 Check character 0 9o0rxX 10 Model year 2 2002 11 Place of manufacture 3 Trollhattan 12 Serial number 000001 999999 Service 11 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 at the first service Oil level check on manual gearboxes has been discontinued while check for oil leaks remains Change of brake and clutch fluid has been changed from the mileage based service interval to a time based service interval For the U S market the new brake and clutch fluid change interval is 24 months New item where the drain hose to t
7. pulses second in close steps e 0 3m 12in or closer continuous tone If the driver reverses at a speed greater than 1 8 m s 6 5 km h or 4 mph the SPA is of no benefit since the indication of distance is limited to 1 8m 5 9ft behind the car The driver has E385D 023 therefore only 1 second to react and bring the car to a halt In addition the braking distance must be taken into account For the SPA to be of benefit moderate speeds must be maintained If the distance sensors are covered by ice snow or dirt their function will be impaired In such cases the distance sensors should be wiped clean When reversing on a surface that is highly reflective to ultrasound the system can indicate the distance to the ground instead of the closest object behind the car This can occur for example on unpaved roads or other uneven surfaces Testing of the function of the SPA must be carried out on an even surface with no objects placed on the ground Objects alongside the car The SPA also takes objects beside the car into consideration such as when reversing alongside a garage wall In cases where the outer distance sensors detect an object that is not detected by the center sensors the object is indicated as an object alongside the car The threshold for detection of objects beside the car is approx 40 cm 16 in If the object alongside the car remains at a constant distance for longer than 3 seconds side indication is
8. 0t V6 Arc Larger ventilated rear discs 300mm 11 81in with new carrier and new rear brake caliper The 3 0t V6 is equipped with larger front discs previously fitted only on 9 5 Aero models 306mm 12 05in In the U S market these changes will NOT pertain to Linear models Location of ABS unit Front wheel sensor mounting Disc backing plates front and rear 50 Brakes 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 market this change means that Arc models will get the larger front disks previously fitted only to Aero models A new carrier has been introduced for the front caliper The distance between the bolts has been increased to reduce strain and to improve stiffness Torx M14 bolts have been used with a fixed washer to protect the aluminium steering swivel member ABS ESP Available on Arc and Aero 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 The ESP stabilizing system Electronic Stability Program is available as an option The master cylinder and lines to the hydraulic unit have been changed because the ESP unit r
9. 229 ft lbs 310 Nm B308E Arc e 2 3T Ecopower 250hp 258 ft lbs 350Nm B235R Aero Note B235R and B308E must be run on high octane fuel min 92 AON in order to deliver the specified engine torque Electrical system Charging system New generator and new cooled battery Lighting system Bi Xenon Bi Xenon lighting is available as an option High pressure headlight washers Headlight lenses are washed with high pressure jets that replace the wash wipe system Rain Sensing Wiper A rain sensor is integrated into the wiper delay function of DICE Saab Parking Assistance system SPA The Saab Parking Assistance system is designed to inform the driver of an obstacle behind the car The system is operational when driving the car in reverse Main instrument unit New compact and lighter main instrument unit with several enhancements such as LEDs instead of bulbs has been introduced Transmission 5 speed automatic transmission New 5 speed automatic transmission replaces the previous 4 speed Brakes Brake system New master cylinders and power assisted brakes on all models Ventilated rear brake discs on certain models Electronic Stability Program ESP This safety system governs the engine torque and brake force to aid the driver during evasive maneuvers Body Exterior New integrated front amp rear bumpers Impact protection Enhanced impact protection Airbag system Highly developed sys
10. New Full Leather interior with Turbo embossment 9 3 Product Overview 89 Vehicle Identification Number VIN M2002 Example YS3EF45C623008642 1 Geographical area Y Northern Europe 2 Country S Sweden 3 3 Saab Automobile AB 5 Model Series F Saab 9 3 SE with driver and passenger airbag Se 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 ee 8 Automatic 4 speed 8 Engine variant K 2 0 turbo High Output Pec G 2 3 Turbo High Output 9 Check character 0 9o0rx 10 Model year 2 2002 11 Place of manufacture 2 Trollhattan 7 Nystad Finland 12 Serial number 000001 999999 9 3 90 Engine Engine Engine range Saab 9 3 model year 2002 en Turbocharger make type Mitsubishi Mitsubishi ee SEER 15T kr rd 15T Wastegate prestressing prestressing Basic charging pressure 0 45 bar 0 03 0 45 bar 0 03 Max power EEC 205hp 151kW 230hp 169kW at 5500 rpm man at 5500 rom 5750 rpm aut Max torque EEC 205 ft lb 280Nm at 258 ft lb 350Nm at 2200 5000 rpm man 1900 4200 rpm man 250Nm at 1900 5750 rpm aut Spark plugs make type 10 10 Spark plugs electrode gap plugs electrode gap 0 95mm 0 05 95 mm 0 05 eme 95 mm 0 05 Engine management system Trone T7 Recommended fuel octane number AON Cooling system
11. VALUE e f the car starts to understeer when the front tends to continue straight ahead in a bend the inside rear wheel will be braked FEFFF FEER E521D039 e Ifthe car starts to oversteer the rear tends to drift out the system will engage and brake the outside wheel until the measured and the calculated yaw rate correspond Programming The ESP control module automatically reads all the information concerning the engine and transmission from DICE Tech 2 is used to program the chassis variant sport or standard Steering angle sensor The steering angle sensor is located on the steering column between the steering wheel and the intermediate steering shaft with universal joint The sensor has its own microprocessor with self diagnosis and is connected to the P bus It is used to send information on the steering angle 530 is turns to the right 530 is turns to the left The control module receives information concerning the intention of the driver i e steering wheel rotation and the control module calculates the speed at which the steering wheel was rotated This information is very important to the ESP control module which has to calculate a possible regulation using this DESIRED VALUE 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
12. Verizon doesn t have direct coverage they have signed agreements with local companies The FCC mandated that the cellular industry build into the system an A and a B side to the signal being carried You or your customer may experience a message when trying to call OnStar or make a Personal Calling call that says something like not authorized to make a call or press your authorization number into the keypad Don t end the call Because if a call is not successful in going through the system will flip over from the A side to the B side or vise versa and will try completing the call again This is more likely to happen if your customer is traveling outside their home cellular market Testing the OnStar System at PDI Be sure the technician tests the OnStar system during the test drive when completing initial PDI All the technician needs to do is push the blue OnStar button twice to connect to OnStar The technician should tell the advisor he is testing the system and ask if they received a GPS signal If a cellular call is not established or there is no GPS signal the technician should write a Repair Order RO to fix the problem This will reduce the likelihood of experiencing a problem at delivery with the customer 106 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
13. angle sensor which is located on the steering column between the steering wheel and the intermediate shaft with the universal joint It has also been given a new 9 5 E631 D013 Miscellaneous Because the new V6 diesel engine has a new power steering pump the front and rear pressure lines are new and have been replaced for space reasons in the engine compartment A new longer cooling coil has been introduced on the front pressure line to provide improved cooling There is an additional cooling fin on the B235R and B308E The steering gear now has narrower tolerances to provide the best possible characteristics for all models The control valve has a new specification and is not backward compatible 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 car s steering is more responsive which the driver experiences as the car responds better and faster A number of different measures have resulted in these new characteristics The front subframe has been modified at several points to further improve impact characteristics The new towers with center bushings are now designed so that the bushings will give in case of hea
14. been introduced Full Leather seats with Turbo embossed backrest Leather textile seats with Turbo embossed backrest standard interior e The Turbo leather seats replace the existing leather seats e Both interior options will have leather inserts in the doors ISO fix mounting for child seat ISO fix is standard on all 9 3 3 door and 5 door models It will also be standard on the convertible from model year 02 Body 95 96 Body Doors and Locks 08310079 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 9 3 Signature Technologies 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 Injuries of this type often called whiplash seem to be caused by the differential movement of the occupant s head relative to the neck and spine that occurs during an impact from behind In certain situations the result can be a serious long term injury With the launch of the 9 5 and
15. 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 The front airbags will be activated earlier if the seat belt buckle is not locked A collision on one side of the car will activate the side airbag only on the side where the collision has taken place In situations where the front airbags are activated to stage 1 only there will be a safety activation of stage 2 after 100 ms This will disarm the airbag so that there is no charge left to activate after the collision The seat belt tensioners will not be activated if the seat belt buckle is not locked Reserve power supply The control module has an integrated reserve power supply that supplies it with current for 150 ms after the normal power supply has ceased This function has three capacitors that maintain the level of current to the system and enable the front airbags to be activated for 150 ms The side impact sensors are then turned off to save energy Bus communication continues during this time Body 79 E850D031 Front impact sensor The front impact sensor is used to detect collision forces at an early stage and send information to
16. door inserts e Manual climate control New 5 spoke 16in alloy wheels are standard on 9 3 SE models 9 3 Options available on 9 3 SE 5 door include Automatic transmission Heated front seats Premium Package Mica Metallic paint The 9 3 SE Premium Package includes Memory driver s seat Power passenger s seat Automatic Climate Control ACC Upgraded audio system with amplifier Full leather interior No charge scheduled maintenance Sport chassis Leather sport steering wheel 86 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 Standard equipment on 9 3 SE convertible models include Power memory driver s seat Power passenger s seat Woodgrain dash Leather seats Leather door inserts Automatic Climate Control No Charge Scheduled Maintenance Options available on 9 3 SE convertible include Automatic transmission Heated front seats Mica Metallic paint Blue convertible top Sport Package The 9 3 SE convertible Sport Package includes 9 3 17in double 3 spoke wheel 17in Pirelli performance tires Rear spoiler Leather Sport steering wheel 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 3 door 5 door or convertible The Viggen will be equipped with t
17. for the ignition on the steering column and then performing all of those other functions in most cars is far from ergonomic The ignition is also located in the center console for simplicity in design and manufacturing All Saab vehicles have a gearbox lock mechanism meaning that the gear selector must be in the appropriate position to get the key out of the ignition e g reverse for manual transmission vehicles Placing the ignition cylinder which is used to lock the vehicle s gearbox near the gear selector allows for fewer parts and a simpler more efficient design Saab Real Life Safety My beautiful 9 3 Convertible was totaled and 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 was in a head on collision with my Saab opened the door and walked out love and appreciate my new Saab as much as my last Bill Berg Atlanta GA These customers know first hand about Saab Real Life Safety They may not know about the Saab accident investigation research team that has studied over 6 000 cases in which a Saab car has been involved in an accident since 1969 But they experienced everything the accident investigation and research team has learned because that knowledge goes directly into the design and development of every Saab That s why Saab s Real Life Safety is such an integral part of our Sa
