2004 SAAB 9-5 check engine

203 Car care and technical information
ORVR (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 154.
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.
IB601
Balance shafts
ProCarManuals.com

204 Car care and technical informationEngine oilChecking the oil level Check the engine-oil level regularly. This
should be done after the engine has been
run to normal temperature and then allowed
to cool for 2–5 minutes, with the car stand-
ing on level ground. Remove the dipstick
and wipe it clean before checking the level.
The oil level must not be allowed to drop
below the MIN mark on the dipstick, nor
should oil be filled beyond the MAX mark, as
this can lead to excessive oil consumption.
The distance between the MIN and MAX
marks on the dipstick corresponds to a
volume of approximately 1.05 qts (1 liter).
When necessary, add oil of the recom-
mended grade via the dipstick tube.
Changing engine oil
WARNING
 Prolonged and repeated exposure of
the skin to engine oil can cause seri-
ous skin disorders. Avoid prolonged
skin contact whenever possible.
 Used engine oil contains chemicals
that have caused cancer in laboratory
animals. Always protect your skin by
washing thoroughly with soap and
water.
 Keep oil out of reach of children.
 Do not touch the turbocharger or
exhaust 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.
IB491
Engine-oil filler cap and dipstick
ProCarManuals.com

205 Car care and technical information
The engine oil must be changed in accor-
dance with the service program, see page
264.
Oil volume and grade, see page 273.
Oil changing should be carried out on a
warm engine.
1 Unscrew the drain plug in the bottom of
the sump and leave the oil to drain into
an oil tray or other suitable receptacle for
at least ten minutes. Take care, as the oil
may be hot.
2 After the oil has been drained, unscrew
and remove the oil filter.
3 Fit a new filter and tighten it by hand.
4 Refit the drain plug with a new washer.
5 Fill with new engine oil.
Run the engine to normal temperature and
check the oil level. Change of engine oil and oil filter may be
required more frequently, see page 264.
IB493
Drain plug and oil filter
ProCarManuals.com

206 Car care and technical informationTransmission fluidManual transmission Check and top up the fluid in accordance
with the service program.
If original fluid cannot be obtained for top-
ping up (see page 276), automatic trans-
mission fluid Dexron III (synthetic oil) can be
used. If so, the car should be taken to an
authorized Saab dealer immediately to
have the reason for low fluid level corrected
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.NOTICEIf there is a smell of burning fluid or the
fluid is black, change the fluid.
IB1923
Dipstick for automatic-transmission fluid
ProCarManuals.com

207 Car care and technical information
Coolant The expansion tank is transparent to facili-
tate checking of the coolant level.
When the engine is cold, the coolant must
not lie over the KALT/COLD mark on the
expansion tank.
If the message ”Coolant level low. Refill.” is
displayed on the SID, check the level of fluid
in the expansion tank.
Top up, as necessary, with equal parts of
clean water and Saab-approved coolant.
If the expansion tank is empty when coolant
is added, run the engine to normal temper-
ature and top up again, as necessary.
Coolant The cooling system is charged at the factory
with coolant containing a 45 % concentra-
tion of a combined antifreeze and corrosion
inhibitor. A weaker mixture will result in
reduced anticorrosion protection. For pro-
tection against freezing in very cold
weather, a stronger concentration will be
needed.
A 60 % concentration of antifreeze will pro-
vide protection at temperatures down to
-58 F (–50°C).
The coolant does not normally have to be
changed during the service life of the car.
The type of coolant used has a reddish color
and should not be mixed with other types of
coolant. Saab Original coolant should be
used all year round. Only use coolant
approved by Saab. Note:
If incorrect coolant is used or added, the
life-time properties will be affected. Even if
the coolant is flushed from the system and
replaced with life-time coolant, life-time
properties are no longer retained and the
coolant must then be drained and replaced
at regular intervals.

