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 S02T, 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 S02T 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 the MY01 Self-Study (S01T), 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 S02T test must be successfully completed during calendar year 2002 to receive
2002 Saab Griffin Society credit and to meet 2002 Dealer Standards.
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Table of Contents
9-3
9-3 Introduction – Model Year 2002
9-3 Product Range ………………………………………………………..…..…. 85
VIN (Vehicle Identification Number) MY2002 ……………………………...…. 89
Engine
9-3 Engine Range, Model Year 2002 ………………………………………..….. 90
Cooling System.........................…………………………………………….....… 91
Electrical System
Main Instrument Unit, MIU .…………………………………………………..….. 92
Body
Body Colors ……………………………………………………………………….. 94
Exterior/Interior ...........................……………………………………………...… 95
Saab Signature Technologies
....................……………………………………………………………………….. 97
Glossary
....................……………………………………………………………………….. 107
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4
General information
Warning, Important and Note
Market codes
The headings Warning, Important and Note
appear from time to time in this service manual.
They are used to draw the attention of the reader
to information of special interest and seriousness.
The importance of the information is indicated by
the three different headings and the difference
between them is explained below.
The codes refer to market specifications.
AT
AU
BE
CA
CH
CN
DE
DK
ES
EU
FI
Austria
Australia
Belgium
Canada
Switzerland
China
WARNING
Germany
Denmark
Spain
Warns of the risk of material damage and grave
injury to mechanics and the driver, as well as
serious damage to the car.
Europe
Finland
FR
GB
GR
IE
France
Important
Great Britain
Greece
Points out the risk of minor damage to the car
and also warns the mechanic of difficulties and
time-wasting mistakes.
Ireland
IL
Israel
IS
Iceland
Note
IT
Italy
Hints and tips on how the work can be done in
a way that saves both time and labor. This
JP
Japan
information is provided as
improving efficiency, not for reasons of safety.
a
means of
LA
ME
MT
NL
NO
PA
PT
RU
SE
TR
US
UC
ZN
Latin America
Middle East
Malta
Netherlands
Norway
Asia/Pacific region
Portugal
Russia
Sweden
Turkey
USA
US California
New Zealand
9-5
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9-5 Product Overview
5
9-5 - Introduction – Model Year 2002
Saab 9-5 Product Range - Model Year 2002 - US
For model year 2002, the trim level of Saab 9-5 models will be designated by new form names.
In the U.S., the 9-5 will be available in three models, each available as a sedan or wagon:
· Linear 2.3t
· Arc 3.0t
· Aero
9-5 Linear 2.3t
New 10-spoke, 16in alloy wheels are standard
on all 9-5 Linear models in the US.
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.
The options available on Linear models are:
·
·
·
5-Speed Automatic Transmission
The Premium Package
Mica/Metallic Paint
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 interior 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.
The 9-5 Linear 2.3t Premium Package includes:
·
·
·
Memory driver's seat
Power Memory Mirrors
The Harman Kardon prestige audio
system.
·
·
·
Electronic Stability Program (ESP)
Heated rear seats
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.”
Auto-dimming rearview mirror
9-5
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6 9-5 Product Overview
9-5 Arc 3.0t
Two special option packages will be offered on
Arc models sold in the U.S.:
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.
An optional ”Visibility Package” will be offered
from November through February production.
This package includes:
·
·
Bi-Xenon headlights with Automatic
Headlight Levelling (AHL)
9-5 Arc 3.0t models have an extensive list of
standard features:
The Rain Sensing Wiper system
·
·
·
Perforated leather seating surfaces and
leather door inserts
In February, 2002, the ”Visibility Package” will
be replaced by an optional ”Touring Package”
which includes:
Power seats with memory on the driver's
seat and power memory mirrors
·
·
·
Bi-Xenon headlights with Automatic
Headlight Levelling (AHL)
The Harman Kardon prestige audio
system
The Saab Parking Assistance system
(SPA)
·
·
·
·
Auto-dimming rear view mirror
Heated & ventilated front seats
Heated rear seats
The Rain Sensing Wiper system
The only other option is:
Mica/Metallic Paint
Electronic Stability Program (ESP)
·
New 5-spoke, 16in BBS wheels are included on
all 9-5 Arc 3.0t models in the U.S.
9-5
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9-5 Product Overview
7
9-5 Aero
Two special option packages will be offered on
Aero models sold in the U.S.:
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).
An optional ”Visibility Package” will be offered
from November through February production.
This package includes:
·
Bi-Xenon headlights with Automatic
Headlight Levelling (AHL)
·
The Rain Sensing Wiper system
In February 2002, the ”Visibility Package” will be
replaced by an optional ”Touring Package”
which includes:
Aero models have the same extensive list of
standard features as 9-5 Arc 3.0t models, but
also include:
·
·
·
Bi-Xenon headlights with Automatic
Headlight Levelling (AHL)
·
·
·
·
·
New Leather Sport seats
The Saab Parking Assistance system
(SPA)
A new ”Aluminum-look” dash
Sport-tuned chassis
The Rain Sensing Wiper system
Aero skirts and air flow panels
Leather-wrapped sport steering wheel
The only other options are:
·
·
5-Speed Automatic Transmission
Mica/Metallic Paint
Note
As a result of the Leather Sport seats being
added, ventilated seats are not available on the
Aero models.
10-spoke, 17in BBS wheels are standard
equipment on all 9-5 Aero models in the U.S.
9-5
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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:
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.
Engine
Engine variants
The following engine variants are available in the
U.S. market for the Saab 9-5 model year 2002:
Main instrument unit
New compact and lighter main instrument unit
with several enhancements, such as LEDs
instead of bulbs, has been introduced.
·
·
·
2.3t Ecopower 185hp (207 ft. lbs. / 280Nm)
B235E (Linear)
3.0t Ecopower 200 hp (229 ft. lbs. / 310 Nm)
B308E (Arc)
Transmission
5-speed automatic transmission
2.3T Ecopower 250hp (258 ft. lbs./350Nm)
B235R (Aero)
New 5-speed automatic transmission replaces
the previous 4-speed.
Note
Brakes
B235R and B308E must be run on high-octane
fuel (min. 92 AON) in order to deliver the
specified engine torque.
Brake system
New master cylinders and power assisted brakes
on all models. Ventilated rear brake discs on
certain models.
Electrical system
Charging system
Electronic Stability Program (ESP)
New generator and new cooled battery.
Lighting system, Bi-Xenon
Bi-Xenon lighting is available as an option.
High pressure headlight washers
This safety system governs the engine torque
and brake force to aid the driver during evasive
maneuvers.
Body
Exterior
Headlight lenses are washed with high pressure
jets that replace the wash/wipe system.
New integrated front & rear bumpers.
Impact protection
Enhanced impact protection.
Airbag system
Rain Sensing Wiper
A rain sensor is integrated into the wiper delay
function of DICE
Highly developed system with 2-stage driver and
passenger airbags, front sensor.
9-5
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9-5 Product Overview
9
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
prices and different emission testing standards.
