Saab 900 Convertible User manual
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-_-_.
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PRODUCT INFORMATION
June
5,1997
Route
To: Service Manager
Subject:
Convertible Troubleshooting Guide
As part of the new training course, Convertible Top Adjustments and Updates
-
CNAA
-
a
Troubleshooting Guide was produced. Each technician attending this course received his/her
own copy of this document.
Enclosed is the final version of this Troubleshooting Guide for your dealership’s service library.
The information contained in this document is the latest and only information that should be
referenced when working on a
1995-
900 Convertible.
In conjunction with the publication of this Guide, several older bulletins have been supersed-
ed. Please make certain all superseded bulletins are deleted (crossed out/torn out) of your
PSI Supplements. The list of affected bulletins are:
?
PSI
08/94-0495
Programming Top Mechanism
(See new PSI
04/97-0758
which gives both
ISAT
and TECH 2 instructions)
?
PSI
09/94-0499
Adjustment of Tonneau Cover Latches
?
PSI
03/95-0554
Improvement to Operation of Top Stack Mechanism
(See new PSI
04/97-0753)
?
PSI
05/95-0570
Correcting Complaint of Water Leakage at Door Mirror
(See new PSI
04/97-0760)
?
PSI
10/95-0628
Adjustment of 5th Bow Latch Motor
?
PSI
02/96-0664
Customer Satisfaction Campaign 428
(See new PSI
04/97-0754)
?
PSI
02/96-0665
Addressing Customer Complaints of Water Leaks
(See new PSI
04/97-0755)
?
PSI
07/96-0693
Correcting Customer Complaint that Headliner at First Bow
is Loose or Hanging Down
(See new PSI
04/97-0756)
?
PSI 1
O/96-071
6 Installing New Fifth Bow Latch Motor Racks
All technicians who attended the training class will be receiving updated pages for their bind-
ers.
If you require additional copies of this Troubleshooting Guide, please contact a Product In-
formation Specialist at 770-279-6484 or 770-279-6324.
97-17
900 Convertible Top Troubleshooting Guide
TOPIC
Table of Contents
PAGE
Table of Contents
A
How to determine if Updates
&
Campaigns have been performed
B
Inoperative Top/Operational Problems/Unsatisfactory Performance
C-E
Squeaks
&
Rattles
Water Leaks
SID Messages
Miscellaneous Problems
F
G
G
H
BULLETINS INCLUDED IN THIS GUIDE:
PSI
04/97-0753
Improvement to Operation of Top Stack Mechanism
PSI
04/97-0754
Customer Satisfaction Campaign 428: Top Mechanism Quality
Improvement
PSI
04/97-0755
Addressing Customer Complaints of Water Leaks
PSI
04/97-0756
Correcting Customer Complaint that Headliner at First Bow is
Loose or Hanging Down
PSI
04/97-0757
New Procedure for Replacement of Convertible Top
PSI
04/97-0758
Programming Top Mechanism (Using
ISAT
or Tech 2)
MI 811-1758 Customer Satisfaction Campaign 450: Replacement of 5th Bow
Latch Motor Assembly (issued as PSI
04/97-0759
in early issues of Troubleshoot-
ing Guide)
PSI
04/97-0760
Addressing Complaint of Water Leaks from Area Around Door
Mirror
A
06/09/97
900 Convertible Top Troubleshooting Guide
How to determine if Updates
&
Campaigns have been performed
The
following
chart
includes some quick visual checks you can make to determine if a
particular campaign or update has actually been performed on a 900 Convertible. Note
that this is not a guarantee that all of the steps of a particular PSI or campaign have
been performed.
Old
“19
Point”
Update, see revised PSI
04/97-0753
I
Right hand 5th bow latch motor microswitch should be disconnected (gone)
!
Check for proper ECM
-
you SHOULD NOT be able to raise the windows while the top is
being
raised. (ECM software version 0402 or higher.)
3
Look at header switches through opening in header
-
silver arm and pure white plastic
arm are early versions. Plastic arm on latest switch is an “off white color”.
1
The 5th bow potentiometer should have a “drive bracket” installed, and the potentiometer
arm should be approx.