18. heats the gas so you get even higher pressures and more power Unfortunately most of that heat which is the same as energy is dumped into the exhaust before it can be used The energy is simply not in the cylinder long enough to transfer all of the heat into useful mechanical energy Enter the turbocharger A turbocharger has two turbines the exhaust gases spin one turbine which is connected via a simple shaft to the turbine on the compressor side The compressor turbine is connected to the air intake of the engine This results in more air being forced into the air intake which eventually is routed to the combustion chamber When you force more air into the combustion chamber you must force in more fuel and the result is more power Using the exhausted air is a good thing because energy heat that would have otherwise been wasted is creating additional energy without putting any major stress on the engine Supercharging accomplishes the same goal but is generally belt driven which requires more energy to be spent to create the increased airflow This means that comparable power by the use of a turbocharger can be created out of a 4 cylinder engine as opposed to using 6 cylinder or 8 cylinder engines which are far less fuel efficient The exhaust side of a turbo When an exhaust pulse exits the cylinder at high temperature and high pressure it gets merged with other exhaust pulses and enters the turbine inlet Since t
19. high speed with the assistance of the rain sensor Washing The washer pumps are activated and the rain sensor starts the windshield wipers 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 with two clips A silicone cushion is located between the sensor and the windshield to follow the shape of the windscreen The rain sensor is protected by a cover The cover can be removed using tool 82 93 474 When activated in automatic mode position 1 the wipers will make one reference stroke to calibrate the sensor while the windshield is clear and to inform the driver that the sensor is activated If the ignition has been turned off the sensor must be reactivated by moving the stalk switch to position 0 and then back to position 1 The rain sensor consists of two LEDs that generate infrared light two photo diodes that receive light signals and one photo diode to distinguish between night and day The sensor controls automatic mode position 1 high speed position 3 and wash wipe position 4 Function A night day photo diode measures the external light and informs the rain sensor so it can adapt its sensitivity The system recognizes that the driver needs increased
20. information that the control module receives from the different sensors the two stages will ignite at different times See control module information The gas composition is e 70 argon e 20 nitrogen e 10 helium Seat belt tensioners U S specification vehicles have a new type of seat belt tensioner with new internal tuning in the torsion section This tensioner is not compatible with previous model year vehicles NATLZ KA _ ALIN 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 The car is equipped with a central warning lamp that MIU turns on together with the airbag warning lamp The airbag warning lamp will come on when the ignition key is turned to ON and stays on for 3 4 seconds provided there are no DTCs stored If a DTC is present the lamp will continue to be lit The airbag warning lamp does not have its own diagnostics 9 5 Body 83 84 Body Doors and locks E831D160 Trunk lid lock cylinder Sedan The lock cylinder in the trunk lid of the Sedans has been
21. into consideration any wear that may be present in the gearbox to ensure smooth gear changing even when the gearbox is worn In this adaptive system the TCM compares the current gear changing performance with a gear changing matrix in the software and learns whatever each gear changing situation requires with respect to pressure time in order to perform the gear change comfortably This memory as well as the memory for fault codes is stored in an EEPROM which means that the information will remain in memory even if the power is cut Because of this the TCM must be reset using Tech 2 after carrying out repairs exchanging the gearbox or TCM and after SPS programming The TCM is located in the same position inside the cabin between the glove box and the bulkhead The TCM self diagnosis continuously monitors all the functions of the system and sets DTC s if necessary As before it is possible to choose between three different driving programs e Normal e Sport e Winter Slipping lock up A new feature with this gearbox is that the lock up clutch is allowed to slip under certain driving conditions allows a difference in speed of 50 200 rpm between the pump and turbine wheels to avoid downshifting unnecessarily for moderate torque requests This feature saves fuel and prevents vibration and noise in the body Slipping lock up is allowed in 4th and 5th gears and only when the transmission fluid temperature is a
22. left wheel sensor 298FL Front right wheel sensor 298FR Rear left wheel sensor 298RL 9 5 Brakes 55 E52 1D036 Rear right wheel sensor 298RR ESP TCS ON OFF switch 660 Steering angle sensor 657 o N Yaw rate sensor side acceleration sensor 658 10 Brake pressure sensor 659 56 Brakes Peele BEE Ce Ole FFF EF FE 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 requesting a certain engine torque The engine control module uses this request to regulate the air mass combustion The stabilizing action of the ESP system is based on calculations made in the control module microprocessor The control module evaluates the information from the system sensors wheel speed sensors steering angle sensor yaw rate sensor side acceleration sensor and pressure sensor Data from these sensors informs the control module of the driver s intentions e g the direction in which the driver wants to go if the driver is braking etc These values are processed in the control module which continuously calculates the course ACTUAL VALUE and compares it with the course determined by the driver with the steering wheel DESIRED
23. pillars is completely new and much thicker than before The B pillars also contain a new seat belt slider to help the movement of the belt 9 5 _L 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 The child safety equipment fulfils the demands of different countries and markets ISO fix cannot be used together with integrated child seats The backrest with mounted child seat is slightly longer and does not allow access to the ISO fix hooks Note Customers must purchase an ISO fix compatible child seat in order for this feature to function properly gt Ess50019 Body 73 74 Body i Eassboig 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 dashb
24. rating used to classify the strength of a battery in cold weather conditions It is measured at 32 degrees Fahrenheit C Pillar The rear pillar connecting the roof to the rest of the vehicle on a Sedan The C Pillar is reinforced and is a crucial part of the safety cage construction and the structural rigidity of the vehicle Convertibles do not have a C Pillar Databus The system that allows the ECMs to communicate to one another if necessary Electronic signals are sent on the bus with instructions or notifications of certain on board changes DICE Dashboard Integrated Central Electronics An ECM which is responsible for many of the lighting circuits on the vehicle e g headlamps turn signals etc DICE is also responsible for activating the AC system compressor DICE acts as the gateway for the databus system meaning Tech 2 uses this system to communicate with the other ECMs DTC Diagnostic Trouble Code The code that identifies a fault or failure The DTCs are stored in the memory of the respective ECM and can be read using the Tech 2 device D Pillar The rear pillar connecting the roof to the rest of the vehicle on a SportWagon and a 3D 5D The D pillar is reinforced and is a crucial part of the safety cage construction and the structural rigidity of the vehicle Convertibles do not have a D Pillar ECM Electronic Control Module A microprocesser that has its own area of responsibility Each E
25. 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 ___ _ E351 D1247 The rear sensor is fitted between the subframe and the lower transverse link and receives information on the transverse link movement in relation to the subframe This information is sent on to the AHL control module as a pulse width modulated signal The AHL control module governs the angle of the headlamps using the information provided by the two load angle sensors 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 9 5 26 Electrical system Wash wipe systems Standard on all 9 5 Models 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 headlamp The washer n
26. 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 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 9 5 N AI WWII SI ee 1n aw Tailgate lock cylinder SportWagon The tailgate lock cylinder remains on the SportWagon but is protected by a cover see illustration above right Note The SportWagons do not require the emergency handle because a release latch is already located on the liftgate and it is possible for the trapped occupant to crawl over the seat back to exit the vehicle in an emergency 9 3 Product Overview 85 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 e SE 5 door amp convertible only e 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 and also as a convertible All 9 3 SE models in the U S will be equipped with the B205R engine Standard equipment on 9 3 SE 5 door models include e Power driver s seat e Sunroof e Woodgrain dash e New Leather textile seats e Leather
27. stored data set that defines ideal driving conditions Using this data as a reference it simultaneously monitors compares and adjusts ignition fuel injection and turbo boost pressure to operate the engine more efficiently 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 management of the engine s combustion process yields numerous advantages It becomes easier to reduce exhaust emissions than in a_ conventional system Fuel consumption is also reduced as a result of a more precise combustion In the Trionic system the fuel injection valves are individually controlled for each cylinder Each injection valve sprays two jets of fuel toward the two intake valves of the cylinder In this way fuel can be supplied to the engine with even greater precision Before the injection valve opens the microprocessor initiates a phase in which it computes the exact amount of fuel to be injected into the cylinders based on engine load RPM temperature and other factors Immediately before the fuel injection phase is terminated the processor monitors whether the driver has moved the accelerator pedal since this phase began and takes any necessary corrective action Fuel inj
28. the course chosen by the driver with the steering wheel DESIRED VALUE 1 Ifthe car starts to understeer when the front tends to continue straight ahead in a bend the measured yaw rate ACTUAL VALUE will be lower than the calculated The system will brake the inside rear wheel in the bend until the measured and the calculated yaw rate DESIRED VALUE correspond with each other 9 5 E521D038 2 If the car starts to oversteer the rear tends to drift out the measured yaw rate ACTUAL VALUE will be higher than the calculated The system will then brake the outer wheels until the measured and the calculated yaw rate DESIRED VALUE correspond with each other When the system is activated it can counteract a skid by braking one or two of the wheels without the driver needing to touch the brake pedal The system reduces engine torque after an engine torque request to the engine control module and applies the brakes on the wheels individually The ESP system comprises three different functions ABS TCS and ESP ABS and TCS have the same function as earlier See the respective description of operation The wheel brakes are the most efficient and fastest way of stopping a spinning wheel while engine torque regulation is the smoothest and most comfortable These two methods often work simultaneously E521D037 Engine torque regulation Engine torque regulation takes place after bus communication with the engine
29. the 9 3 in early 1998 the Saab Active Head Restraint SAHR introduced a world first innovation which effectively reduces the relative movement of the front seat occupant s head and consequently also reduces the risk of whiplash Volvo has a system called Whiplash Protection System WHIPS intended to achieve the same objectives WHIPS is standard on all Volvos just as SAHR is standard on all Saabs While SAHR and WHIPS have the same objective they accomplish it in very different ways Saab s SAHR is a mechanical device based on the lever principle and is designed to operate in rear collisions equivalent to as little as a 10 mph impact In a rear collision of sufficient force the occupant s body is naturally forced into the seat back engaging a pressure plate which moves toward the rear of the seat A lever attached to the pressure plate moves the head restraint up and forward to catch the occupant s head before the occupants head can whip back Whiplash generally occurs when the head passes beyond parallel when being forced back The occupant is naturally forced down and into the seat SAHR helps keep the occupant in position and maintain head neck and spine cervical and lumbar alignment In fact lumbar injuries can be reduced by up to 70 The SAHR system may also reduce injuries during a strong rebound from the restraint system caused by a frontal impact After SAHR has been activated it simply retur
30. 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 leads connected to them one for the power supply and one for transmitting the signal to the control module The sensor contains an acceleration sensor and a communication circuit It sends digital information containing status messages for diagnosis and acceleration values from 0 127 g on a lead to the control module Calculations concerning the igniter and whether it should be activated are made in the control module In case of a fault in the front impact sensor the airbags will still inflate but somewhat later than would otherwise be the case The front impact sensors communicate by modulating the continuous power supply from the airbag control module which means that the sensors draw more or less current These changes are detected by the microprocessor in the control module Side impact sensor 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 Seat belt buckle sensor This sensor is used to detect whether the seat belt buckle is locked or not Using information from the seat belt buckle sensors and the seat posi