9-5
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10 9-5 Product Overview
Vehicle Identification Number (VIN) M2002
Example: YS3EF45C623008642
1 - Geographical area
2 - Country
Y = Northern Europe
S = Sweden
3 - Car manufacturer
4 - Product line
3 = Saab Automobile AB
E = 9-5
5 - Model Series
B = Saab 9-5 Linear 2.3t with driver and passenger airbag
D = Saab 9-5 Arc 3.0t with driver and passenger airbag
H = Saab 9-5 Aero with driver and passenger airbag
6 - Body type
7 - Gearbox
4 = 4-door
5 = 5-door (SportWagon)
5 = Manual 5-speed
9 = Automatic 5-speed
E = 2.3t
8 - Engine variant
G = 2.3 Turbo (High Output)
Z = 3.0t V6
9 - Check character
10 - Model year
0 - 9 or X
2 = 2002
11 - Place of manufacture
12 - Serial number
3 = Trollhättan
000001-999999
9-5
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Service 11
Service
Service Saab 9-5
Revisions
·
A
maintenance-free battery has been
·
“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.)
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.
·
·
·
The customer can request the car to be
programmed to an optional level of
customization at the first service.
-
If the indicator is dark, the electrolyte level
is correct.
Oil level check on manual gearboxes has
been discontinued while check for oil leaks
remains.
-
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.
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 the 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.
9-5
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12 Engine
Engine
Engine range, Saab 9-5 model year 2002 (US)
Engine
B235E (Linear)
B235R (Aero)
B308E (Arc)
Compression ratios
9.3:1
9.3:1
9.5:1
Turbocharger
make, type
Garrett
GT17
Mitsubishi
Garrett
GT15
TD04HL-15T
Wastegate pre-stressing
Basic charging pressure
Max. power, EEC
2 mm
2 mm
-
0.40 Bar ±0.03
0.45 Bar ±0.03
0.27 Bar ±0.03
185hp/136kW
at 5500 rpm
250hp/183kW
at 5500 rpm
200hp/147kW
at 5000 rpm
Max, torque, EEC
207 ft. lbs. (280 Nm)
at 1800-3500 rpm
258 ft. lbs. (350 Nm)
at 1900-4000 rpm (man)
229 ft. lbs. (310 Nm)
at 2300-4500 rpm
258 ft. lbs. (350 Nm)
at 1900-4700 rpm (aut)
Spark plugs
make, type
NGK,
NGK,
NGK,
BCPR6ES-11
PFR6H-10
BKR7ES-11
Spark plugs
electrode gap
1.05 mm
±0.05
0.95 mm
±0.05
1.05 mm
±0.05
Engine management
system
Trionic T7
Trionic T7
Trionic T7
Recommended fuel octane
number (AON)
87
92
92
9-5
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Engine 13
Cooling system
New coolant
Note
Do not top up with the earlier type of coolant
(blue-green), as this will impair the corrosion
protection properties.
A new "Long-life" coolant is used in all Saab
engines for model year 2002. The new coolant
was actually introduced during late 2001
production.
The orange coolant will also be discolored by
the blue-green coolant and may appear to be
contaminated with engine oil, etc.
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.
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 coolant (or even using shared
containers) may contaminate the system
enough to affect the "Long-life" properties.
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
50 %
Mixing
Part Number
-200 l (drum) available later
-4 l (can)
02-86-542
9-5
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14 Electrical system
Electrical system
Charging system
Generator
1. Stator
2. Rotor with slip rings
3. Integrated fans
4. Rectifier
5. Regulator
6. Pulley
The generator is an alternating current generator
with integrated charge regulator. Maximum
current is now 140 A, up from 130 A in 2001.
The generator is driven by the engine through a
multi-groove V-belt from the crankshaft belt
pulley.
The drive ratio is 1:2.85.
9-5
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Electrical system 15
Battery and battery cooling
A new style battery is introduced for model year
2002. It is a sealed, maintenance-free battery.
The battery has a capacity of 70 Ah, and a cold
cranking rating of 700 CCA.
The battery has a level window to indicate
whether there is sufficient electrolyte (battery
fluid) in the battery. The window should normally
be dark/black when the level is sufficient. If it is
shiny like a mirror, the battery should be changed
as the level is too low.
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 spoiler. The air from
the air duct passes through the battery cover and
cools the battery.
9-5
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16 Electrical system
Relay and Fuse Box
Relay and fuse box
A new relay and fuse box has been introduced on
model year 2002.
A new type of fuse, a microfuse, has been
introduced. These fuses have the same function
as earlier types, but are smaller in size.
9-5
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Electrical system 17
Bi-Xenon Headlights (Available on Arc & Aero)
Brief description
There is
headlight assembly housing.
headlight flashers are used while the low beam
is turned off, only the halogen bulb lights up
(sometimes called the “flash to pass” function).
a
halogen bulb mounted in the
When the
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.
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.
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 by a solenoid that is activated from
the control module. This increases the beam of
light from the lamp.
9-5
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18 Electrical system
·
·
·
·
·
Headlamps (663FL/FR)
System overview
AHL control module (664)
·
·
·
·
Halogen bulb (11)
Main beam damping solenoid (665)
Load angle sensor, front (704F)
Load angle sensor, rear (704R)
Xenon headlight (11a)
Parking light bulb (13)
Headlight beam length adjustment motor
(280)
·
Main instrument unit (540)
9-5
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Electrical system 19
Principal components
1. DICE control module (628)
2. Light switch (10)
8. Halogen bulb (11)
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)
12. Parking light bulb (13)
5. Headlight filament monitor (228b)
Main beam flasher relay (666)
Dipped beam relay (8)
13. AHL control module (664)
14. Headlight Assembly (663FL/FR)
Main beam relay (8a)
6. Load angle sensor, front (704F)
7. Load angle sensor, rear (704R)
9-5
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20 Electrical system
Description of operation
Xenon lamp
General
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 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).
The xenon lamp is driven 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.
9-5
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Electrical system 21
Dip switch solenoid
Xenon lamps always have the same brightness.
The beam of light from a xenon lamp is limited for
dipped beam (low beam) use by a screen, which
is opened by a solenoid for main beam (high
beam) use to give a brighter light.
9-5
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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.
9-5
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Electrical system 23
Automatic headlight beam adjustment
Headlight beam adjustment motor
Cars with the Bi-Xenon headlight system are
equipped with automatic headlight beam
adjustment. The control system ensures that the
headlights are always at an optimum angle
during acceleration, braking and at varying loads.
When the front of the car lifts during fast
acceleration, the headlights will be angled down
and during heavy braking when the front of the
car dips, they will be angled up. The correct
angle is maintained even when the car is heavily
loaded.
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.
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.
9-5
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24 Electrical system
Load angle sensors
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.
Cars with automatic headlight beam adjustment
are fitted with a front and rear load angle sensor.
The front sensor is fitted between the subframe
and the wishbone and receives information on
the wishbone movement in relation to the
subframe. This information is sent on to the AHL
control module as a pulse width modulated
signal.
The AHL control module governs the angle of the
headlamps using the information provided by the
two load angle sensors.