3/8”
long
;
The 5th bow motor on the passenger’s side of the car should have a protective plate
installed over the gear, so the wiring harness can’t be damaged by the gear.
Service Campaign
#428,
see revised PSI
04/97-0754
I
“2nd bow drive link” installed
?
2 holes drilled in bottom of front door pockets. (1997 models have the holes drilled differ-
ently from the Factory.)
Customer Satisfaction Campaign
450,5th
Bow Latch Motor Update,
see MI 811-1758
(The 5th bow latch motor assembly has been updated as from VIN
V7010306
in Fac-
tory production)
1
Round plug in hole over 5th Bow Latch Motor
How to Determine Which Type of Top is Installed on the Convertible you are going
to work on:
1
Original M95 900 Top is “ASC”: rear window is glued in place
2
Later style Top is
“CT%
rear window is clipped in place.
B
06109197
900 Convertible Top Troubleshooting Guide
Inoperative Top/Operational Problems/Unsatisfactory Performance
(Note that problems are listed in order of top operating sequence, beginning with top fully raised)
PROBLEM
POSSIBLE CAUSE ACTION
1
Nothing happens when attempting
a. Top switch on center console
See page 1
to lower top (no movement at all,
defective
no noises, etc.) b. Fuse blown
c. Trunk bag raised?
2
First bow raises a few inches and Fifth Bow latch motor stuck or
in-
See page 1
stops
operative
3
Fifth bow raises all the way, then
a. Header Switches closed by
See pages 1
-
3
top stops other movement
dowel pin
b.
5th bow potentiometer will not
reach high limit
c. Tonneau motor disengaged
4
Tonneau cover catches going up
-
Latch Adjustment
See page 4
“snaps” when opening
5
Grinding, ticking when tonneau Tonneau motor not fully engaged
See page 4
goes up
6
Top stops
l/Z
way when lowering
a. Missing 2nd bow drive link or See pages 5-6
the top 2nd bow binding on fabric
b. Programming
c. Main motor or 5th bow poten-
tiometer faulty
7
Top hesitates when lowering top a. Programming
Seepages6-7
b. 2nd bow catching on fabric
8
Rear window hits rear headrest
Programming See page 7
when lowering’ top
9
5th bow hits Tonneau cover
a. Programming
See page 7
hinges when lowering top
b. Tonneau motor drive shaft
twisted
IO
First bow hits Tonneau cover
a. Programming
See page 8
when lowering top
b. Twisted Tonneau shaft
c.
Bent Tonneau cover hinges
11
“Snapping” noise from rear as top Broken or missing stops on rear
See page 9
is being lowered into “boot” window
C
06/09/97
900 Convertible Top Troubleshooting Guide
Inoperative Top/Operational Problems/Unsatisfactory Performance
(Note that problems are listed in order of top operating sequence, beginning with top fully raised)
PROBLEM POSSIBLE CAUSE ACTION
12
Top gets caught on interior trim Early interior trim panel not cut at
See page 10
panel on way down
rear edge
13
Top won’t park low enough a. Main motor low limit See page 11-12
b.
Side rail screws loose
c.
Side rail laying on main motor
-
balance link bent
d. B-pillar hinge hitting main mo-
tors when top is lowered
14
Tonneau cover does not close all
a.
Top not down all the way
See page 12
the way
b.
Tonneau latches out of
adjustment
c.
Tonneau motor drive shaft
twisted
15
SID does not beep when top is ful- a. SID incorrectly programmed
See page 12
ly lowered
b.