31. the speedometer will illuminate Also any gauge will be individually reactivated if necessary For example if the fuel level drops below 4 gallons the fuel gauge cluster will light up Or if the radio is adjusted the Saab Information Display SID will illuminate for about 10 seconds If any warning lamps need to illuminate the Main Instrument Unit will provide the driver with the information they need The Night Panel feature benefits our customers because glare from the instruments at night is often enough to cause significant eye fatigue When a customer wears eyeglasses the sensitivity to the light becomes greater and eye fatigue is increased Console Mounted Ignition Building on our aircraft heritage the console mounted ignition is designed to be both safe and convenient for the driver and provide additional security for the car itself For the driver this location keeps the key and any other items on a key chain away from his her knee in the event of an accident minimizing the chance of injury Saab s real life crash investigations revealed a number of knee injuries due to steering column mounted ignitions From a convenience and ergonomic perspective placing the ignition in the center console allows the driver to make one simple move to buckle their seatbelt start the vehicle release the emergency brake select the appropriate gear and put their hand back on the steering wheel in one fluid motion Searching
32. the stalk switch The sensor is most sensitive with the knob in its uppermost position The system switches between single and continuous strokes depending on the amount of snow or water that is on the windscreen The sensitivity will increase in darkness In the U S the system will be available as part of an optional package on Saab 9 5 Arc 3 0t and Aero models 29 30 Electrical system 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 61 4618 Principal components Rain sensor 649 Windshield wiper stalk switch 61 618 Windshield wiper motor 62F Relay rain sensor 650 a fF WP Relay intermittent wiper 83 9 5 Electrical system 31 Relay headlamp wsher fluid pump 667 Washer fluid motor 63b Washer fluid motor 668 SID 541 10 DICE 628 o Oa N amp 32 Electrical system E363D029 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 Low speed The wiper motor is activated at low speed without the assistance of the rain sensor High speed The wiper motor is activated at
33. though the ESP OFF indicator is illuminated Request for engine torque Engine torque regulation takes place through throttle control and ignition retardation Throttle control is relatively slow in comparison with ignition retardation A rapid engine torque regulation means that the brake will not have to be applied as often and therefore offers a much higher level of comfort Torque request during engine braking The function is the same as in earlier TC ABS systems The request for higher engine torque is sent by the control module in order to maintain course stability The function is activated when downshifting severely and on slippery surfaces 60 Brakes E521D037 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 e Wheel speed sensors e Steering wheel angel sensor e Yaw rate sensor e Side acceleration sensor e Brake pressure sensor Data from these sensors inform the control module of the driver s intentions such as the direction in which the driver wants to travel if the driver is braking etc The ESP control module which is integrated in the hydraulic unit continuously calculates the course of the vehicle ACTUAL VALUE and compares it with
34. to avoid an intrusion into the passenger cabin Crumple zones are simply how the sheet metal distorts to absorb energy during a collision Saab also uses crumple zone technology to assist in the energy absorption process but will not rely solely on it for passenger safety Pendulum B Pillar For decades Saab has worked diligently to develop and refine side impact protection systems to better protect the vehicle s occupants One of the most recent Saab safety developments is a system that actually directs side impact collision forces away from the upper body area of front seat and rear seat passengers Detailed automotive safety studies and computer simulations have helped Saab engineers learn how a car s structure should deform in a collision to minimize occupant injury As a result Saab has configured the side structure particularly the B pillar directly behind the front door door beams and floor structure to act like a pendulum Here s how it works the B pillar in all Saab hardtop models is constructed of high strength steel to be very stiff in the upper and center sections This helps prevent the pillar from deforming into the driver s and front passenger s upper body area and to direct the energy caused by the impact into the lower structure The lower part of the pillar is more flexible therefore it will give way easier and will absorb more of the collision force The collision force or impact ener
35. 628 Windshield wiper stalk switch 61 Relay high pressure headlight washer fluid pump 667 Motor high pressure headlight washer pump 668 9 5 Electrical system Rain Sensing Wipers Available on Arc and Aero Brief description e Stalk switch 61 e Rain sensor 649 e 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 arms with wiper blades The function is controlled by the rain sensor via two wiper relays The windshield wipers have two speeds high low and an automatic mode In automatic mode the rain sensor sensitivity can be adjusted using a control on the stalk switch The rain sensor measures the amount of moisture on the windshield using sensors that generate infrared light The sensor automatically starts the wiper blade on the windshield and adjusts the speed to the current weather conditions The system calculates the need to activate the windshield wipers in all weather conditions J E363D026 The rain sensor assumes the DICE functions regarding windshield wipers The system is activated by moving the stalk switch on the steering wheel located to the right of the steering wheel to position 1 On cars without rain sensor this position is for intermittent wiper operation How sensitive the sensor is and how often the wipers operate can be adjusted with the knob on
36. CM monitors and adjusts for optimal performance in its specific area Most ECMs communicate via a databus system ESP Electronic Stability Program A system that uses the brake system and throttle to help correct for Oversteer and Understeer in abnormal driving conditions i e crash avoidance 108 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 Hp Horsepower The amount of stamina power that a vehicle has in order to maintain a desired speed More aerodynamic vehicles require less Hp as a result of lower resistance IR Infrared A signal sent to detect items that are different from ideal or stable conditions e g Rain Sensing Wipers use an infrared signal to detect water on the windshield LED Light Emitting Diode These are used in lieu of bulbs LEDs last much longer and provide more subtle but effective lighting LEDs are used on the SID ACC and MIU for example Linear The entry level form designation for our brand strategy moving forward Our vehicles should not ever be considered base cars The replacement for the 9 3 will carry these form names as well MED NET An OnStar service that can store a customer s personal medical information to assist in an emergency MIU Main Instrument Unit The component that is
37. 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 Some explanations are technical in nature to clearly describe how the features work The Griffin Society test must now be taken on line at www saab edu com This self study book no longer includes the Griffin Society test which ALL dealership personnel except technicians who have a separate Griffin Society Test must pass in order to qualify for recognition in the 2002 Saab Griffin Society program as well as meeting the minimum dealer training standards If you already completed a written version of SO2T you do not have to retake this test using the eLearning version In order to participate in the 2002 Saab Griffin Society recognition program you must successfully PASS the on line SO2T test with a score of 80 or better You must participate each year in order to maintain your status Bronze Silver or Gold All Griffin Society and training requirement information can be found on IRIS The prerequisite for this course is t
38. Spark plugs GK GK NGK make type BCPR6ES 11 PFR6H 10 BKR7ES 11 Spark plugs 1 05 mm 0 95 mm 1 05 mm electrode gap 0 05 0 05 0 05 Engine management Trionic T7 Trionic T7 Trionic T7 system Recommended fuel octane 87 92 92 number AON 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 from earlier types of coolant that were blue green Saab Original Long life Coolant must be used in order to obtain the desired coolant properties The normal mixture of 50 coolant still applies The earlier blue green type and the new orange type will both be available as spare parts Technical Data Saab Original Long life Coolant Type Ethylene glycol Color Orange Mixing 50 Part Number 200 I drum available later 02 86 542 4 can Engine 13 Note Do not top up with the earlier type of coolant blue green as this will impair the corrosion protection properties The orange coolant will also be discolored by the blue green coolant and may appear to be contaminated with engine oil etc In an emergency conventional blue green coolant can be mixed with the Long life orange coolant However once the conventional co
39. The importance of the information is indicated by the three different headings and the difference between them is explained below AN warnine Warns of the risk of material damage and grave injury to mechanics and the driver as well as serious damage to the car Important Points out the risk of minor damage to the car and also warns the mechanic of difficulties and time wasting mistakes Note Hints and tips on how the work can be done in a way that saves both time and labor This information is provided as a means of improving efficiency not for reasons of safety Market codes The codes refer to market specifications ustria Australia Finland France Iceland lus US California New Zealand 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 e Linear 2 3t e Arc 3 0t e 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 3t models will be equipped with the B235E engine with manual as standard equipment or the optional new 5 speed automatic transmission All 9 5 models in the U S will be equipped with the sliding glass sunroof Linear models will have leather seating surfaces as standard equipment Cloth inte
40. 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 60 km h 37 5 mph ESP can be engaged at any speed ESP will remain active during braking as a safety aid for the driver irrespective of whether the system is disengaged or not This means that if the control module detects that the conditions for ESP regulation have been fulfilled and the driver starts to brake the control module will control the application of the brakes E521D070 9 5 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 ESP OFF indicator lamp The ESP OFF lamp comes on in case of a fault in the ESP or TCS system or when the system has been turned off manually The lamp is turned on off by a bus message ON OFF from the ESP control module to the main instrument unit The switch can be used to disengage ESP and TCS at speeds below 60 km h 37 5 mph ESP can be engaged at any speed Note that even if ESP is shut OFF the ESP function will remain active during braking as a safety aid for the driver even
41. ard position i e more than 30 from its front position stage 2 will be inflated This means that 100 of the maximum pressure in the airbag will be utilized The passenger airbag consists of a gas generator and an airbag It has a volume of approx 120 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 The gas generator comprises a steel housing with two electric igniters with individual coding two pyrotechnical ignition charges of different strengths for stage one and stage two pressurized gas and a gas distributor for cooling and distributing the gas pressure After an activation command the control module will apply a current to ignite the driver charges In stage 1 a projectile 1 is shot through a diaphragm 2 which opens the pressure vessel 3 containing the gas mixture The projectile continues on its path and ignites the 28g driver charge for stage 1 4 The compressed gas will expand due to the heat release and pass the gas distributor 6 before reaching the airbag When stage 2 is activated a 6g charge 5 will be ignited by an electric igniter and heat the compressed gas even more The gas generator is divided into two stages These stages are a primary stage that provides 80 of the pressure and a secondary stage that provides another 20 Depending on the
42. b buyers Hands free telephone capability also provides another Saab Real Life level of safety The following is from a GM news release dated August 22 2001 An unprecedented study conducted as part of General Motors SenseAble driving program a 10 million multi year effort to address driver distraction reveals that the embedded cellular phone used in GM s OnStar system has had an outstanding safety performance record since it was initiated five years ago The study is the world s first analysis of a database that has extensive and actual not estimated information about whether a crash occurred at the same time a cell phone was in use This database maintained by GM s OnStar subsidiary consists of automated information with time stamps that show exactly when a cell phone voice call was initiated and when the OnStar advisor was in contact with a vehicle after an airbag deployment Previous studies that have attempted to associate cell phone use with crashes including a much publicized 1997 University of Toronto report could use only small statistical samples and estimates of when calls were made in relation to a crash Using the actual OnStar data the GM study concludes that an air bag deployment crash associated with the use of OnStar s embedded phone system was rare and that the chance an embedded cell phone actually caused a crash was even more rare Here are the facts F