9-5
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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
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26 Electrical system
Wash/wipe systems (Standard on all 9-5 Models)
Description of operation, high
pressure headlight washers
Note
All 9-5 models sold in the U.S. for model year
If the fuse (#35) for Daytime Running lamps is
2002 will be equipped with the new “High
Pressure Headlight Washer” system. (Including
models not equipped with Bi-Xenon headlights.)
pulled, the headlamp washer system will not
activate when the headlamp selector is in the
OFF position.
There is a washer nozzle fitted on a cylinder in
the spoiler in front of each headlamp. The washer
nozzles are covered in the spoiler when not in
operation. 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.
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Electrical system 27
(A)
(A)
System overview, high pressure
headlight washers
·
·
·
DICE control module (628)
Windshield wiper stalk switch (61)
Relay, high pressure headlight washer fluid
pump (667)
·
·
Motor, high pressure headlight washer pump
(668)
High pressure “pop-up” sprayer washers (A)
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28 Electrical system
Main components, high pressure
headlight washers
1. DICE control module (628)
2. Windshield wiper stalk switch (61)
3. Relay, high pressure headlight washer fluid
pump (667)
4. Motor, high pressure headlight washer pump
(668)
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Electrical system 29
Rain Sensing Wipers (Available on Arc and Aero)
61
649
650
83
E 36 3D 02 6
Brief description
·
·
·
Stalk switch (61)
Rain sensor (649)
Relay (83 and 650)
The rain sensor assumes the DICE functions
regarding windshield wipers.
Windshield wipers with rain sensor
The windshield wiper unit is located under the
cover below the windshield and comprises a
motor, arm system and two wiper arms with
wiper blades. The function is controlled by the
rain sensor via two wiper relays.
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 the stalk switch.
The sensor is most sensitive with the knob in its
uppermost position.
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.
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.
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30 Electrical system
649
541
61,618
62F
667
83
650
628
63b
668
E363D045
System overview
·
·
·
·
·
·
·
·
·
·
Rain sensor (649)
Relay, rain sensor (650)
Relay, headlamp washer fluid pump (667)
Windshield wiper stalk switch (61,618)
Windshield wiper motor (62F)
Washer fluid motor, windshield (63a, 63b)
Washer fluid motor, headlamps (668)
Relay, intermittent wiper (83)
DICE (628)
SID (541)
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Electrical system 31
2
(61/618)
1
(649)
4, 5, 6
83
667
3
(62F)
7
(63B)
650
8
8
9
(541)
(668)
5
7
4
6
3
9
10
(628)
10
2 1
E363D046
Principal components
1. Rain sensor (649)
6. Relay, headlamp wsher fluid pump (667)
7. Washer fluid motor (63b)
8. Washer fluid motor (668)
9. SID (541)
2. Windshield wiper stalk switch (61,618)
3. Windshield wiper motor (62F)
4. Relay, rain sensor (650)
5. Relay, intermittent wiper (83)
10. DICE (628)
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32 Electrical system
1
4, 0
2
3
E 3 63 D 0 29
Activating positions
Wipers are activated with the stalk switch in the
following positions:
1. Automatic mode
The rain sensor controls the wiper motor from
intermittent to high speed.
2. Low speed
The wiper motor is activated at low speed
without the assistance of the rain sensor.
3. High speed
The wiper motor is activated at high speed
with the assistance of the rain sensor.
4. Washing
The washer pumps are activated and the rain
sensor starts the windshield wipers.
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Electrical system 33
E3 6 3 D0 28
Rain sensor
The light sensors generate infrared light that is
refracted at a certain angle in the surface layer of
the windshield if there is no snow or rain on the
windscreen. When there are raindrops or
snowflakes on the area that the sensors cover,
the light will refract at a different angle.
The rain sensor is a control module with its own
logic. It is NOT connected to the bus and,
therefore, will not generate fault codes or
communicate with Tech 2. 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.
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
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.
·
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.
·
·
Splash - If a shower of water washes over
the windscreen, high speed will be activated
until the water has been wiped away.
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.
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.
The sensor controls automatic mode (position 1),
high speed (position 3), and wash/wipe (position
4).
Function
·
Dirt function - The wiper blades will not be
activated if the sensor detects
a
dirty
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 sensitivity in darkness.
windscreen. The driver will have to wash the
windshield first.
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34 Electrical system
Main instrument unit, MIU
A
new main instrument unit with several
The following changes have also been carried
out:
modifications has been introduced on the Saab
9-5. All the electronics and other components are
now combined on one circuit board, thus
reducing the depth and weight of the main
instrument unit. Instrument lighting comprises
only LEDs, which provide a more agreeable light
and are very reliable.
·
·
Only one 22-pin connector.
All lamp bulbs 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.
Four new warning and indicator lamps have been
added and certain functions have been revised.
·
Only the front glass and complete units are
available as spare parts.
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Electrical system 35
km/hr instrument shown
New warning and indicator lamps
Functional changes
·
ESP (Electronic Stability Program) indicator.
·
·
The miles graduation is more compressed in
the higher speeds.
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.
The airbag lamp is now governed via bus
information from SRS to the main instrument
unit. The main instrument unit uses the
information to turn the lamp on/off.
·
·
ESP 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
comes on in case of a fault in the system.
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36 Electrical system
Saab Parking Assistance, SPA (Available on Arc and Aero)
Brief description
In the Sedan variant, the control module is
located behind the backrest member, under the
side trim on the left-hand side.
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.
In the SportWagon variant, the control module is
located under the front floor in luggage
compartment.
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.
The four distance sensors 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:
·
·
·
·
Left-hand outer distance sensor (RL)
Left-hand center distance sensor (RLC)
Right-hand center distance sensor (RRC)
Right-hand outer distance sensor (RR)
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.
(Note that this system will not be available until
February, 2002)
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Electrical system 37
System overview
·
Ultrasound distance sensors:
·
·
·
·
Right-hand outer sensor (631RR)
Right-hand center sensor (631RRC)
Left-hand center sensor (631RLC)
Left-hand outer sensor (631RL)
·
·
·
·
·
SPA control module (630)
SID control module (541)
DICE control module (628)
TWICE control module (632)
TCM control module (502)
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38 Electrical system
Main components
1. SPA control module (630)
2. Distance sensor, LH outer (631RL)
3. Distance sensor, LH center (631RLC)
4. Distance sensor, RH center (631RRC)
5. Distance sensor, RH outer (631RR)
6. SID (541)
7. DICE control module (628)
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Electrical system 39
Turning off SPA
The text message is stored in English, Swedish,
German, Spanish, French and Italian in the SPA
unit. It is sent via the I bus to the SID, where it is
displayed.
If you wish to turn off the SPA, for example,
when towing a trailer, press the CLEAR button
on the SID when “PARK ASSIST” is displayed
until ”PARK ASSIST OFF” appears, approx. 1-2
seconds.
The text messages are as follows:
If you wish to reactivate the SPA there are two
methods:
- PARK ASSIST
- PARK ASSIST FAILURE
- PARK ASSIST OFF
·
Press CLEAR until the SID text changes (the
text is not shown until the function is
ON/OFF).
·
Turn the 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.
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40 Electrical system
Distance measurement and indication
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.
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.
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.
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.
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.
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.
Objects alongside the car
The frequency of the signal increases the closer
to the object the car comes. The signal changes
as follows:
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 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.
