2002 SAAB 9-5 transmission

192 Car care and technical informationORVR (Onboard Refueling Vapor
Recovery)Hydrocarbon vapors formed when refueling
will be recovered by the car and not
released into the atmosphere. The hydro-
carbons are absorbed in a evaporative
emission canister. When the engine is sub-
sequently started, the evaporative emission
canister is gradually purged as air is sucked
into it through a shut-off valve. The hydro-
carbon/air mixture passes through the evap
canister purge valve and into the engine
where it is burned.
When refueling, make sure you screw the
filler cap on and keep turning until it has
clicked at least 3 times. Otherwise, it is pos-
sible for the CHECK ENGINE light to illumi-
nate and a ”TIGHTEN FUEL FILLER CAP”
message to appear on SID.
Refueling, see page 152.
Engine2.3-liter engineThe 2.3-liter model is a transverse, 4-cylin-
der in-line engine with twin overhead cam-
shafts and 4 valves per cylinder.
This engine is equipped with balance shafts
that reduce engine vibration to a minimum.
The balance shafts are chain driven and
rotate at twice the speed of the crankshaft.
They produce forces and torques that are
opposed to those generated by the pistons
and connecting rods, an effect that occurs
twice for each revolution of the engine.
Engine noise is also reduced as the
counter-rotating shafts counteract the vibra-
tion from the moving parts of the engine.
The transmission, located on the right
(viewed from the front), is integrated with
the engine. All models have front-wheel
drive.
3.0t V6 engine The 3.0-liter engine is a transverse, V6
engine with each bank of cylinders having
double overhead camshafts and 4 valves
per cylinder.
The transmission, located on the right
(viewed from the front), is integrated with
the engine. All models have front-wheel
drive.
IB601
Balance shafts, 4-cyl. engine
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195 Car care and technical information
Transmission fluidManual transmission Check and top up the fluid in accordance
with the service program.
If original fluid cannot can be obtained for
topping up (see page 254), automatic trans-
mission fluid Dextron III (synthetic fluid) can
be used. If so, the car should be taken to an
authorized Saab dealer as soon as possible
to have the reason for low fluid level cor-
rected and original fluid installed.Automatic transmission Check the fluid level as follows:
1 Stand the car on level ground and apply
the parking brake. The automatic trans-
mission fluid must be at normal running
temperature, approximately 175°F
(80°C). This can be achieved by driving
the car for about 30 min on the open
road.
2 With the engine idling, move the selector
lever to D and wait for at least
15 seconds. Next, move the selector
lever to R and wait for 15 seconds again.
Finally, move the selector lever to P. Let
the engine idle.
3 Wipe the dipstick clean with a lint-free
cloth and put it back.
4 With the fluid at normal temperature, the
level should be between the MAX and
MIN marks on the dipstick. Top up, as
necessary, with Saab 3309 automatic
transmission fluid (mineral oil-based),
adding it through the dipstick pipe. The distance between the MIN and MAX
marks on the dipstick corresponds to a
volume of approximately 0.4 qts
(0.4 liter).
If the outside temperature is below 50°F
(10°C), the fluid will not reach the specified
temperature of 175°F (80°C). In this case,
the correct fluid level may be 0.8 in (20 mm)
below the MAX mark.
WARNING
 Prolonged and repeated exposure of
the skin to engine oil can cause seri-
ous skin disorders.
 Avoid prolonged skin contact when-
ever possible. Wash the affected area
thoroughly with soap and water after
any contact.
 Keep oil out of reach of children.
 Do not touch the turbocharger or
manifold. These get very hot when the
engine has been running.
 Do not spill oil on hot parts of the
engine as this could cause a fire. Used
engine oil is particularly flammable.
 Protect the environment. Do not dis-
pose of oil in the ground or down a
drain. Dispose of all used oil and oil fil-
ters at an appropriate disposal facility.
NOTEIf there is a smell of burning fluid or the
fluid is black, change the fluid.