43. bove 40 C 104 F The fluid used in this transmission system is a completely new type due to the increased stress caused by the slipping lock up The fluid is designated JWS 3309 Aisin AW spec JWS 3309 is a mineral based ATF with unique additives high coefficient of friction and very high resistance to thermal oxidation This fluid is factory standard on model 02 cars and applies also to 9 3 4 speed aut JWS 3309 will mix with Dexron Il and Ill JWS 3309 is therefore backwards compatible but will not provide any advantages over standard fluid in earlier 4 speed automatic transmissions However only JWS 3309 is to be used in Aisin AW 33 5 and no other fluid The gearbox can withstand a torque of 350 Nm 258 ft lb that is allowed in 3rd 4th and 5th gears In 1st and 2nd gears a torque of 330 Nm is allowed Overboost 2 3HOT on Aero is not allowed 42 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 Solenoids S1 S5 control the flow of oil to the various clutches and brakes as b
44. by a solenoid that is activated from the control module This increases the beam of light from the lamp 9 5 Electrical system Essibi2s 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 In many world markets the halogen bulb comes on together with the xenon lamp for main beam high beam Due to U S Federal Regulations the halogen bulb does not come on simultaneously with the xenon lamp for main beam high beam on the U S specification vehicles 17 18 Electrical system 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 rear 704R Electrical system 19 10 11a E351D092 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 10 Xenon headlight 11a 4 Xenon lamp indicator 662 11 Main beam damping solenoid 665 5 Headlight filament monitor 228b Main beam flasher relay 666 12 Parking light bulb 13 Dipped beam relay 8 6 Load angle sensor front 704F 14 Headlight A
45. comes on in case of a fault in the system E381D249 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 36 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 The distance is indicated via the SID Saab Information Display in the form of acoustic signals beeps in addition to the message PARK ASSIST displayed on SID While the vehicle is reversing as it gets closer to an object the signal beeps from the SID become more frequent more signals per unit of time In this way the driver can avoid damage to the vehicle when reversing e g when parking SPA is activated only when the reverse gear is selected E385b 022 In the Sedan variant the control module is located behind the backrest member under the side trim on the left hand side In the SportWagon variant the control module is located under the front floor in luggage compartment The four distance sen
46. 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 These actions mean that kinetic energy in the drive wheels is converted into heat in both cases Applying the brakes heats the wheel brakes and ignition retardation increases the exhaust temperature Ignition retardation is not allowed at high exhaust temperatures to protect the turbocharger and catalytic converter Brake application The brakes are applied through the ESP control module governing the pump motor the pressure increase and pressure reducing valves and the inlet and outlet valves in the hydraulic unit so that the braking force on each wheel can be controlled individually The ESP control module receives information on the brake pressure from the brake pressure sensor This information is used to control the braking force on each wheel to correspond to the braking force applied by the driver An ESP regulated wheel is controlled using the ESP criteria 9 5 Brakes E521D038 Both front wheels and rear wheels are connected to the pressure increase and pressure reducing valves in the hydraulic unit This arrangement allows each wheel to be controlled in
47. d on impact allowing the subframe and drive unit to slide downward and cushion the impact 66 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 New integrated brackets in the subframe for the anti roll bar Rear subframe bushings are 20 stiffer and A bushings in the longitudinal link are also 20 stiffer The arm between the MacPherson strut and the anti roll bar has been given a larger contact surface and is secured with flange nuts The rear wishbone mounting is also new The bracket for the front anti roll bar is integrated in the subframe In Fall 2002 it will be possible to equip the sports and standard chassis with the Nivomat Load Compensating Rear Shocks as an option 9 5 Body 67 Body Body colors Two new body colors have been introduced and Note that Cosmic Blue 264 is once again one shade has been discontinued available in the U S market e Polar White 283 a base solid paint replaces Cirrus White e Hazelnut 286 is a new metallic paint Color code Color Paint type Note 9 5 Lin
48. dependently Friction is estimated by calculating the drive wheel torque during acceleration which is a function of the engine torque or braking which is a function of braking force If performing evasive action during emergency braking the vehicle can be manuevered by regulating the braking pressure applied by the driver using the control module and the pump The applied braking force on each wheel can therefore be both above and below that requested by the driver Braking distance is given priority when braking in a straight line and stability is given priority during evasive action ESP can be active both when the driver applies the brakes and when the driver is not even touching the brake pedal 61 62 Brakes 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 wheel brakes and the inlet and outlet valves are also activated during ESP regulation This arrangement enables the brake pressure on all four wheels to be modulated This solution makes it possible to build up pressure maintain pressure and reduce pressure individually on all four wheels If the driver applies the brakes while ESP regulation is active the brake pressure senso
49. der is a plunger type deep cylinder without central valve but with seals Half the function is now integrated in the brake servo 52 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 The brake caliper piston diameter has been changed from the earlier standard 38mm 1 49in to 40mm 1 57in on the new brake caliper with ventilated disc Other brake calipers still have 38mm 1 49in pistons 9 5 E521D084 Brakes 53 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 includes ABS and TCS which have the same function as before ESP is a development of these two systems with each function acting individually as well as together in one control module A fault in either the ESP or TCS function will disengage them both but not the ABS which will continue to function unl
50. 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 When your customers arrive for their Dedicated Delivery appointment push the OnStar button while in the car and complete the process This is an impressive demonstration for your customers when the Advisor comes on the line and says How may help you Mr Jones The activation must be completed from the car as data is exchanged with the Saab and the OnStar center Be sure to tell the customer the PIN you assigned in the event the customer didn t supply one The customer can change the PIN at any time 9 3 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 Aero The high performance meets high end luxury form Aero for 2002 is more aggressive and sportier Aero has been a nameplate for Saab since MY 1993 Ah Amp hour A rating used to classify the strength of a battery AHL Automatic Headlamp Leveling The system that maintains the appropriate angle of the beam emitted by th
51. e TCM compares the current gear changing performance with a gear changing matrix in the software and learns whatever each gear changing situation requires with respect to pressure time in order to perform the gear change comfortably Because of this the TCM must be reset using Tech 2 after carrying out repairs or exchanging the gearbox or TCM and after SPS programming The control module can be SPS programmed using the diagnostic instrument 45 46 Transmission E4400 127 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 Max speed mph changing E440D 124 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 9 5 Transmission 47 48 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
52. e increase valve and open the pressure reduction valve The valves and the pump return to their normal states A termination of regulation with brake application due to the risk of overheating the brakes is achieved by the ESP control module continuously registering the total time that regulation with brake application has been active during a certain period of time This value is then compared to a programmed maximum value If this value is exceeded regulation with brake application will be terminated 64 Steering assembly Steering assembly Steering arrangement for steering wheel adjustment cm A 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 cast in aluminum die casting with integrated hub The front wheel bearing is a complete hub that is bolted directly to the steering swivel member with three bolts Replacement hubs are fitted complete with three bolts This arrangement has reduced the weight of each steering swivel member by 1 5kg 3 3lb A number of other adaptations have also been made These changes are designed to help the overall handling of the vehicle Steering column The steering column assembly has been adapted for the new steering
53. e list of standard features as 9 5 Arc 3 0t models but also include e New Leather Sport seats e Anew Aluminum look dash e Sport tuned chassis e Aero skirts and air flow panels e Leather wrapped sport steering wheel KA l REJ 10 spoke 17in BBS wheels are standard equipment on all 9 5 Aero models in the U S Two special option packages will be offered on Aero models sold in the U S An optional Visibility Package will be offered from November through February production This package includes e Bi Xenon headlights with Automatic Headlight Levelling AHL e The Rain Sensing Wiper system In February 2002 the Visibility Package will be replaced by an optional Touring Package which includes e Bi Xenon headlights with Automatic Headlight Levelling AHL e The Saab Parking Assistance system SPA e The Rain Sensing Wiper system The only other options are e 5 Speed Automatic Transmission e Mica Metallic Paint Note As a result of the Leather Sport seats being added ventilated seats are not available on the Aero models 8 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 e 2 3t Ecopower 185hp 207 ft lbs 280Nm B235E Linear e 3 0t Ecopower 200 hp
54. e new Bi Xenon lights It will adjust up or down as necessary based on the load forces being placed on the front and rear of the vehicle e g going up a steep driveway the AHL will adjust the lamps down to keep them on the driving surface AON Average Octane Number A number used to rate the quality of fuel e g 87 89 92 etc Arc The touring edition of the form names The next progression in the level of luxury and comfort This form essentially replaces the SE model in the model designations ATF Automatic Transmission Fluid A lubricant required for the proper operation of the automatic transmission A Pillar The front structure of the vehicle that the windshield fits into The A Pillar has reinforced beams to assist in a front impact collision and is a crucial part of the safety cage construction which greatly effects the structural rigidity of the passenger compartment BBS The supplier used by Saab for the new wheels on the 9 5 Arc 3 0t and the 9 5 Aero B Pillar The middle beam connecting the roof to the rest of the vehicle The front doors latch into and the rear doors are hinged from the B Pillar The B Pillar is reinforced and is a crucial part of the safety cage construction and the structural rigidity of the vehicle The B Pillar is Pendulum styled on all hardtop vehicles Convertibles do not have a B Pillar and therefore do not have a Pendulum B Pillar CCA Cold Cranking Amp A
55. e parking lot and pressed the Medic Emergency button on OnStar A young lady came on and asked if had a medical emergency It seemed it was all could do just to say yes She dialed 911 and stay on the line with me talking to me It was only minutes before heard the sirens From OnStar they knew who I was where was what kind of vehicle was in OnStar saved my life wanted to write and tell you there is absolutely no doubt that OnStar saved my life No doubt None know it my family knows it my friends know it tell everyone know about what happened to me because know how valuable OnStar is know there are other benefits to OnStar But please tell people OnStar saves lives I m living proof of that Here is an excerpt from the August 22 2001 edition of the Detroit Free Press that credits OnStar with saving another life OnStar saves GM official s wife Woman one of many boosting new service Don Trabolsy a General Motors Corp business manager never thought he d be telling a harrowing first person tale about his company s OnStar vehicle communications system Trabolsy who works for GM s preproduction operations division in Pontiac is one of hundreds of people around the country who OnStar President Huber says have become unexpected boosters through real life experience Trabolsy says the technology saved his wife s life last month when he took his OnStar equi
56. ear Arc 9 5 Aero 283 Polar White Base solid 268 i Metallic X 286 x All exterior colors are available with either Sand Beige or Charcoal interior upholstery Important Use car color code for all paint repairs Base solid paint with clear varnish All solid paints have now been superseded by base solid paint with clear varnish The risk of mistaking these two paint systems is high when repainting Cars with base solid paint are marked BASE on the color code and tire pressure label 9 5 68 Body 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 fastened on attachment rails in the fenders and bolted to the fender liners and body The upper section with integrated grille is fastened to the body with clips Grill The grill is integrated in the front bumper and has three detachable louvers 9 5 E801D 046 Rear bumper The rear bumper comprises an aluminum rail a core of cellular plastic and a painted plastic shell with integrated corner covers There is a three piece removable decor strip inset in the shell two outer pieces and one center piece The center decor strip contains the SPA sensors The lower section o