Tonneau cover latch
micro-
switches not closing properly
16
First bow has white mark near First bow rubs on 5th bow latch
See page 13
“grab handle” motor cover
17 Tonneau cover catches going up
-
Latch Adjustment
See page 13
“snaps” when opening
18
Top stops or hesitates when
rais-
2nd bow is bent
-
flat steel piece
See page 14
ing the top
on the side of the drive link is bent
19 Grinding/ticking when raising top
Tonneau motor not fully engaged See page 15
20
Top does not go up (rise) evenly
-
Weak main motor See page 15
one side rises quicker than the
other
21
First bow slams header when rais- a. Top stops misadjusted
See Page 15
ing top (pin alignment ok)
b. Loose screws
22
First bow header pins do not
a. Top stops misadjusted
See page
15-l
6
reach guide holes in header
b. Shim adjustment
c. Loose screws
D
06/09/97
900 Convertible Top Troubleshooting Guide
Inoperative
Top/Operational Problems/Unsatisfactory Performance
(Note that problems
are listed in order of top operating sequence, beginning with top fully
raised)
23
First bow comes down on header
Top out of adjustment See page 16
crooked, straightens as 5th bow
latches
24
Access flaps won’t open (raise) 5th bow latcli motor jammed with
See page 16
when raising top
-
flaps may be latches closed or inoperative
broken off
25 Tonneau cover slams closed a. Tonneau cover catches on
fabric when closing
See pages 17
b. Tonneau cover latches not
aligned properly
c. Tonneau motor drive shaft
twisted
26
5th
Bow
won’t close properly
a.
5th bow latch motor jammed
See page 18
b. Misaligned strikers
c. Incorrect programming?
27
SID does not beep when top is
a.
SID
rncorrectly
programmed
See page 18
fully raised
b. 5th bow latch microswitches or
Tonneau cover latch
micro-
switches not closing properly
E
06/09/97
900 Convertible Top Troubleshooting Guide
Squeaks
&
Rattles
PROBLEM POSSIBLE CAUSE ACTION
1
Clicking/snapping noise from the Loose bolts at front side rail
See page 19
1st bow header
?
Rattle from “pull down” handle at
Incorrect fit
See page 19
center of 1 st bow
3
Rattle from tonneau cover with 5th 5th bow fabric rubbing on tonneau
See page 19
bow latched
1
Rattle at 2nd bow (above driver’s a. Incorrect cut at ends of 2nd
See page 20
or passenger’s head)
bow
b. Round rubber plug not inserted
in square rubber stop between 1st
and 2nd side rail
c. 2nd bow flipper rod rattling
5
Rattle from C-pillar area while
Bolts beneath 2nd side rail loose
See page 21
driving
3
Rattle in rear side trim area by rear Seat belt pretensioner tube
con- See page 21
speaker (only 1995 VIN up to
tatting
sheet metal
s7003000)
7
Creaking or rattling noise when Improper window rollers (must be
See page 21
raising front windows
lubricated)
3
Creaking or rattling noise while
Improper window rollers (must be
See page 21
driving down road
lubricated)
9
Squeaking noise from rear when Access flap lower surface rubbing
See page 21
driving with the top raised on 5th bow motor
F
06/09/97
900 Convertible Top Troubleshooting Guide
Water Leaks
PROBLEM POSSIBLE CAUSE ACTION
1
Leaks from header while driving a. Water coming in between
See page 22
(determine whether water comes header and front side rail seal
in while driving only, or while sitting
still)
b.
Water coming in under header
seal (only while driving)
2
Water leaks at outside rear view a. Seal deformed or damaged
See page 22
mirror “bird beak” seal
b.
Sheet metal not straight
-
(ver-
tical “bird’s beak” surface)
3
Leaks at A-pillar and B-pillar (side
Seals improperly adjusted
See page 22
windows wet inside)
SID Messages
PROBLEM POSSIBLE CAUSE ACTION
1
“Check Soft Top” while top is
oper-
See page 23
ating, top works O.K.
2
“Check Latches”
See page 22
3
“Check Trunk” See page 23
4
“Close Trunk Lid” See page 23
G
06/09/97
900 Convertible Top Troubleshooting Guide
Miscellaneous
PROBLEM
POSSIBLECAUSE
ACTION
1
DTC B1605, top works O.K.
See page 24
2
ACC does not switch to manual SID misprogrammed
See page 24
mode when lowering top
3
ACC does not switch to automatic Stuck
/
defective header switch
See page 24
mode when raising top
4
No convertible top SID messages SID misprogrammed
See page 24
5
Side rail seals drooping Side rail seal not secured
Seepage24-25
6
Trunk release button inoperative
a. Programming
See page 26
b. Is fuse 25 blown?
7
DTC
B1309
-
Potentiometer Fault
Variety of reasons
See page 26
06/09/97
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