Convertible Top - Jams on Opening
SI. No. 811-1989PI No.
Date: February 1999
Distr.: all
9-3
Soft top (tonneau) cover does not open
Cars affected
Saab 9-3 CV X7002303
Background
The soft top cover latches on certain cars may not open fully or not fast enough when the soft top cover is being opened. This may result in the soft top cover jamming and breaking the drive mechanism shear pin.
The reason for the latches not opening may be found in the cables controlling them. Their inner friction may be too great, or they may be deformed, or kinked.
The problem can be rectified by changing to newer, stronger and more flexible cables consisting of more strands. Taking these measures will reduce the friction and help to avoid kinking.
The cable fastenings to the body are also modified. To address a customer complaint of soft top cover operation, proceed with these measures.
Parts required
1) 51 11 653 Cable, LH side (CA: 30577776)
2) 51 11 661 Cable, RH side (CA: 30577777)
3) 85 30 917 Cable clips (2 pcs.) (CA: 30514349)
4) 85 52 663 Cable ties (2 pcs.) (CA: 30514976)
5) 48 07 939 Cable tie (1 pc.) (CA: 30564040)
Fabric-backed tape
Tools
82 93 177 Gauge for adjusting soft top cover latches
(CA: 30581884)
(US: This tool was issued to all Saab dealers by Kent-Moore during 1998.)
Procedure
1. Operate the soft top so that the fifth bow is raised and the soft top cover is both closed and latched.
2. Remove the backrest cushion and the rear side trim panels. See "8. Convertible 9-3, Adjustment and replacement, Backrest cushion".
3. Remove the cover over the hydraulic unit.
4. Undo the bottom of the trim for the luggage compartment and fold it back.
5. Undo the cables on the right and left-hand sides at the soft top cover latches. Remove the cable tie end fabric-backed tape.
6. Hang up the soft top storage bag.
7. Remove the side trim on the right-hand side of the luggage compartment and the floor mat. (The left-hand trim need not be removed.) See "8. Convertible 9-3, Adjustment and replacement, Luggage compartment upholstery".
8. Detach the cables from the soft top cover drive mechanism and from the cable tie and fabric-backed tape.
9. Remove the cables.
10. Fit new cables to the soft top cover drive mechanism.
11. Fit new cable ties (part no. 48 07 939) and fabric-backed tape.
12. Fit the cables to the soft top cover latches.
13. Fit two cable clips (part no. 85 30 917).
14. Fit two cable ties (part no. 85 52 663) and new fabric-backed tape.
15. Adjust the latch cables so that the equalizer lever on the soft top cover drive mechanism is horizontal when the latches are locked.
16. Check that the distance between the cable adjuster and the end of the cable eyelet is at least 2 mm.
17. Adjust the cable with the cable adjuster by the latches.
18. Make sure the latch opens fully.
19. The soft top cover latches must be checked and - adjusted If necessary after fitting the new cables.
Important:
This adjustment is essential as the latch fittings can bend in the latches and sever the shear pin in the soft top mechanism.
20. Raise the soft top cover sufficiently for latch adjusting special tool 82 93 177 to be placed as illustrated.
21. Make sure the soft top cover latch fitting goes freely into the latch without touching the tool. Listen for a "clicking" sound as the microswitch is activated. The latch must be adjusted towards the front if it touches the tool.
22. Adjustment
Undo the two nuts securing the latch and push it forwards. Tighten the nuts.
Return to step 20 and check the adjustment. The soft top cover may "knock" on the latch when closing. If this is the case, lower the latch slightly so that the soft top cover rests on the seals.
Important:
Check the drive mechanism shear pin at the universal joint. If it has been severed, the soft top cover will react almost as normal as the friction in the joint may be sufficient to operate the soft top cover. On such occasions, the soft top cover will "slam" when being closed.
23. Fit the cover over the hydraulic unit.
24. Fit the backrest cushion and rear side trim. See "8. Convertible 9-3, Adjustment and replacement, Backrest cushion".
25. Fit the side trim and floor mat in the luggage compartment. See "8. Convertible 9-3, Adjustment and replacement, Luggage compartment upholstery".
26. Cycle the soft top to be sure it is functioning correctly.
Warranty/Time Information
Failed Object: 81419
Fault/Reason code: 37
Location code: 0
Warranty type (US): 01
Repair/Action code: 01
Labor Operation (US): 81419 1.6
(CA: B3278 1.6)
PLEASE ADD THE FOLLOWING INFORMATION TO YOUR DCS TABLES:
FAILED PART TABLE:
FAILED OBJECT: 81419
DESCRIPTION: WIRE CV TOP
MODELS: D
OPERATION NUMBER TABLE:
OPERATION NUMBER: 81419
DESCRIPTION: INSTALL WIRE CV TOP
TRANSMISSION TYPE: B
ENGINE TYPE: 9
DIAG CODE REQD: 0
MODELS: M94 900
HOURS: 1.6
BEGIN YR.: 95
END YR.: 99
DISCLAIMER