·
·
·
1.8m (71in) - 1.3m (51in): 2 pulses/second
1.3m (51in) - 0.9m (35in): 3 pulses/second
0.9m (35in) - 0.3m (12in): from 5 to 12
pulses/second in close steps
·
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
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Transmission 41
Transmission
5-Speed automatic transmission (Available on Linear and
Aero, Standard on Arc)
Brief description
position, inside the cabin between the glove box
A new 5-speed automatic transmission has been
and the bulkhead.
introduced on the 9-5 engines.
The TCM self-diagnosis continuously monitors all
The new transmission is based on the tried and
the functions of the system and sets DTC’s if
tested 4-speed Aisin-AW that has been fitted on
necessary.
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.
As before, it is possible to choose between three
different driving programs:
·
·
·
Normal
Sport
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.
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 above
40°C (104°F).
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 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.
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 II and III. 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.
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
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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.
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.
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 before. The current consumption of the 5 "on-
off" solenoids is 1A continuous and 2A maximum.
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.
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.
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).
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.
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Transmission 43
System overview
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44 Transmission
Principal components
The automatic transmission consists of the
following principal components:
6. Clutch disc pressure solenoid valve (SLS)
531
1. Gearbox
2. Control module, (TCM) 502
3. Gearshift solenoid valves, (S1-S5) 531
4. Lock Up solenoid valve, (SLU) 531
5. System pressure solenoid valve, (SLT) 531
7. Input shaft speed sensor, 532
8. Output shaft speed sensor, 533
9. Transmission fluid temperature sensor, 535
10. Gear selector position sensor, 245
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Transmission 45
Control modules
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.
The transmission control module primarily
controls
·
·
·
Shift points
System pressure
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.
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
programmed 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).
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 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. 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.
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).
The control module can be SPS programmed
using the diagnostic instrument.
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46 Transmission
Electronic overspeed protection
In order to prevent the engine from overspeeding,
the transmission control module is programmed
with an electronic overspeed protection function.
This means that it is not possible to gear down
until the vehicle speed is below the relevant limit.
Gear
Max speed km/h
Max speed mph
changing
5-4
4-3
3-2
2-1
175
125
75
109
78
47
35
22
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Transmission 47
Electronic reverse gear detent
When changing to R from D, 4, 3 or L while the
vehicle speed exceeds 7 km/h (4.3 mph), the
control module will energize the S1 solenoid to
prevent reverse gear from being engaged (brake
B3 released).
The electronic reverse gear detent is disengaged
when the speed of the car is below 7 km/h
(4.3 mph) or the selector lever is moved to a
position other than R.
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48 Transmission
Limp-home
Limp-home mode provides the following gear
positions:
In case of a major system error, such as a
mechanical fault with the system input or output
functions, or an internal fault in the control
module, all the control module functions will be
deactivated at the same time as the control
module sends the bus message "CHECK
GEARBOX unit ON" to turn on the indicator lamp
in the main instrument unit. A fault code will also
be stored.
Gear
P
P
R
R
N
N
D
5
4
5
3
5
L=2, 1
2
position
Limp-
home
Note that 2nd gear must be engaged manually.
The transmission will now be controlled solely by
the hydraulic system.
This means that the
The CHECK GEARBOX lamp lights up and a
diagnostic trouble code is stored in the memory.
transmission functions will be limited to enable
the car to be driven to a garage, thus the name
limp-home.
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Brakes 49
Brakes
Brake system
System revisions
The following are new:
A number of revisions and adaptations have
been made on the Saab 9-5 to give more space
in the engine compartment – mostly as a result of
the introduction of the new V6 diesel engine in
some markets.
·
·
·
Master cylinder
Brake servo
The carrier up to the brake caliper has been
adapted to the steering swivel member
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.)
·
More powerful brake system for 2.3 Turbo
(Aero) and 3.0t 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
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50 Brakes
Front brake system
ABS/ESP (Available on Arc and Aero)
A number of modifications have been made at
the front. With the new steering swivel member,
the wheel sensors are now screwed directly into
the steering swivel member.
A number of changes have been made in the
engine bay and, because of this, the ABS unit
has been located on a new bracket closest to the
bulkhead.
9-5 models with the 3.0t 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.
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 requires 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).
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.
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.
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Brakes 51
Brake servo and master cylinder
Master cylinder
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.
1. Pushrod with primary piston
2. Pressure chamber, primary circuit
3. Central valves
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.
4. Secondary piston
5. Pressure chamber, secondary circuit
6. Return spring
7. Stop pin
The primary cylinder is identical with the earlier
master cylinders on the 9-5.
8. Stop pin
The secondary cylinder is a plunger-type deep
cylinder without central valve, but with seals. Half
the function is now integrated in the brake servo.
9. Seals
The brake servo and brake fluid reservoir are
new and adapted to the new master cylinders.
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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.
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Brakes 53
Electronic Stability Program, ESP (Available on Linear,
Standard on Arc and Aero)
Brief description, ESP
In the U.S. market, ESP will be standard
equipment on the Aero and Arc models. ESP
will be optional on the Linear model.
ESP (Electronic Stability Program) is a system
that regulates the engine torque and braking to
assist the driver with stabilizing the vehicle
during unexpected situations that would
otherwise be difficult to handle.
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 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 unless it is affected by the fault. The
system includes a switch on the dash to shut off
the ESP (and TCS) functions.
ESP does not mean you can drive faster, but
should be regarded as
unexpected situations.
a
safety net for
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.
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.
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.
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.
·
If the car starts to understeer (when the front
tends to continue straight ahead in a bend),
the inside rear wheel will be braked.
·
If 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.
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54 Brakes
System overview
·
·
Hydraulic unit with control module (671)
·
·
·
·
Wheel sensor (298)
Yaw rate sensor, side acceleration sensor
(658)
ESP switch (660)
·
·
Steering angle sensor (657)
Brake pressure sensor (659)
ESP indicator lamp (47x)
ESP OFF indicator lamp (47y)
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Brakes 55
Principal components
6. Rear right wheel sensor (298RR)
7. ESP/TCS ON/OFF switch (660)
8. Steering angle sensor (657)
1. Brake unit including control module, valve
body and pump (671)
2. ABS warning lamp. TCS and ESP indicator
lamp. TCS OFF and ESP OFF indicator lamp
(540)
9. Yaw rate sensor, side acceleration sensor
(658)
3. Front left wheel sensor (298FL)
4. Front right wheel sensor (298FR)
5. Rear left wheel sensor (298RL)
10. Brake pressure sensor (659)
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56 Brakes
Control module
·
If 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.
The control module is integrated in the ESP unit
and has a 31-pin connector. The control module
also governs the coordinated functions of ABS,
EBD and TCS.
Programming
The ESP function reduces engine torque and
handles the braking on all four wheels. Torque
reduction takes place after the ESP control
module sends a bus message requesting a
certain engine torque. The engine control module
uses this request to regulate the air
mass/combustion.
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.
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.
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).
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 VALUE).
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.
·
If the car starts to understeer (when the front
tends to continue straight ahead in a bend),
the inside rear wheel will be braked.