57. eat belt tensioner driver and passenger The activating time after a collision is different for the various circuits The primary acceleration sensor measures the acceleration and retardation forces in the longitudinal and lateral directions of the car The secondary sensor measures the longitudinal acceleration and retardation forces only 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 A side impact sensor in each front door provides information to the control module on collision forces from the side This information is provided together with signals from the seat position sensors and seat belt buckle sensors for calculating if and how the front airbags side airbags and belt tensioners should be activated If the seat belt buckle is not locked or the seat is far forward the airbag will be inflated earlier than normal The seat belt tensioner is activated only if the seat belt buckle is locked The front impact sensors contain an acceleration sensor and a communication circuit for sending information that is used by the control module If the values obtained from the impact sensors and the control module accelerometers correspond concerning collision force the contro module will activate the seat belt tensioners and airbags Conditions for Airbag Activation If the control module
58. ection can be varied from two milliseconds to the entire injection phase The wide range of control capability in fuel injection is important when the fuel used may be pure gasoline or a variety of different mixtures of gasoline and alternative fuels such as methanol or ethanol A Trionic system in fact is the key to Saab s prototype multi fuel engine This is because in principle fuel consumption is doubled when the engine is burning alcohol instead of gasoline Saab s unique Direct Ignition DI system is also incorporated in the Trionic system The Saab DI cassette is a Capacitive ignition system without moving parts This eliminates starting problems during moist and cold weather The DI cassette supplies a constant spark to each spark plug and eliminates the need for a distributor cap and spark plug wires Each spark plug is equipped with its own ignition coil mounted inside a cassette attached directly to the spark plug itself thus eliminating the need for ignition cables as well All ignition system components are housed inside the cassette where they are well protected from dirt and moisture Signature Technologies 101 The spark plugs last several times longer than the plugs in a conventional ignition system because the DI system can handle larger variability in the electrode gap size of the spark plugs Ignition timing is set permanently at time of production at the factory The fact that each combustion event for
59. efore The current consumption of the 5 on off solenoids is 1A continuous and 2A maximum As on earlier models the new transmission has shifting programs for different situations In short the TCM detects the driving conditions with respect to terrain and driver characteristics and can adapt the shifting points according to this information For example when driving up a long hill the TCM will detect that the load is not decreasing despite the fact that a higher gear should have been engaged at the current speed This means that the transmission will stay in the lower gear to avoid hunting due to continual up and down shifting This system provides a pronounced improvement in riding comfort E4400 081 Three different temperature programs are also stored in the TCM in order to spare the gearbox from thermal damage that can result in burned discs and black oxidized burned oil HOT 1 activated at a transmission temperature of 128 C 262 F and deactivated at 120 C 248 F This is achieved by engaging lock up in 3rd gear lock up is normally allowed in 4th and 5th gears only which gives lower oil temperatures thanks to the elimination of slip in the converter HOT 2 activated at 135 C 275 F and deactivated at 130 C 266 F This is achieved by engaging lock up in 2nd gear HOT 3 activated at 145 C 293 F and deactivated at 135 C 275 F At this temperature TCM will request torque limitation to 200Nm from Trionic 7
60. 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 The correct angle is maintained even when the car is heavily loaded The headlight beam adjustment system is equipped with two load angle sensors located by the front and rear axle respectively These Hall sensors detect whether the front of the car is lifting or dipping The two AHL control modules one for each headlight receive information on the car s movement from the load angle sensor and instruct the motors to adjust the angle of the headlights The system is calibrated when the xenon lamps are ignited by angling down the headlights to their lowest position and then up again to their normal position In the event of a system malfunction the headlights will be adjusted to a position slightly below normal and an indicator lamp in the dashboard will come on Electrical system 23 280 E351D11 Headlight beam adjustment motor There is a stepping motor located in each headlight housing The headlight beam adjustment motors change the angle of the headlights according to instructions from the AHL control module 24 Electrical system E351 D123 Load angle sensors Cars with automatic headlight beam adjustment are fitted with a front and
61. equires a greater flow from the master cylinder to and from the hydraulic unit The pipe diameter in the brake lines between the unit and the master cylinder has been increased from 4 7mm 10 19in to 6mm 0 24in All the brake systems ABS TC ABS and ESP from model year 2002 have 6 0mm 0 24in brake lines between the primary cylinder and the unit The ABS and TC ABS systems have 4 7mm 10 19in lines between the secondary and the hydraulic unit as before 9 5 Brake servo and master cylinder Master cylinder 1 Pushrod with primary piston Pressure chamber primary circuit Central valves Secondary piston Pressure chamber secondary circuit Return spring Stop pin Stop pin o oo NP aA A CO N Seals The brake servo and brake fluid reservoir are new and adapted to the new master cylinders f 9 5 as Brakes 51 la 2 39 8 E521D086 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 The master cylinder has been modified by raising the height of the brake fluid reservoir tower by 35mm 1 37in This is so that the brake fluid reservoir will come above the hydraulic unit which has been given a new location adjacent to the bulkhead The primary cylinder is identical with the earlier master cylinders on the 9 5 The secondary cylin
62. er 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 If the sensor detects that the vehicle is within ideal conditions it will send a signal to the ECM advising that the vehicle is stable 9 3 Glossary 109 110 Notes Glossary 9 3 2002 Griffin Society Product Test IMPORTANT Test Instructions The 2002 Griffin Society Product Test SO2T 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 SO2T 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 saab edu com and click on the SO2T Product Test Take your time and research your answers carefully You must score 80 or higher in order to pass this test and achieve the proper recognition level in the 2002 Griffin Society Program Page 111
63. ess it is affected by the fault The system includes a switch on the dash to shut off the ESP and TCS functions When ESP engages during a skid it will counteract the skid by braking one or more wheels without the driver needing to touch the brake pedal Engine power can also be reduced to prevent wheelspin after the ESP control module requests an engine torque The engine control module governs the engine torque according to this request The system receives information from a number of sensors that measure the wheel speed side acceleration yaw rate steering angle and brake pressure These values are used by the ESP system control module which is integrated in the hydraulic unit The control module continuously calculates the course of the vehicle ACTUAL VALUE the direction of the vehicle and compares it with the direction determined by the driver with the steering wheel DESIRED VALUE If the ACTUAL VALUE does not correspond to the DESIRED VALUE the system will intervene as necessary by braking one or two wheels and limiting the engine torque e f the car starts to understeer when the front tends to continue straight ahead in a bend the inside rear wheel will be braked e lf the car starts to oversteer the rear tends to drift out the system will engage and brake the outside wheel until the measured and the calculated yaw rate correspond 9 5 In the U S market ESP will equipment on the Aero and Arc models w
64. ess likely to invade the passenger compartment thus avoiding or minimizing injuries The large front and rear beams are designed to create a stable and robust characteristic through their broad structure The front and rear structure has three load distribution paths where 50 of the total impact goes through the central lower member and 25 through each of the upper and lower paths Therefore 75 of the energy caused by an impact is directed down and away from the passenger compartment The remaining 25 is directed on a higher path and will be sent toward the A Pillar or C Pillar in the event of a rear end collision if necessary depending on the severity of the crash By directing the energy down if the collision was severe enough to invade the passenger compartment the impact to the passengers would be in the foot leg pelvis region rather than the more critical and life threatening head and chest region Saab s Triple Load Path system is different from most of the industry in that it is designed to protect passengers during both typical and atypical crashes The U shaped beams in the front and rear provide protection for passengers during collisions in which the bumper is not squarely impacted e g off set collisions The beams are designed in this U shape to still be as effective during any angle of impact Most other manufacturers simply use sheet metal or crumple zones to absorb the energy caused by a collision
65. f bumper shell is painted black on the Linear and Arc and body color matched on the Aero The Arc and Aero variants also have a cutout for the tailpipe at the bottom On the SportWagons the top section of bumper is black and can be replaced separately The bumper is fastened to the body and fender liners Body 69 8010047 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 9 5 E801D048 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 9 5 Body 71 Body modifications for made Body modifications have been three reasons e Improved impact characteristics e Exterior modifications e 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 new much larger integrated impact boxes The objective is t
66. fety Brand Pillar and why automobile consumers know that Saab builds safe cars Saab engineers have set the standard when it comes to safety OnStar helps take that standard to another level Having OnStar on board is like driving with a personal assistant ready to summon help at a moment s notice That help can be a lifesaver OnStar Information Automatic Emergency Response If one of your customers is involved in a traffic accident that is severe enough to set off the airbags the OnStar system will automatically connect the driver with an OnStar Advisor Also exclusively in Saab models equipped with OnStar if the automatic front seat belt pretensioners are activated the OnStar system will automatically connect the driver with an OnStar Advisor Emergency Button Pressing the red cross button on the OnStar keypad makes a call that is given top priority at one of OnStar s three call centers The following letter and newspaper excerpt demonstrate how valuable the emergency button can be Louise Srofe from Palm Harbor Florida credits OnStar with saving her life Signature Technologies 103 On December 26 2000 while driving in Clearwater Florida suffered a stroke I m only 48 years old had a cell phone with me but was rapidly losing the vision in my eye and was becoming paralyzed on the right side didn t think had the where with all to even call 911 was able to pull into a grocery stor
67. grammed for the correct engine type using Tech 2 and the SPS procedure The control module receives information from a number of its own sensors as well as from other electronic systems This information is processed by the control module for controlling the current gear and shift points based on the selected driving program NORMAL SPORT or WINTER Gear changing takes place when the control module acts on solenoid valves S1 S2 S3 S4 and S5 which are mounted in the transmission valve body The control module also determines if and when the torque converter lock up is to be engaged based on a certain combination of solenoid valve settings Three linear solenoids are mounted in the valve body and control the lock up SLU system pressure SLT and the clutch disc pressure SLS 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 In the event of a fault in any of the inputs outputs the transmission will go into Limp home mode All control module functions will then be disengaged or an emergency operation program will be activated The car can then be driven but with limited shifting capability TCM also takes into consideration any wear that may be present in the gearbox which ensures smooth gear changing even when the gearbox is worn This adaptive system means th