WARNING
 Proceed with caution if the radiator is
boiling when you open the hood.
Never remove the expansion-tank
filler cap when the radiator is boiling.
 The cooling system is pressurized –
hot coolant and vapor can escape
when the filler cap is released. These
can cause injury to your eyes and
burns. Loosen the cap carefully, and
let the engine cool before removing
the cap.
 Exercise care when adding coolant.
Coolant on hot surfaces constitutes a
fire risk.
NOTICEAlways mix the antifreeze with the
appropriate volume of water before
adding it to the cooling system.
If pure antifreeze is added, the engine
could still freeze and be damaged. This is
because the antifreeze will not mix
properly with the coolant before the
thermostat has opened to allow full
circulation.
IB1338
Coolant expansion tank
ProCarManuals.com

209 Car care and technical information
Power steering fluidCheck the level of the power steering fluid in
the reservoir regularly, in accordance with
the service program.
The wheels should point forward during the
check.
Clean around the cap before it is
unscrewed. Clean the dipstick. Screw in the
cap completely again before checking the
level.
The oil should lie between the MAX and MIN
marks when the oil temperature is about
70°F (+20°C). If the oil is colder the level can
be lower, and in higher temperatures the
level can be higher, both of which are
acceptable.
Top up with ”Power Steering Fluid
CHF 11S”.
Air filter
WARNING
Do not fill the power steering fluid to
above the MAX mark. Too much fluid can
result in leakage.
Power steering fluid on hot engine com-
ponents constitutes a fire risk.
WARNING
For Service and Repair, parts equivalent
to those used by Saab should be used.
Be aware that some non standard
replacement parts may put you in an
unsafe condition, even if they might fit.
IB501
Power steering fluid reservoir
ProCarManuals.com

215 Car care and technical information
Changing bulbsCheck that the new bulb is working when finished.
Use only "Long Life" bulbs.
Headlight aiming, see page 259.
Xenon headlight (certain variants)Xenon headlights produce roughly twice as much light as halogen
bulbs and have a significantly longer service life.
The lamp units consist of a gas discharge lamp containing xenon.
When the lights are switched on a very high voltage activates the
xenon gas. The lamps soon reach full intensity.
Cars with xenon headlights have automatic levelling. The levelling
system comprises two sensors on the front axle, one on the rear axle
and a control unit under the headlight housing. Headlight alignment
is regulated automatically to prevent dazzling oncoming traffic.
Alignment is also adjusted during braking.
WARNING
Before changing a bulb in the engine bay, switch off the engine to
avoid danger of fingers and hands being injured by moving parts.
The radiator fan can start up even when the engine is switched off.
Xenon headlights are high voltage and must therefore be
changed at an authorized Saab workshop. Work involving
high-voltage components is potentially lethal.NOTICE Since the headlight lenses are made of plastic, rinse dried-on
dirt with water and allow it time to soften up before cleaning
the lenses. Avoid rubbing the lenses when dry and never use
solvents.
 Use de-icer spray instead of scraping the ice off.
NOTICE Do not fit bulbs with a higher rating than 55 W, since the head-
light reflector and the wiring of the car are not designed for a
higher wattage.
 Switch off the ignition before changing a bulb, to avoid possi-
ble short-circuiting.
 Do not touch the glass of the bulbs with your fingers. The oil
on your skin can shorten the life of the bulb.
ProCarManuals.com

219 Car care and technical information
Front turn signal bulbsTo change the bulb, the complete lamp unit
has to be removed.
1 Depress the catch, accessed from the
engine bay.
2 Carefully pull out the lamp unit.
3 The bulb holder has a bayonet fitting.
Grip the holder and twist it counterclock-
wise.
4 Withdraw the bulb holder from the lamp
unit.
5 The bulb also has a bayonet fitting.
Press in the bulb and twist it counter-
clockwise.
6 Fit the new bulb and check that it is cor-
rectly seated.
To re-install the lamp unit1 Align the catch with the recess in the
lamp housing holder.
2 Press the lamp housing towards the
headlight slightly and press the housing
towards the rear of the car.
3 Make sure the locating pin and the two
plastic lugs enter their respective holes.
4 Press the lamp housing until it click into
place.
IB1789
2
13
3
Front turn signal bulb1Catch
2 Bayonet pin
3 Plastic lugs
IB1875
Catch seen from engine bay, left-hand
side
IB1876
Catch seen from engine bay, right-hand
side
IB1790
ProCarManuals.com