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Brakes 57
Function, micro-mechanical yaw rate sensor
Yaw Rate / Side Acceleration 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.
This sensor consists of a combined micro-
mechanical yaw rate sensor and
a
side
acceleration sensor. It is located on a bracket on
the exhaust tunnel in front of the gear lever. This
location positions the sensor as close to the car's
center of gravity and center-line (X-axis) as
possible.
Its 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.
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.
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58 Brakes
Function, side acceleration sensor
Brake pressure sensor
The side acceleration sensor registers the lateral
forces that arise during cornering. It provides the
ESP control module with information on the
magnitude of the lateral forces that are trying to
make the car change direction. It sends this
ACTUAL VALUE to the ESP control module,
which compares it with the DESIRED VALUE
given by the steering angle sensor.
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 & 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.
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
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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.
ESP switch
Note that even if ESP is shut OFF, the ESP
function will remain active during braking as a
safety aid for the driver, even though the ESP
OFF indicator is illuminated.
A
spring-loaded switch is located on the
dashboard to the right of the steering wheel for
turning the ESP function ON/OFF. The TCS
function will also be turned off when the ESP
function is turned off. The ESP OFF lamp in the
main instrument unit will come on.
Request for engine torque
Engine torque regulation takes place through
throttle control and ignition retardation. Throttle
control is relatively slow in comparison with
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.
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.
ESP will remain active during braking as a safety
aid for the driver, irrespective of whether the
system is disengaged or not.
Torque request during engine braking
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.
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.
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60 Brakes
ESP function
ESP is a stabilization system that helps to keep
the vehicle on the right course when cornering,
taking evasive action, braking and accelerating.
The stabilizing effect of the ESP system is based
on calculations made by the control module,
which evaluates information sent from the various
system sensors:
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.
·
·
·
·
·
Wheel speed sensors
Steering wheel angel sensor
Yaw rate sensor
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.
Side acceleration sensor
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 the
course chosen by the driver with the steering
wheel (DESIRED VALUE).
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.
1. If the 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.
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Brakes 61
Engine torque regulation
Engine torque regulation takes place after bus
communication with the engine control module.
The ESP control module requests an engine
torque between -100 and +400 Nm. This is
achieved through ignition retardation and throttle
control, i.e. by changing the throttle angle and the
boost pressure (air mass/combustion). Using
engine torque regulation means that the brakes
need not be applied as often, resulting in a higher
degree of smoothness.
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
independently.
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.
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
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.
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.
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62 Brakes
ESP valve block
Brake application
The hydraulic unit comprises 12 solenoid valves
that govern the brake pressure to the brake units
during ABS, TCS or ESP regulation.
For ESP regulation, the control module starts the
pump, which continues during the entire
regulating process, at the same time as the
pressure-reducing valve is closed to enable a
build up of pressure. Pressure is built up by
opening the pressure-increase valve to supply
the pump with brake fluid.
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.
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
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.
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.
The pump is active continuously during ESP
regulation.
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Brakes 63
Brake fluid is returned from the wheel outlet valve
through the pressure-reducing valve to the
master cylinder. The pump is running.
Braking phases
Phase 1. Pressure build up on all four wheels
(filling pulse and pressure retention)
Driver not braking
Driver applying the brakes, see phases 1-3
If the driver applies the brakes while ESP
regulation is active, the brake pressure sensor
will inform the control module of the input brake
pressure in the hydraulic unit. With this
information, the brake pressure to the wheels not
under ESP regulation can be controlled to
correspond to the driver's braking force.
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 wheel under ESP regulation when the
brakes are applied is controlled according to the
ESP criteria.
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.
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.
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.
Regulation continues until:
·
·
the wheel/wheels are below limits for ESP
regulation.
regulation is terminated by the ESP control
module because there is a risk of the brakes
overheating.
Phase 2. Pressure increase on wheels under
ESP regulation
After regulation is terminated, the control module
will stop the pump, close the pressure-increase
valve and open the pressure-reduction valve. The
valves and the pump return to their normal
states.
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.
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 means that the pressure to the wheel
cylinders also increases and the wheel brake is
applied. The pump is running.
Phase 3. Pressure reduction on wheels under
ESP regulation
This value is then compared to a programmed
maximum value. If this value is exceeded,
regulation with brake application will be
terminated.
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.
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64 Steering assembly
Steering assembly
arrangement for steering wheel adjustment.
Steering
System overview
Miscellaneous
The steering system now has a number of new
components that have been replaced and
modified due to adaptation to the new V6 diesel
engine and to lower the gross weight of the
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.
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 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
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Suspension 65
Suspension
Suspension
A number of modifications have been made to
the Saab 9-5 to increase safety and adapt it to
the new V6 diesel engine. These modifications
have meant that the chassis has been given
sportier characteristics. It has become even more
balanced and remains stable when negotiating
tight turns on dry asphalt.
The front subframe has been modified at several
points to further improve impact characteristics.
The new towers with center bushings are now
designed so that the bushings will give in case of
head-on impact, allowing the subframe and drive
unit to slide downward and cushion the impact.
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.
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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.
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Body 67
Body
Body colors
Two new body colors have been introduced and
one shade has been discontinued:
Note that Cosmic Blue (264) is once again
available in the U.S. market.
·
·
Polar White (283), a base solid paint, replaces
Cirrus White.
Hazelnut (286) is a new metallic paint.
Color code
170
Color
Paint type
Base solid
Note
9-5 Linear/Arc
9-5 Aero
Black
X
X
X
X
X
X
278
283
257
264
268
273
279
286
Laser Red
Polar White
Midnight Blue
Cosmic Blue
Silver
Base solid
Base solid
Metallic
Metallic
Metallic
Metallic
Metallic
Metallic
Mica
Mica
X
X
X
X
X
X
X
Sun Green
Steel Grey
Hazelnut
Mica
X
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.
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68 Body
Exterior
Front bumper
Rear bumper
The front bumper consists of a cellular plastic
core and a shell of painted plastic in which the
grille is an integral part. There is a three-piece
removable decor strip inset in the shell, two outer
pieces and one center piece. The covers for the
headlight washer nozzles are also in the shell.
The rear bumper comprises an aluminum rail, a
core of cellular plastic and a painted plastic shell
with integrated corner covers. 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 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.
The lower section of 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.
Grill
The grill is integrated in the front bumper and has
three detachable louvers.
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Body 69
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.
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70 Body
SportWagon
The emblems on the Saab 9-5 SportWagon are
affixed in the same way as the 9-5 Sedan, with
double-sided adhesive tape.
The emblems are affixed in the same location as
on the Sedan model with the 9-5 emblem on the
left-hand side of the tailgate and the emblem
showing the engine variant on the right-hand
side.
Decor panel
There is a decor panel mounted in the space for
the licence plate on the trunk lid or tailgate.
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Body 71
Body modifications
Body modifications have been made for
three reasons:
Exterior modifications and engine
modifications
·
·
·
Improved impact characteristics
Exterior 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.
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 to 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.
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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 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.
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Body 73
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.
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74 Body
Dashboard
·
·
·
Linear
The classy and simple model of the Saab 9-5
range. Includes new style wood inserts in the
dashboard (a lighter shade of walnut).