68. gy is naturally directed down so that if the passenger compartment is intruded into the occupant the contact will occur in the stronger pelvic area not the rib cage head or chest where our more vulnerable organs are located After the side structure has directed the collision forces downward strong cross member beams under the floor of the passenger compartment serve to further distribute side impact forces to other areas of the vehicle s body structure away from the passenger compartment Fact 30 of fatalities from automobile accidents are caused by side impact collisions Fact Saab has been a pioneer in side impact protection As early as Model Year 1973 Saab incorporated side impact protection technology into Saab 99 models 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 an enclosed space or the volume goes up it expands Also gases naturally flow from a high pressure low volume area to a low pressure larger volume area and the greater the difference the bigger the push A 4 stroke engine produces energy by expanding a gas in a confined space where the high pressures created can push against a piston The process of creating this energy
69. halted and only objects directly behind the car are indicated If the object alongside the car subsequently comes 5 cm 2 in closer to the car the control module will again inform the driver of the object via the SID Transmission 41 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 advantages of the new transmission include faster acceleration lower fuel consumption and improved utilization of engine capacity through more gear steps The control module TCM is also new and now has adaptive functions with two 38 pin connectors The control module software is updateable using procedures in SPS The AF33 5 automatic transmission has a 5 speed gearbox with Lock Up The AF33 5 is principally built around 4 planetary gears a torque converter with lock up a hydraulic control system and an electric control system The transmission is governed by a control module TCM that continuously processes the information it receives from its own sensor and from other control modules Using this information the control module governs the transmission hydraulic system so that the correct gear is selected with respect to the conditions at hand The TCM also takes
70. he B235R engine and manual transmission only The Viggen is equipped with all of the standard features found on SE models In addition the Viggen is equipped with e Viggen sports suspension Skirts and air flow panels e 17in alloy wheels amp high performance tires e High performance brakes e Metal look dash panel with Rocky Black interior e Carbon fiber dash panel with Sand Beige interior e Heated front seats e No Charge Scheduled Maintenance 9 3 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 Options available on 9 3 Viggen include e Mica Metallic paint e Blue convertible top Only available on silver exterior 88 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 Body Exterior e SE body colored skirt kits for all non Viggen models Interior e New Leather Textile with Turbo embossment seats as standard equipment e
71. he MY01 Self Study SO1T which was required for qualification into the 2001 Griffin Society If you have not completed the 2001 test ordering instructions for that test can be found on IRIS The SO2T test must be successfully completed during calendar year 2002 to receive 2002 Saab Griffin Society credit and to meet 2002 Dealer Standards e Table of Contents 9 5 9 5 Introduction Model Year 2002 9 5 Product Rand es eaa eaat aa SEDA a EEEE EEE EET 5 VIN Vehicle Identification Number MY 2002 W u u d dsscs seere kerner rr rr rrnnee 10 Service NOLES rese ESS DONE a EN RAN A Eaa 11 Engine 9 5 Engine Range Model Year 2002 u W M G sseseeeeeeeere cece cent ee eeeeeeeeeeeeeeeaes 12 Cooling Systemi R RE je aia EE E ene a ieee enh ie eee 13 Electrical system Charging System rari eevee oe EM weds aceon ssisetere ouput E A AERA E 14 Bi Xenon Headlights 133 seescguse ances watersancdenupdececseccetinede we ezemapddexeaceewdpeions 17 High Pressure Headlight Washers c eceeee cece eee ec ee eee ktr rer nn 26 Rain Sensing Windshield Wipers cccceeeeeeeeeeeeee tees ee eeeeeaeneaeaenees 29 Main Instrument Unit MIU ws cchoxevssanacaewceuvan sven docdunanenauaiwiunatenobsowaundaund 34 Saab Parking Assistance SPA ccceeeeeeeeeeeeee eee eee ee eeeneeeeeeaeaes 36 Transmission 5 Speed Automatic Transmission ccceeeeeeee cece ee ee ee ee ee eeeeeeeeeeeees 41
72. he Viggen and the convertible the GPS antenna can be found attached to the inside of the windshield The cellular antenna is in the roof antenna for the Viggen hardtop and the short rubber antenna on the right rear fender on convertibles When OnStar is activated the system generates a phone number with a 500 area code If the customer wants OnStars Personal Calling service then a new phone number is generated with an area code based upon where the 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 You may have noticed at times when you travel out of your home market with your hand held cellular phone the display may say No Service This is because you are either too far from a tower or your cellular provider doesn t have a reciprocal agreement with the owner of the nearest tower and that tower doesn t recognize your phone Verizon Wireless is OnStar s cellular provider Verizon has the largest coverage of any national provider in the U S market In those areas where
73. he false bulkhead space cover must be cleaned on each service occasion An extended change interval in CA US for platinum plugs in B235R engines The new interval is 40 000 miles 30 000 miles in other markets The extended change interval also applies to 9 3 models with B205R and B235R engines Drive belt multi groove belt checked on each service occasion A new coolant with a life expectancy of the car has been introduced during the spring of 2001 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 The window indicating electrolyte level must be checked at every service If the indicator is dark the electrolyte level is correct If the indicator is clear i e if it reflects the light like a mirror the electrolyte level is too low and the battery must be changed 12 Engine Engine Engine range Saab 9 5 model year 2002 US B235E Linear B235R Aero B308E Arc Turbocharger Garrett Mitsubishi Garrett make type GT17 TD04HL 15T GT15 Basic charging pressure 0 40 Bar 0 03 0 45 Bar 0 03 0 27 Bar 0 03 Max power EEC 185hp 136kW 250hp 183kW 200hp 147kW at 5500 rom at 5500 rom at 5000 rom Max torque EEC 207 ft Ibs 280 Nm 258 ft Ibs 350 Nm 229 ft Ibs 810 Nm at 1800 3500 rpm at 1900 4000 rpm man at 2300 4500 rom 258 ft Ibs 350 Nm at 1900 4700 rpm aut
74. he ignition ON and OFF Note To deactivate SPA you must press the CLEAR button on the SID until it shows PARK ASSIST OFF each time the ignition is cycled 9 5 Electrical system 39 The text message is stored in English Swedish German Spanish French and Italian in the SPA unit It is sent via the bus to the SID where it is displayed The text messages are as follows PARK ASSIST PARK ASSIST FAILURE PARK ASSIST OFF 40 Electrical system Distance measurement and indication E335 0002 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 The driver receives information from the SID regarding the closest object behind the vehicle in the form of pulses of sound of varying frequencies The first indication is given when there is an object 1 8m 5 9ft behind the vehicle The frequency of the signal is then 2 pulses per second The frequency of the signal increases the closer to the object the car comes The signal changes as follows e 1 8m 71in 1 3m 51in 2 pulses second e 1 3m 51in 0 9m 35in 3 pulses second e 0 9m 35in 0 3m 12in from 5 to 12
75. he inlet is a very small space very Signature Technologies high pressure and very high heat exists which means the gas has a very high energy level As the gas is released from the combustion chamber into the turbine housing it moves from a small space to a larger space Accordingly it expands cools slows down and dumps all of the energy by pushing against the turbine blades causing it to rotate Thus with all else being equal the amount of energy that can be created with exhaust turbine is determined by the pressure differential at the inlet and outlet i e raise the turbo inlet pressure and lower the outlet pressure or both and more power is made Raising the inlet pressure is possible but is more difficult to accomplish Lowering the outlet pressure is much easier to accomplish by simply using a freer flowing exhaust The compressor side of a turbo Since it is possible to extract energy from an expanding gas via a turbine it stands to reason that it is possible to use that energy to compress a gas via a turbine In other words the compressor side is just the exhaust turbine side driven backwards The exact same laws of physics apply just in reverse Unfortunately the laws of physics have worked negatively because the act of creating energy with the air intake to compress it has significantly raised its temperature So the air must be cooled again without losing any pressure thus the need for an intercooler
76. ill be optional on the Linear model be standard ESP Note The course of the car is compared with the one determined by the driver with the steering wheel and if they do not agree ESP will be engaged The driver must turn the steering wheel to the correct direction of travel if the system is to be able to function correctly ESP does not mean you can drive faster but should be regarded as a safety net for unexpected situations On road surfaces with low friction it does not matter much how you turn the steering wheel When the lateral forces between the tires and the road surface are close to zero it is extremely difficult to correct the direction of travel of the car Cars with standard chassis equipped with ESP must not be fitted with a sports chassis because the ESP system cannot be reprogrammed to accept it This feature will be available later during the model year If the car chassis is too stiff ESP will respond too quickly 54 Brakes E5210035 System overview e Hydraulic unit with control module 671 i g J e Yaw rate sensor side acceleration sensor Wheel sensor 298 658 e ESP switch 660 Steering angle sensor 657 e ESP indicator lamp 47x Brake pressure sensor 659 e ESP OFF indicator lamp 47y Principal components 1 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 Front
77. ion are normally illuminated here e g radio station CD Play etc SRS Supplemental Restraint System The system that controls various airbags located in the vehicle Please note these are supplemental meaning the primary restraint system is always the seat belt SRS is designed to work in conjunction with seat belts fastened T7 Trionic The ECM that controls the Trionic Engine Management system T7 is the seventh generation of the system that Saab invented and implemented as early as model year 1993 Torque The amount of power twisting force being sent to the drive wheels Torque is the acceleration power that gets you from 0 60 A favorable torque rating at low RPMs can provide excellent power Torque is measured in ft Ib RPM Torx A special head on a screw or bolt which require a torx driver There are a variety of different sizes and they are used throughout the vehicle e g the license plate screws have a torx head TCS Traction Control System TCS works in conjunction with ABS and the electronic throttle to either limit torque to the drive wheels or actually apply brakes to the drive wheels to keep them from spinning TWICE Theft Warning Integrated Central Electronics The ECM that is responsible for the door locks the alarm and the immobilizer features of the vehicle It also controls the brake light illumination the power front seats and the heated rear seat timer functions Underste
78. irrors e The Harman Kardon prestige audio system e Auto dimming rear view mirror e Heated amp ventilated front seats e Heated rear seats e Electronic Stability Program ESP New 5 spoke 16in BBS wheels are included on all 9 5 Arc 3 0t models in the U S Two special option packages will be offered on Arc models sold in the U S An optional Visibility Package will be offered from November through February production This package includes e Bi Xenon headlights with Automatic Headlight Levelling AHL e The Rain Sensing Wiper system In February 2002 the Visibility Package will be replaced by an optional Touring Package which includes e Bi Xenon headlights with Automatic Headlight Levelling AHL e The Saab Parking Assistance system SPA e The Rain Sensing Wiper system The only other option is e Mica Metallic Paint 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 Note that Aero models equipped with both automatic transmission and manual transmission have the same horsepower and torque ratings for 2002 however the RPM range for maximum torque differs slightly between the two versions see chart on page 11 Aero models have the same extensiv
79. is more compressed in the higher speeds 9 3 94 9 3 Body Body Body color range Two new colors have been introduced Note that Cosmic Blue 264 is once again available in the U S market e Hazelnut 286 e Polar White 283 a base solid paint replaces Cirrus White 170 Black Base solid X 257 Hemin Blue Metallic 273 Sun Green Metallic i x 281 Grey Structure For bumpers X and trim 286 Metalic J X All exterior colors are available with either Sand Beige or Charcoal interior upholstery Important Use car color code for all paint repairs Base solid paint with clear varnish All solid paints have now been superseded by base solid paint with clear varnish The risk of mistaking these two paint systems is high when repainting Cars with base solid paint are marked BASE on the color code and tire pressure label Note Viggen interior is Rocky Black with Charcoal inserts or Sand Beige Leather Sport Seats 9 3 Exterior interior The following features are new for the 9 3 model year 2002 e Upgraded interior e New 16in 5 spoke alloy wheels e Body colored skirting on all SE models e New color options e SO 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 e All SE models will be fitted with new wheel rims ALU37 see page 103 e Two new interior options have also