IB1923
Dipstick for automatic-transmission fluid
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218 Car care and technical informationFuse panel in instrument panel
# Amp Function
A 30 Trailer lights
B 10 Automatic transmission
C 7,5 Electric door mirrors; DICE
115Brake lights
2 15 Reversing lights
3 10 Parking lights, left
4 10 Parking lights, right
5 7,5 DICE / TWICE
6 30 Electric windows, right ; trailer charging
6B 5 Brake lights, trailer
7 10 Engine injectors
8 15 Trunk lighting; trunk lock; door lighting, circulation
pump; parking assistant
9 15 Audio System; diagnostic instrument; CD changer
10 15 Door mirrors; heating, rear seat
11 30 Central locking; electrically adjusted passenger seat
12 7,5 Automatic transmission
13 20 Audio System, amplifier
14 30 Ignition system, engine
15 20 Preheated oxygen sensor (catalytic converter); fuel
pump
16 20 DICE (direction indicators)
16B – –
17 20 Engine-management system
18 40 Door-mirror heating; rear-window heating
19 10 OnStar;Telematics
20 15 ACC; interior lighting; rear fog light
21 10 Audio System; rear-view mirror with auto dimming
function; low beam headlight (xenon) left/right; navi-
gation (accessory); Cruise Control
22 40 Interior fan
23 15 Sunroof
24 40 Air pump (3.0t V6 only)
25 30 Electrically adjustable driver’s seat; fuel-filler flap
26 7,5 Driver seat memory; mirrors memory; sunroof; park-
ing assistant; rain sensor
27 10 Engine-management system; SID
IB530
BC123456 A
14
121110987
13
6B
1516
2324
222120191817
16B
5425262728293031
3635343332
39383755525356
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219 Car care and technical information
Relay panel under instrument panel Relay panel under instrument panel (cont.)28 7,5 Airbag (SRS)
29 7,5 ABS/TCS/ESP
30 7,5 Starter motor
31 7,5 Cruise control; water valve; fog lights, front
32 15 Ventilated front seats
33 7,5 Direction-indicator switch
34 30 Cigarette lighter (front/rear)
35 15 Daytime running light
36 30 Electric windows, left
37 30 Windshield wipers
38 30 Electric heating, front seats
39 20 Limp-home solenoid (automatic transmission);
OnStar; telematics
52-
56Spare fuses
# Function
A –
B Electric heating of rear seat
C1 –
C2 –
D –
E Main relay (engine management system)
F Fuel filler flap
G Fuel pump
H Ignition switch
I Rear-window / door mirrors heating
J–
KStarter relay
L1 Limp-home function
L2 Bootlid
IB1796
A
BC1
C2
L2 L1 D
GE
F
H
I
K J
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227 Car care and technical information
Changing a wheel
WARNING
 The car jack is designed solely for use
in changing a wheel or fitting snow
chains. It must not be used to support
the car during repair work or servicing.
 Never crawl under a car that is
supported only by a jack.
 Special care must be taken if the car is
on a slope – use wheel chocks!
 Position chocks, one ahead and one
behind, the wheel that is diagonally
opposite to the one to be changed.
 Switch on the hazard warning lights if
the car is on a road.
 Apply the parking brake and leave the
car in gear (1st or reverse). Automatic
transmission: move selector to the
P position.
 Ensure that everybody is out of the car
before jacking it up.
 Never start the engine while the car is
jacked up.
 The jack must stand on a firm, level
surface.
 Stow the jack in the place provided for
it under the panel in the floor of the lug-
gage compartment. Secure it properly
to avert injury to passengers in the
event of a crash.
 Do not use the jack for any purpose
other than for jacking up the car.
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237 Car care and technical information
4Inspect the undercoating and touch
up if necessary.
Pay particular atten-
tion to the fenders and wheel housings,
which are exposed to abrasion by flying
gravel, etc. If the composition has worn
or flaked off, the steel must be thor-
oughly cleaned and dried before a fresh
coat is applied. The cleaning is best
done with a scraper and a steel wire
brush, followed by washing with solvent.
Apply the new coating thinly, as other-
wise it may run off or fall off when dry.
For long tripsBefore setting off on a long journey, it is
advisable to have your car checked over by
your Saab dealer.
Obtain a few important items to take along
on your journey such as spare bulbs, wiper
blades, fuses, a Poly-V-belt and the like.
You can check some points yourself before-
hand:
 Make sure that the engine is in good con-
dition.
 Check that no oil or gasoline leaks out of
the engine or gearbox/transmission.
 Check the coolant and power steering
fluid levels. Check also for leaks.