Arc
The elegant touring model in the Saab 9-5
range. Includes new style wood inserts in the
dashboard (a lighter shade of walnut).
Aero
The top of the line model, exuding sporty
features with high performance. Very high
equipment level with “Aluminum-look”
dashboard.
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Body 75
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:
·
·
·
·
·
2-stage driver and passenger airbags
Two front impact sensors
Seat-belt buckle (active Hall sensor)
Seat position sensor (active Hall sensor)
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.
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76 Body
·
·
·
Side impact sensors (328D, 328P)
Seat-belt tensioners (236LH, 236RH)
System overview
·
·
·
·
·
·
·
Dual-stage airbag, driver (333D)
Dual-stage airbag, passenger (333P)
Seat position sensor (669D, 669P)
Seat-belt buckle (70D, 70P)
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)
Front impact sensor (332FL, 332FR)
Contact roller (336a)
Side airbags (333Db, 333Pb)
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Body 77
Principal components
7. Knee shield, driver, 3-piece
8. Knee shield, passenger
1. Airbag control module (331)
2. Side impact sensors (328D, 328P)
3. Dual-stage airbag, driver (333D)
4. Dual-stage airbag, passenger (333P)
5. Side impact airbags (333Db, 333Pb)
6. Seat-belt tensioners (236LH, 236RH)
9. Front impact sensor (332FL, 332FR)
10. Seat-belt buckle (70D, 70P)
11. Seat position sensor (669D, 669P)
12. Contact roller (336a)
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78 Body
Control modules
The control module receives its information from
the two front impact sensors. The sensors are
located on the car's bumper member so that
collision forces can be detected as early as
possible.
The main task of the control module is to
recognize the situation arising from a collision
and inflate the airbag with the correct force
and/or ignite the correct seat-belt tensioner. The
control module contains two accelerometers, a
microprocessor, a reserve power source and a
voltage converter.
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.
The control module has the capacity to activate
eight ignition circuits:
·
·
·
·
Driver airbag, dual stage
Passenger airbag, dual stage
Side airbag, driver and passenger
Seat-belt tensioner, driver and passenger
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 activating time after a collision is different for
the various circuits.
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 control module will
activate the seat-belt tensioners and airbags.
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.
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Body 79
Conditions for Airbag Activation
If the control module detects a high collision force
and the seat is more than 30% from its front
position, the front airbags will be inflated in two
stages with a 5 to 20 ms delay between the
deployment of the two stages. If the collision
force is low, only stage 1 will be activated. If the
seat position sensor indicates that the seat is less
than 30% from its front position, stage 1 will be
activated. 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.
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80 Body
Side impact sensor
Front 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.
The front impact sensor is used to detect collision
forces at an early stage and send information to
the control module.
The system has two front impact sensors. They
are located on the bumper rail at the same height
as the detachable grille on the front of the car.
The two sensors are identical and both have two
leads connected to them, one for the power
supply and one for transmitting the signal to the
control module.
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
position sensors, the control module will be able
to decide how the ignition circuits for the belt
tensioners and the front airbags should be
activated.
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.
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 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.
The seat position sensors are mounted on
manual seats as well as electrically adjustable
seats.
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Body 81
Driver airbag
The driver airbag is mounted inside the steering
wheel.
After an activation command, the control module
will apply a current to ignite the driver charges.
The driver charges generate a gas when they
burn. The filter cools the gas and removes any
particles before it passes to the airbag.
The driver airbag is a dual-stage type. This
means that it can be inflated in two stages at
different pressures depending on the force of the
impact and the position of the seat.
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.
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
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.
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82 Body
The passenger airbag consists of
a
gas
generator and an airbag. It has a volume of
approx. 120 l (4.2 cu.ft.). The airbag is screwed
to the dashboard and held in place with fabric foil.
The wiring harness is connected to a 4-pin
connector that branches off to two 2-pin
connectors on each igniter.
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.
Passenger airbag
The passenger airbag is standard on all Saab 9-5
models in all markets.
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
information that the control module receives from
the different sensors, the two stages will ignite at
different times. See control module information
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.
The gas composition is
·
·
·
70% argon
20% nitrogen
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.
With the seat in a rearward 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.
This tensioner is not compatible with previous
model year vehicles.
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Body 83
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.
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84 Body
Doors and locks
Trunk lid lock cylinder, Sedan
Tailgate lock cylinder, SportWagon
The lock cylinder in the trunk lid of the Sedans
has been removed. The trunk lid can now be
opened by pressing the trunk lid button on the
remote control or the switch located in the
driver's door.
The tailgate lock cylinder remains on the
SportWagon, but is protected by a cover (see
illustration, above right).
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.
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.
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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:
· SE (5 door & convertible only)
· Viggen (3 door, 5 door, and convertible)
9-3 SE 5 Door
Options available on 9-3 SE 5 door include:
For 2002 in the U.S., the 9-3 SE will be available
·
·
·
·
Automatic transmission
Heated front seats
Premium Package
Mica/Metallic paint
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:
·
·
·
·
·
·
Power driver’s seat
Sunroof
The 9-3 SE ”Premium Package” includes:
·
·
·
·
·
·
·
·
Memory driver's seat
Woodgrain dash
Power passenger’s seat
New Leather/textile seats
Leather door inserts
Manual climate control
Automatic Climate Control (ACC)
Upgraded audio system with amplifier
Full leather interior
New 5-spoke, 16in alloy wheels are standard on
9-3 SE models.
No charge scheduled maintenance
Sport chassis
Leather sport steering wheel
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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.
Options available on 9-3 SE convertible include:
·
·
·
·
·
Automatic transmission
Heated front seats
Mica/Metallic paint
Blue convertible top
Sport Package
Standard equipment on 9-3 SE convertible
models include:
·
·
·
·
·
·
·
Power memory driver’s seat
Power passenger’s seat
Woodgrain dash
The 9-3 SE convertible Sport Package includes:
Leather seats
·
·
·
·
17in double 3-spoke wheel
17in Pirelli performance tires
Rear spoiler
Leather door inserts
Automatic Climate Control
No Charge Scheduled Maintenance
Leather Sport steering wheel
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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.
For M2002, the Viggen will be available in Black,
Silver, Laser Red, and Steel Gray. The interior
will be available in black leather with charcoal
inserts, or sand beige leather. The seats are
Viggen-embossed, bolstered leather.
The Viggen will be equipped with the B235R
engine and manual transmission only.
The Viggen is equipped with all of the standard
features found on SE models. In addition, the
Viggen is equipped with:
Options available on 9-3 Viggen include:
·
·
Mica/Metallic paint
·
·
·
·
·
Viggen sports suspension
Blue convertible top
(Only available on silver exterior)
Skirts and air flow panels
17in alloy wheels & high performance tires
High performance brakes
Metal-look dash panel with “Rocky Black”
interior
·
Carbon fiber dash panel with “Sand Beige”
interior
·
·
Heated front seats
No Charge Scheduled Maintenance
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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
·
SE body-colored skirt kits for all non-
Viggen models
Interior
·
New Leather/Textile with “Turbo”
embossment seats as standard
equipment.