80. ith Trionic both exhaust emissions and fuel consumption are reduced to the point that they conform with the most rigorous emission standards in the U S Serving as the main sensors required to gather information about the combustion process the spark plugs constitute one of the latest improvements of the Saab Trionic Engine Management System A low voltage across the electrodes continuously senses combustion conditions within the chamber where the actual combustion occurs This eliminates the need for a separate knock sensor This is possible because the Saab Direct Ignition DI system is integrated into the Trionic system Earlier systems used a separate knock sensor to detect engine knocks which may occur due to variations in fuel quality It worked like a microphone mounted to the engine block but its sensing function could become erratic in the case of other mechanical clatter in the engine The brain of Management the Saab Trionic Engine System is a powerful microprocessor The processor is 32 bits wide and is capable of performing two million calculations per second While driving at 55 miles per hour the processor is able to perform calculations equivalent to a whole binder full of single spaced pages all in the time required for the car to roll half a yard down the road It has deliberately been designed with excess capacity in order to accommodate future additions to the system The microprocessor contains a
81. iven by the AHL control module The control module sends high voltage pulses to the ignition transformer for turning on the lamp The ignition transformer which is integrated in the xenon lamp generates the ignition voltage approx 23 000 volts that is required to turn on the lamp Once the discharge is in progress the voltage requirement will drop to around 85V The AHL control module governs the current voltage supply to the lamp Important Make sure to use only lamps with the correct output when changing or some components may be damaged Electrical system 21 E351D115 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 9 5 E351D116 22 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 Essib117 Automatic headlight beam adjustment Cars with the Bi Xenon headlight system are equipped with automatic headlight beam adjustment The control system
82. king phases Phase 1 Pressure build up on all four wheels filling pulse and pressure retention Driver not braking Filler pulse 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 the pressure reduction valve closes and the pressure increase valve opens limited duration The inlet and outlet valves are in their normal position in the valve block i e the inlet valves are open and the outlet valves are closed Pressure retention As the filler pulse finishes each inlet valve will close to prepare for individual regulation of each wheel On wheels that ESP will not be applying the brakes pressure retention will take place as the pressure increase and pressure reduction valves on each circuit are closed and the inlet and outlet valves for each wheel are closed This is to prepare them for a possible brake application Phase 2 Pressure increase on wheels under ESP regulation The pressure increase valve opens to supply the pump with brake fluid that is to be pumped into the circuit The pressure reduction valve is closed The inlet valve on the wheel having its brakes applied will be open until the conditions that apply for pressure build up have been attained This means that the pressure to the wheel cylinders also increases and the wheel brake is applied The pump is
83. located in the dash that illuminates the necessary information that the driver needs while operating the vehicle e g speedometer Nm Newton Meters The measurement used to measure torque This measurement is used mostly outside of the U S Torque in the U S is measured in foot pounds ft Ib Oversteer The rear end of the vehicle tends to drift out or fish tail in a turn Relay An electro mechanical switch that powers up a component or components It is able to withstand a high electrical current draw RPM Revolutions Per Minute A measurement to describe the amount of times something cycles e g engine cycles turbochargers etc SAHR Saab Active Head Restraint The whiplash reduction system that uses natural body weight and forces to react in a way to help keep the front seat occupants head and neck in a position that will not cause serious injuries 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 SPS Service Programming System A software system that allows for different settings to be adjusted on the various ECMs located throughout the vehicle SID Saab Information Display The component that is located above the radio which includes the Saab Car Computer The date time and radio funct
84. ms ions electrically charged molecules in the combustion chamber opens up a unique opportunity to monitor the combustion process This is accomplished by imposing a voltage across the electrode gap during the combustion phase of each plug Measuring the current at the control unit that is due to ionization makes it possible to analyze the combustion process in each cylinder If knocking or misfiring occurs the boost pressure is adjusted immediately The Saab Trionic shows very good results in terms of exhaust emissions reducing hydrocarbon carbon monoxide and nitrogen oxide levels Previous Saab models already achieved emissions below California s legally mandated maximum levels beginning with 1993 models The Saab Trionic also provides unique opportunities to further enhance the performance of Saab engines The 2 3 liter turbocharged engine for example already reaches its maximum output torque at a very low 1 800 RPM 102 Signature Technologies 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 the day The sole remaining light from the Main Instrument Unit will be the speedometer which is only displayed up to 90 mph when 85 mph is approached the rest of
85. n It sends this ACTUAL VALUE to the ESP control module which compares it with the DESIRED VALUE given by the steering angle sensor A capacitive principle is used to measure the side acceleration A capacitor plate with moveable mass is suspended so that it can swing to and fro On either side of the moveable capacitor plates are two more fixed capacitor plates In this way it is constructed of two capacitors connected in series Electrodes are used to measure the charge that the capacitors are able to store When the sensor is affected by side acceleration the capacitor with the moveable mass will move towards the fixed capacitors and thereby increase the charge in the capacitor towards which the moveable mass is approaching measured in amperes Main components of side acceleration sensor 1 Fixed capacitors 2 Capacitor plate with moveable mass 3 Electrodes E5210069 Brake pressure sensor The brake pressure sensor is located on the ESP unit and is connected between the master cylinder and the ESP unit It measures the input brake pressure from the master cylinder primary circuit FL amp RR up to 250 bar 3 626 psi The ESP control module uses the information on the current brake pressure in order to calculate the correct braking force on the wheels 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
86. ns to its original position there is nothing to reset and no costly repairs are necessary to restore the seat to its fully functional condition Therefore the seat is ready for any subsequent impacts caused by multiple car collisions Accidents involving more than two cars or more than one impact account for approximately 25 30 of rear impact collisions Volvo s WHIPS reacts differently As the occupant s body is forced back into the seat a pin and bracket in the base of the seat breaks or bends allowing the entire seatback to fall backwards towards the rear passenger compartment As a result repairs may be necessary In contrast SAHR has no maintenance and is reusable over and over during the lifetime of the car The SAHR system has been tested in over 90 separate real world crash conditions involving different occupant sizes occupant positions seatback angles and differing impact speeds Note Insurance companies average 4 1 billion per year in spending on whiplash injury claims alone 97 98 Signature Technologies 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 which split into three paths to direct the energy in such a way that is l
87. nt or even using shared containers may contaminate the system enough to affect the Long life properties 92 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 Four new warning and indicator lamps have been added and certain functions have been revised The following changes have also been made Only one 22 pin connector All lamp bulos have been replaced with LEDs Some lamps have been moved Stepping motors for all gauges instead of moving coil instruments The stepping motors are controlled internally by the main instrument unit control module The main instrument unit calibrates the stepping motors automatically as soon as the instrument is powered up 30 The motors then take up a mechanical stop position on their shafts Only the front glass and complete units are available as spare parts Electrical system 93 km hr instrument shown D381D342 New warning and indicator lamps e TCS indicator lamp The lamp comes on when TCS is active e TCS ABS OFF lamp The lamp comes on when TCS is disengaged and also in case of a fault in TCS Functional changes e The miles graduation
88. o absorb the forces from the impact more efficiently both at low speed and high speed As the impact boxes absorb the impact forces and delay the actual impact inside the car the airbag control module must be informed of the collision earlier For this reason front sensors accelerometers have been fitted that detect the impact in the bumper rail The bottom part of the bulkhead has been reinforced with 3mm 0 12in thick aluminum plate to prevent the entry of the engine mounting system into the passenger compartment in case of a collision 9 5 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 The ABS bracket has been moved close to the bulkhead 72 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 A B C pillars The covering on the
89. oard 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 the control module that measures the lateral acceleration forces The system has been adapted and supplements the improved impact characteristics that have been developed in the chassis and body The protection has been optimized for minimum injury to the passengers The following components and functions are new on all Saab 9 5 models e 2 stage driver and passenger airbags e Two front impact sensors e Seat belt buckle active Hall sensor e Seat position sensor active Hall sensor e Control module The airbag system has been given a new control module with higher capacity to activate more ignition circuits and to improve diagnostics It can define impact force more reliably and earlier using two new front impact sensors mounted on the bumper member Using sensors in the seat belt buckles and seat position sensors the control module can define the way in which the front airbags are to be inflated and whether the seat belt tensioners should also be ignited The cars are equipped with driver and passenger airbags as standard Body 75 76 Body System overview Dual
90. oiler The air from the air duct passes through the battery cover and cools the battery 9 5 Esai Goes 15 16 Electrical system Relay and Fuse Box 567 VR113 i Paw om ash Spare Postion ER26 Fan High II 31 C6 C8 42 GS 83 C49 CZ 01 OS 8 5 8 17 04 17 Frort Viper E 371D1 24 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 Bi Xenon Headlights Available on Arc amp Aero 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 approx 23000 volts before they ignite The normal operating voltage is around 85V The control module also governs the stepping motors for the automatic beam length adjustment The AHL control module receives information from the front and rear load angle sensors concerning the front and rear height of the car and then adjusts the angle of the headlights based on this information Xenon lamps always light with the same brightness The light beam from a xenon lamp is limited by a screen which is opened for main beam use
91. olant has been added the Long life properties are lost and the coolant must be changed at normal intervals For this reason care must be taken when topping off a vehicle with Long life coolant to be sure contamination does not result Adding any conventional coolant or even using shared containers may contaminate the system enough to affect the Long life properties 14 Electrical system Electrical system Charging system E32 10026 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 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 The battery is enclosed in a battery cover to reduce heating An air duct allows air to pass from an opening in the car s sp
92. or 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 driver was on the phone within 10 minutes before a crash that deployed the air bags In all eight incidents there is no evidence that these calls actively contributed to the crashes We already knew from our research and thousands of customers testimonials that OnStar enhances vehicle safety and security said Chet Huber president of OnStar in announcing the findings This study confirms that our customers can safely use the embedded cell phone technology of OnStar From the beginning OnStar sb unique three button system was designed with safety as a priority This is another example of how OnStar helps take Saab Real Life Safety to another level Cellular Overview When equipped with OnStar you have to think of the Saab 9 3 or 9 5 as a very big cellular phone that your customers can drive The main components of OnStar are the Vehicle Communications Unit VCU a cellular antenna and an antenna for the Global Positioning System GPS antenna These work through the Vehicle Interface Unit VIU The cellular and GPS antennas are housed in the Sharkfin antenna found on the roof of the 9 5 and 9 3 SE hardtop For t