 Inspect the Poly-V-belt and replace it if it
shows any signs of hard wear.
 Check the battery charge.
 Check the tires for tread pattern and air
pressure, including the compact spare
wheel.
 Check the brakes.
 Check all bulbs.
 Check for the presence of the tool kit and
the jack in the car.
Recovery and/or
recycling of automotive
materialsA typical car consists of metals (65–75%),
plastics (10–14%), rubber (5%) and small
quantities of glass, wood, paper and tex-
tiles.
Some of these materials can be recycled,
while others can be recovered in chemical
processes for reuse in new products or as a
source of energy.
While the Saab 9-5 was still at the draw-
ing-board stage, Saab engineers were
giving serious consideration to how the
maximum quantity of materials could be
reclaimed from the car on its eventual
scrapping. To facilitate sorting, plastic parts,
for instance, have been marked to identify
the precise nature of the plastic.
Approximately 90% of the materials in the
car can be recycled or recovered, where
facilities exist.
Before the car is scrapped, all the oils and
other fluids that could pollute the environ-
ment should be recovered from the car. It
may be of interest in this context to learn that
the refrigerant used in the Saab 9-5’s ACC
systems (R134a) contains neither CFCs nor
any other chlorine compounds.
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245 Maintenance and owner assistance
Service record retentionService instruction coupons and record
stubs are provided in the Saab Warranties
and Service Record Booklet which accom-
panies this Owner’s Manual. The coupons
are arranged in the order that normal ser-
vice should be performed. The edge of each
coupon is shaded to correspond to the type
of service point:
 Striped - "Check Up"
 Blue - Oil change/inspection service
 Black - Major service
Note that in Canada a combined service
and warranty book is used, but not service
coupons.
When scheduled services are performed,
your dealer will tear out the applicable
coupon and use it to check off the opera-
tions performed and enter it into the service
file at the dealership. The servicing dealer’s
stamp, along with the date and mileage at
which the service was done, should be
entered on the corresponding stub which
remains in your booklet. The booklet is your
permanent record of the services per-
formed. It also includes a log sheet for
unscheduled repairs.
It is advisable to retain receipts and, if pos-
sible, copies of shop work orders for all ser-
vice and repair work, wherever performed.
Service costsDealer pricing practices and labor for ser-
vice work vary. Saab’s recommended ser-
vice times for each service point do not
include the labor required to replace wear
items, such as wiper blades, brake pads or
tires. Nor is labor to perform other service or
repairs found to be necessary as a result of
the inspections included in these times.
Additional labor and parts will be charged
for such work when necessary, except as
covered under an applicable Saab warranty
or any optional extended service contract.
Transmission fluid changes or suspension
alignment, when necessary, are also addi-
tional.
Dealer charges for general shop material,
regulated hazardous waste removal, recy-
cling expenses or other operation costs may
also be applied to service and repair
invoices and are apt to vary by dealer and
locality.
Owner assistanceWarranties and service problem
assistanceFor complete information about all applica-
ble warranties, including the New Car War-
ranty, Perforation Warranty, Vehicle Emis-
sion Warranty and Emission Perforation
Warranty, consult the Warranties and Ser-
vice Record Booklet which accompanies
this Owner’s Manual. It also contains owner
assistance information including Saab
Roadside Assistance. If the booklet is lost or
misplaced, a new one may be ordered
through a Saab dealer or by contacting
Saab.
In the U.S. there is a national Customer
Assistance Center at Saab Cars USA, Inc.
The toll-free number to call from all 50 states
is 1-800-955-9007.
In Canada, please call the Saab Customer
Assistance Centre at 1-800-263-1999.
A list of authorized Saab sales and service
dealers is available for those planning to
travel in the United States and Canada.
Canadian or U.S. travelers may call the
Customer Assistance Center in the country
in which they are traveling.
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247 Specifications
Specifications General.............................. 248
Engine ............................... 250
Fuel.................................... 250
Engine oil .......................... 251
Engine variants ................ 252
Electrical system.............. 253
Drive belts......................... 253
Manual gearbox................ 254
Automatic transmission .. 254
Suspension....................... 255
Steering............................. 255
Brake system.................... 255
Wheels and tires .............. 256
Plates and labels .............. 257
IB603
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