·
New Full Leather interior with “Turbo”
embossment.
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Product Overview 89
Vehicle Identification Number (VIN) M2002
Example: YS3EF45C623008642
1 - Geographical area
2 - Country
Y = Northern Europe
S = Sweden
3 - Car manufacturer
4 - Product line
3 = Saab Automobile AB
D = 9-3
5 - Model Series
F = Saab 9-3 SE with driver and passenger airbag
P = Saab 9-3 Viggen with driver and passenger airbag
3 = 3-door
6 - Body type
5 = 5-door
7 = 2-door (convertible)
7 - Gearbox
5 = Manual 5-speed
8 = Automatic 4-speed
8 - Engine variant
K = 2.0 turbo (High Output)
G = 2.3 Turbo (High Output)
9 - Check character
10 - Model year
0 - 9 or X
2 = 2002
11 - Place of manufacture
2 = Trollhättan
7 = Nystad, Finland
000001-999999
12 - Serial number
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90 Engine
Engine
Engine range, Saab 9-3 model year 2002
Engine
B205R (SE)
B235R (Viggen)
Compression ratios
8.8:1
9.3:1
Turbocharger make, type
Mitsubishi
Mitsubishi
TD04HL-15T
TD04HL-15T
Wastegate prestressing
Basic charging pressure
Max. power, EEC
2mm
2mm
0.45 bar +/- 0.03
0.45 bar +/- 0.03
205hp/151kW
at 5500 rpm (man)
230hp/169kW
at 5500 rpm
5750 rpm (aut)
Max torque, EEC
205 ft.lb. (280Nm at)
2200-5000 rpm (man)
258 ft.lb. (350Nm at)
1900-4200 rpm (man)
250Nm at
1900-5750 rpm (aut)
NGK,
NGK,
Spark plugs make, type
PFR6H-10
PFR6H-10
Spark plugs electrode gap
Engine management system
0.95 mm +/- 0.05
Trionic T7
92
0.95 mm +/- 0.05
Trionic T7
92
Recommended fuel octane
number (AON)
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Engine 91
Cooling system
A new “Long-life” coolant will be used in all Saab
engines for model year 2002. The new coolant
was actually introduced during late 2001
production.
Note
Do not top up with the earlier type of coolant
(blue-green), as this will impair the corrosion
protection properties.
The coolant that is filled in production does not
require changing throughout the service life of
The orange coolant will also be discolored by
the blue-green coolant and may appear to be
contaminated with engine oil, etc.
the car.
The fluid is orange in color to
distinguish it from earlier types of coolant that
were blue-green.
In an emergency, conventional (blue-green)
coolant can be mixed with the "Long-life"
Saab original “Long-life” Coolant must be used
in order to obtain the desired coolant properties.
(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 coolant (or even using shared
containers) may contaminate the system
enough to affect the "Long-life" 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
50 %
Mixing
Part Number
-200 l (drum) available later
-4 l (can)
02-86-542
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92 Electrical system
Main instrument unit, MIU
A
new main instrument unit with several
The following changes have also been made:
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.
·
·
Only one 22-pin connector.
All lamp bulbs 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.
Four new warning and indicator lamps have
been added and certain functions have been
revised.
·
Only the front glass and complete units are
available as spare parts.
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Electrical system 93
km/hr instrument shown
New warning and indicator lamps
·
·
TCS indicator lamp. The lamp
comes on when TCS is active.
TCS/ABS OFF lamp. The lamp
comes on when TCS is disengaged
and also in case of a fault in TCS.
Functional changes
·
The miles graduation is more
compressed in the higher speeds.
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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.
·
·
Hazelnut (286)
Polar White (283),
replaces Cirrus White.
a
base solid paint,
Color code
170
Color
Paint type
Base solid
Base solid
Base solid
Metallic
Note
9-3 SE
9-3 Viggen
Black
X
X
X
X
X
X
X
X
X
X
278
Laser Red
Polar White
Midnight Blue
Cosmic Blue
Silver
283
257
Mica
Mica
264
Metallic
268
Metallic
X
273
Sun Green
Steel Grey
Grey
Metallic
279
Metallic
X
X
281
Structure
For bumpers
and trim
286
Hazelnut
Metallic
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.
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Body 95
Exterior/interior
The following features are new for the 9-3 model
year 2002:
·
·
·
·
·
Upgraded interior
New 16in 5-spoke alloy wheels
Body colored skirting on all SE models
New color options
ISO-fix mounting for child seat
To mark the occasion of Saab’s 25 years using
turbo technology, the word “Turbo” will be
embossed on all outboard seats of the SE
models.
·
·
All SE models will be fitted with new
wheel rims, ALU37 (see page 103)
Two new interior options have also been
introduced:
-
Full Leather seats with “Turbo”
embossed backrest
-
Leather/textile
seats
with
“Turbo” embossed backrest
(standard interior)
·
·
The “Turbo” leather seats replace the
existing leather seats.
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.
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96
Body
Doors and Locks
Emergency opening of tailgate (US/CA)
There is a luminous handle on the inside of the
tailgate in case someone gets trapped in the
luggage compartment. The handle can be
pulled down towards the floor in order to release
the lock so that the luggage compartment can
be opened from the inside.
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Signature Technologies 97
Signature Technologies
Saab Active Head Restraint (SAHR)
Neck injuries are one of the most common
results of rear-end collisions, and the majority
occur during low-speed collisions. In fact,
statistics indicate that 25% of automobile
accidents with injuries involve rear-end collisions
and 75% of those result in neck injuries. 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.
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 returns
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
With the launch of the 9-5 and 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.
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
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,
compartment.
necessary.
maintenance and is reusable over and over
during the lifetime of the car.
As a result, repairs may be
In contrast, SAHR has no
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.
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
Note: Insurance companies average $4.1 billion
per year in spending on whiplash injury claims
alone.
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98 Signature Technologies
Triple Load Paths
Pendulum B-Pillar
The body of the 9-5 is designed to maintain a
survival area for the occupants in the event of a
collision. Basically, the energy caused by a
collision is directed along designated paths to
avoid an intrusion into the passenger
compartment. 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 less likely to invade the passenger
compartment, thus avoiding or minimizing
injuries.
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.
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.
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 energy 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.
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.
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.
Most other manufacturers simply use sheet
metal or “crumple-zones” to absorb the energy
caused by a collision to avoid an intrusion into
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.
the passenger cabin.
simply how the sheet metal distorts to absorb
energy during a collision. Saab also uses
“Crumple-zones” are
“crumple-zone” technology to assist in the
energy absorption process, but will not rely
solely on it for passenger safety.
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Signature Technologies 99
Turbocharger
high pressure and very high heat exists, which
means the gas has a very high energy level.
The basics of why a turbocharger works
The Ideal Gas Law states that gas temperature,
pressure, and volume are all related. Compress
a gas (reduce the volume) and pressure and
temperature goes up. Let it expand, and
temperature and pressure go down. Increase
the temperature, and the pressure goes up (in
an enclosed space) or the volume goes up (it
expands). 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.
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.
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
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.
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
Enter the turbocharger. A turbocharger has two
turbines; the exhaust gases spin one turbine,
which is connected (via a simple shaft) to 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.