93. ozzles are covered in the spoiler when not in operation The cylinder raises the nozzle from the spoiler for washing whereby two jets are directed onto the protective headlight lens The headlight washers are started by activating the windshield washer switch 61 for longer than 0 5 seconds The ignition must be ON and the vehicle speed must be below 200 km h 124 3 mph before the washers will start The washer jets are active for about one second and then again briefly after one more second In order to activate the headlight washers again a period of more than 120 seconds must have passed since the washer pump was last activated or the windshield washers must have been used at least 5 times If the ignition is turned off and then on again the headlight washer pump will operate the next time the windshield washer switch 61 is activated E363D048 Note If the fuse 35 for Daytime Running lamps is pulled the headlamp washer system will not activate when the headlamp selector is in the OFF position Electrical system 27 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 28 Electrical system Et 560068 Main components high pressure headlight washers 1 2 3 DICE control module
94. pped Buick to a weekend getaway at a friends northern Michigan cottage His wife Brenda suffered a 104 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 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 And Trabolsy hadn t a clue how to get to the hospital He pushed a button on the dashboard that in seconds connected him with an OnStar adviser who patched him directly into the hospital for emergency instructions from a nurse and then gave him street by street turn by turn directions to the hospital am not being overly dramatic when say that OnStar saved my wife s life he says The doctor told us that if there had been much more of a delay getting there she would have died Brenda Trabolsy was treated and released the next day 9 3 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 As other states consider and pass similar legislation the hands free telephone technology in each Saab equipped with OnStar will become more and more important to Saab customers and potential new Saa
95. r will inform the control module of the input brake pressure in the hydraulic unit With this information the brake pressure to the wheels not under ESP regulation can be controlled to correspond to the driver s braking force The wheel under ESP regulation when the brakes are applied is controlled according to the ESP criteria The pump is active continuously during ESP regulation 9 5 Es215009 Brake application 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 The control module closes the pressure increase valve when a predetermined pressure has been attained The pressure is then modulated by the control module opening the pressure increase valve It will keep the pressure increase and pressure reducing valves closed to retain pressure and open the pressure reducing valve for pressure reduction The inlet and outlet valves are activated to regulate each wheel independently The valves are activated by a pulse train where the duration corresponds to a pressure increase or a pressure reduction Any excess brake fluid resulting from the pressure reduction valve opening is returned to the master cylinder The ESP function will regulate up to two wheels simultaneously Bra
96. rior fabric will be available as a special order no cost option Power driver and passenger front seats are also standard equipment on Linear models For 2002 heated front seats will be standard equipment on all 9 5 models in the U S Rear heated seats are available as part of a Premium Package however ventilated seats will not be available on Linear models All Saab models sold in the US will be equipped with OnStar as standard equipment All 9 5 vehicles sold in the U S will also include No Charge Scheduled Maintenance New 10 spoke 16in alloy wheels are standard on all 9 5 Linear models in the US The options available on Linear models are e 5 Speed Automatic Transmission e The Premium Package e Mica Metallic Paint The 9 5 Linear 2 3t Premium Package includes e Memory driver s seat e Power Memory Mirrors e The Harman Kardon prestige audio system e Electronic Stability Program ESP e Heated rear seats e Auto dimming rearview mirror 6 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 0t models have an extensive list of standard features e Perforated leather seating surfaces and leather door inserts e Power seats with memory on the driver s seat and power memory m
97. running Phase 3 Pressure reduction on wheels under ESP regulation The pressure increase valve is closed and the pressure reduction valve opens to lower the pressure in the circuit The inlet valve is closed and the outlet valve opens to lower the pressure at the wheels Brakes 63 Brake fluid is returned from the wheel outlet valve through the pressure reducing valve to the master cylinder The pump is running 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 With this information the brake pressure to the wheels not under ESP regulation can be controlled to correspond to the driver s braking force The wheel under ESP regulation when the brakes are applied is controlled according to the ESP criteria Phase 4 Termination The criteria for ESP regulation have ceased to apply All the valves take their normal positions i e the pressure reducing valves are open the pressure increase valves are closed the inlet valves are open and the outlet valves are closed The pump stops Regulation continues until e the wheel wheels are below limits for ESP regulation e regulation is terminated by the ESP control module because there is a risk of the brakes overheating After regulation is terminated the control module will stop the pump close the pressur
98. sensitivity in darkness Electrical system 33 E363D028 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 photo diodes receive incoming light and from this information the microprocessor can determine whether the rain sensor should activate the wipers Operation in special conditions e Tunnels When the car is driven through a tunnel the wipers will be interrupted Outside the tunnel after the interruption high speed can be activated rapidly if the sensor detects any drops of water e Splash If a shower of water washes over the windscreen high speed will be activated until the water has been wiped away e Worn wiper blades smearing Worn or dirty wiper blades will form a fast drying film of water that covers the sensor surface The sensor will prevent unnecessary wiper action and excessive wear of the wiper blades e Dirt function The wiper blades will not be activated if the sensor detects a dirty windscreen The driver will have to wash the windshield first 34 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 circui
99. sors use ultrasound to measure the distance to the closest object behind or alongside the car The sensors are located in the rear bumper and are named as follows e Left hand outer distance sensor RL e Left hand center distance sensor RLC e Right hand center distance sensor RRC e Right hand outer distance sensor RR Note that this system will not be available until February 2002 Electrical system 37 System overview gt Q SP z E3850017 e Ultrasound distance sensors e Right hand outer sensor 631RR e Right hand center sensor 631RRC e Left hand center sensor 631RLC e Left hand outer sensor 631RL e SPA control module 630 e SID control module 541 e DICE control module 628 e TWICE control module 632 e TCM control module 502 9 5 38 Electrical system Main components NOOB OD SPA control module 630 Distance sensor LH outer 631RL Distance sensor LH center 631RLC Distance sensor RH center 631RRC Distance sensor RH outer 631RR SID 541 DICE control module 628 E335 0004 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 e Press CLEAR until the SID text changes the text is not shown until the function is ON OFF e Turn t
100. ssembly 663FL FR 7 Load angle sensor rear 704R 9 5 20 Electrical system E3s1D113 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 plastic protective lens that does not refract the light 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 KXXKKKKKKKKK KR KXXKKKKKKKKKKKR RRR SENER Ebert x KARREN X xx pi SER x XX X XX hi pi X X MERE PEE BEBES pa 3 KER KER Ex KERN XX SKR SEX xx xx xx ig XX KKR E351D 114 Xenon lamp 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 The discharge generates a large amount of visible light and a certain amount of ultraviolet radiation The xenon lamp has an outer casing that reduces the dispersion of ultraviolet radiation The xenon lamp is dr
101. 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 833Db 333Pb 9 5 Side impact sensors 328D 328P Seat belt tensioners 236LH 236RH Airbag warning lamp in main instrument unit 540 47t SRS control module 331 TWICE control module 632 DICE control module 628 Data link connector 445 5 333Db Pb G 2365RHLH 7 8 E8500052 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 Contact roller 336a 78 Body DD 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 the capacity to activate eight ignition circuits e Driver airbag dual stage e Passenger airbag dual stage e Side airbag driver and passenger e S
102. t 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 Four new warning and indicator lamps have been added and certain functions have been revised The following changes have also been carried out e Only one 22 pin connector e All lamp bulbs have been replaced with LEDs Some lamps have been moved e Stepping motors for all gauges instead of moving coil instruments The stepping motors are controlled internally by the main instrument unit control module The main instrument unit calibrates the stepping motors automatically as soon as the instrument is powered up 30 The motors then take up a mechanical stop position on their shafts e Only the front glass and complete units are available as spare parts Electrical system 35 km hr instrument shown 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 The lamp comes on when ESP has been disengaged It also comes on in case of a fault in the TCS or ESP functions Available on cars with ESP or TC ABS Xenon indicator The lamp is available on cars with optional Bi Xenon headlamps The lamp
103. tem with 2 stage driver and passenger airbags front sensor 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 PMs are limited as it pertains to emissions with the California Low Emissions Vehicle LEV standards being the most rigid with a PM tolerance of 0 0 gm Even with several upgrades today s diesel technology engines are not currently allowed to be sold in California Starting in MY 2004 the following states will adopt the California LEV standards New York Massachusetts Vermont and Maine More than 30 of our sales are represented from these four states and California Although Diesel technology is much cleaner than it used to be the U S car buying public does not view diesel as Premium There currently is no direct competitor of ours that is offering a diesel engine in the U S Mercedes Benz offered a diesel on the 300 Sedan Wagon but with the introduction of the new E class they opted to stop production in 1999 As a result of this and many other factors the U S will opt to remain with gasoline engines only Diesel technology is readily accepted and utilized in other world markets because of fuel
104. than 30 from its front position stage 2 can also be inflated depending on the force of impact This means that 100 of the maximum pressure in the airbag will be utilized Body 81 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 charge is split into two stages These stages are a primary stage 1 that provides 80 of the pressure and a secondary stage 2 that provides another 20 Depending on the information that the control module receives from the different sensors the two stages will ignite at different times E850D 077 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 front position stage 1 will be inflated This means that only 80 of the maximum pressure in the airbag will be utilized This function is an adaptation of the personal protection system i e the protection will be optimized according to the present circumstances and the airbag will not be inflated to full pressure if the seat occupant is sitting far forward With the seat in a rearw
105. tion sensors the control module will be able to decide how the ignition circuits for the belt tensioners and the front airbags should be activated Seat position sensor The seat position sensors are used to detect whether the seat is in a forward position i e less than 30 away from the front position or in a rear position i e more than 30 or approx 65mm 2 56in from the front position of the seat Using this information from the seat position sensor the control module will be able to determine how to activate the ignition circuits See control module information p 77 The seat position sensors are mounted on manual seats as well as electrically adjustable seats E850D 076 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 front position stage 1 will be inflated This means that only 80 of the maximum pressure in the airbag will be utilized This function is an adaptation of the personal protection system i e the protection will be optimized according to the present circumstances and the airbag will not be inflated to full pressure if the seat occupant is sitting far forward With the seat in a rearward position i e more
106. 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 This means that the transmission functions will be limited to enable the car to be driven to a garage thus the name limp home Te oa T m ee rr a S is E 40D123 Limp home mode provides the following gear positions Gear position Note that 2nd gear must be engaged manually The CHECK GEARBOX lamp lights up and a diagnostic trouble code is stored in the memory Brakes 49 Brakes Brake system Eseealoes 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 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 In the U S market these changes will be included on Arc and Aero models 9 5 The following are new Master cylinder Brake servo The carrier up to the brake caliper has been adapted to the steering swivel member More powerful brake system for 2 3 Turbo Aero and 3

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