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.
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.
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 the inlet is a very small space, very
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100 Signature Technologies
Why use Turbocharging?
Trionic Engine Management
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.
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: with 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 the Saab Trionic Engine
Management
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 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.
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Signature Technologies 101
The Saab Trionic is an adaptive system,
meaning that it “learns” about different driving
conditions, storing this information for use when
similar driving conditions reoccur. It makes
instantaneous adjustments to fuel injection,
ignition and boost pressure parameters,
depending on external conditions.
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 forms ions
Precise
combustion
management
process
of
yields
the
engine’s
numerous
(electrically
combustion chamber opens up
charged
molecules)
in
unique
the
a
advantages.
exhaust emissions than in
system. Fuel consumption is also reduced as a
result of a more precise combustion.
It becomes easier to reduce
conventional
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.
a
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.
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
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 injection can be varied from two
milliseconds to the entire injection phase.
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.
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.
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102 Signature Technologies
Night Panel
Console-Mounted Ignition
When activated, the night panel mode can assist
nighttime driving by extinguishing most
instruments and displays as long as the
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.
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 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.
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
for the ignition on the steering column and then
performing all of those other functions in most
cars is far from ergonomic.
The Night Panel feature benefits our customers
because glare from the instruments at night is
often enough to cause significant eye fatigue.
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.
When
a
customer wears eyeglasses, the
sensitivity to the light becomes greater and eye
fatigue is increased.
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Signature Technologies 103
Saab Real Life Safety
“My beautiful 9-3 Convertible was
totaled and I got out with only a scratch
on my thumb. The car’s engineering,
the seat belt, and the reinforced roof
saved my life.” -- Marsha Metzger, North
Caldwell, NJ
“On December 26, 2000, while driving
in Clearwater, Florida, I suffered a
stroke (I’m only 48 years old). I had a
cell phone with me but was rapidly
losing the vision in my eye and was
becoming paralyzed on the right side. I
didn’t think I had the where-with-all to
even call 911. I was able to pull into a
grocery store parking lot and pressed
the “Medic” [Emergency] button on
OnStar. A young lady came on and
asked if I had a medical emergency. It
seemed it was all I could do just to say
“yes”. She dialed 911 and stay on the
line with me, talking to me. It was only
minutes before I heard the sirens.
From OnStar they knew who I was,
where I was, what kind of vehicle I was
in. OnStar saved my life.
”I was in a head-on collision with my
Saab, I opened the door and walked
out. I 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 Safety Brand Pillar — and why
automobile consumers know that Saab builds
safe cars.
I wanted to write and tell you there is
absolutely no doubt that OnStar saved
my life. No doubt. None. I know it, my
family knows it, my friends know it. I
tell everyone
I
know about what
happened to me because I know how
valuable OnStar is… I know there are
other benefits to OnStar. But, please
tell people OnStar saves lives. I’m
living proof of that.”
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.
Here is an excerpt from the August 22, 2001
edition of the Detroit Free Press that credits
OnStar with saving another life.
OnStar Information
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…
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.
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
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
experience.
Trabolsy says the
excerpt
demonstrate
how
valuable
the
technology saved his wife’s life last
month when he took his OnStar-
equipped Buick to a weekend getaway
emergency button can be.
Louise Srofe, from Palm Harbor, Florida, credits
OnStar with saving her life.
at
a
friend’s northern Michigan
cottage. His wife, Brenda, suffered a
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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.
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 Saab buyers.
“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.
Hands-free telephone capability also provides
another Saab Real Life level of safety.
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.
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-
“I am not being overly dramatic when I
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.
year
distraction),
effort
to
reveals
address
that
driver
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
publicized 1997 University of Toronto
report could use only small
—
including
a
much-
—
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.
9-3
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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
Here are the facts:
-For the period from October, 1996
through May, 2000, a driver was on
the phone at the time of a crash
severe enough to deploy the vehicle’s
air bags during only two of the 8.1
million embedded cell phone calls
placed to an OnStar Call Center
-In six other cases, it was determined
that the driver was on the phone within
10 minutes before
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.
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
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 Verizon doesn’t have direct coverage,
they have signed agreements with local
companies.
technology of OnStar.
From the
beginning, OnStar’sb unique three-
button system was designed with
safety as a priority.”
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.
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 the 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.
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.
When OnStar is activated, the system generates
a phone number with a 500 area code. If the
customer wants OnStar’s Personal Calling
service, then a new phone number is generated
with an area code based upon where the
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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 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 I 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.
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Glossary 107
Glossary
ABS Anti-lock Brake System – The system that
Convertibles do not have a B-Pillar, and
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.
therefore do not have a Pendulum B-Pillar.
CCA Cold Cranking Amp – A rating used to
classify the strength of a battery in cold weather
conditions. It is measured at 32 degrees
Fahrenheit.
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.
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.
Ah Amp hour – A rating used to classify the
strength of a battery.
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.
AHL Automatic Headlamp Leveling – The
system that maintains the appropriate angle of
the beam emitted by the 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).
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
AON Average Octane Number – A number
used to rate the quality of fuel (e.g. 87, 89, 92,
etc.).
communicate with the other ECMs.
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.
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.
ATF Automatic Transmission Fluid – A lubricant
required for the proper operation of the
automatic transmission.
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.
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.
ECM Electronic Control Module – A
microprocesser that has its own area of
responsibility. Each ECM monitors and adjusts
for optimal performance in its specific area.
Most ECMs communicate via a databus system.
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.
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).
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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.
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).
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.
SPS Service Programming System – A
software system that allows for different settings
to be adjusted on the various ECMs located
throughout the vehicle.
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).
SID Saab Information Display – The component
that is located above the radio, which includes
the Saab Car Computer. The date, time and
radio function are normally illuminated here (e.g.
radio station, CD Play, etc.).
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.
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.
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.
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.
MED-NET – An OnStar service that can store a
customer’s personal medical information to
assist in an emergency.
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. lb. @
RPM.
MIU Main Instrument Unit – The component
that is 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. lb.).
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).
Oversteer – The rear end of the vehicle tends to
drift out or “fish-tail” in a turn.
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.
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.).
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.
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.
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Glossary 109
Understeer – The front of the vehicle tends to
continue straight ahead in a turn as the steering
wheel is being turned in the intended direction.
VIN Vehicle Identification Number – A number
assigned to each individual vehicle that is
manufactured. Each VIN is unique to its vehicle.
Viggen – Swedish for “Thunderbolt.”
YRS Yaw Rate Sensor – The sensor used with
ESP to measure side acceleration, vehicle
speed and the steering angle of the vehicle. 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.
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110 Glossary
Notes
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2002 Griffin Society Product Test
IMPORTANT - Test Instructions!!
·
The 2002 Griffin Society Product Test, S02T, must be taken on-line at www.saab-edu.com.*
* This only applies to those employees still needing to take the test. If you already
completed a written version of S02T, you do not have to retake this test using the
eLearning version.
·
·
Detailed test instructions are provided at www.saab-edu.com. Just click on How to Take an
Online Test.
·
When you are ready to take the test, go to www.saab-edu.com and click on the S02T
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
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