Saab 900 Convertible Service Manual Download Page 76

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Summary of Contents for 900 Convertible

Page 1: ...Saab 900 SERVICE MANUAL 8 3 Heating and ventil ation system air conditioning system M 1979 86 J _...

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Page 3: ...I i 028 Technical data SAftB 108 Special tools b O O Heating and ventilation system 854 air conditioning system 899 Alphabetic index SERVICE MANUAL 8 3 Heating and ventilation sfstem air conditioning...

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Page 5: ...kg clutch Speed 500 7000 500 7000 500 6000 upto 7000 r min r min r min r min Capacity Type designation Delco R4 Delco R4 1131061 1131223 1131331 Expansion valve Cycling Clutch Superheat 3 9 7 Superhea...

Page 6: ...mm long compressor suction line small condenser kg 1 0 1 05 Clarion Tightening torques for the compressor 15 11 for Clarion 15 1 1 for Clarion Suniso 5GS Texaco Capella E WF100 BP Energol LPT100 Refr...

Page 7: ...45 28 33 Smaller coupling Nm Ibfft 20 27 15 20 1 Small coupling Nm Ibfft 7 10 5 7 1 1 Delco Cycling Clutch system Model year 1980 Condenser Dryer receiver Condenser Nm Ibfft 14 20 10 15 Dryer receive...

Page 8: ...tion Evaporator Compressor i I I Evaporator Nm Ibfft 28 39 21 29 I Compressor Nm Ibfft 30 34 22 25 Expansion valve connection to the evaporator Nm Ibfft 21 27 15 20 I I Expansion valve compensating pi...

Page 9: ...lutch Robinair 10472 8393308 Installing tool KMJ 9480 01 8393373 Key removal of front plate com pressor S 150 Special tools Fixture compressor Saab900 8393233 8393241 Sleeve to replace magnetic clutch...

Page 10: ...r undoing and tighten ing pulley securing nut I lIt iii ill I I 0 11 Fitting tool two hooks Se 8393738 Fitting tool three hooks Used for removing and fitting the shaft seal Since two different types o...

Page 11: ...the seal Press sleeve Used for pressing the felt ring onto the shaft Protective sleeve Should be fit ted onto the shaft to avoid damaging the shaft seal Special tools 108 3 I Other equipment Refco typ...

Page 12: ...i Ii I I I I Ii i II I ii i I I I i I I I 1 I...

Page 13: ...r is forced into the inlet by the ram effect when the car is travelling The airthen flows through an efficient filter which arrests particles of dust and dirt The air then continues through the fan ca...

Page 14: ...position These functions are control led by microswitches actuated by the air distribu tion control knob 1 1 Air intake 2 Filter 3 Fan motor 4 Heat exchanger 5 Temperature control valve Positions and...

Page 15: ...defroster nozzles for the side windows cannot be closed 1 Switch for fan motor 2 Temperature control 3 Air distribution control vacuum distributor 4 Recirculation switch as from the 1984 model 5 AC sw...

Page 16: ...s 2 and 6 open and 8 and 9 partially open Cars with air conditioning vents 8 and 9 closed Defroster outlet closed but some flow of air 1979 80 models with air conditioning system Compressor in operati...

Page 17: ...culars of the vacuum servo location Vacuum servos 5 and 7 operative 7 in the first stage Air valves 6 8 and 9 open 8 and 9 partially open Position Floor Current to fan motor Regulation of fan speed po...

Page 18: ...rvos 3 and 7 operative 7 second stage See page 852 2 for particulars of the vacuum servo location See page 852 2 for particulars of the vacuum servo location Vacuum servo 3 operative Air valves 4 open...

Page 19: ...f there is a change in pressure there will be a cor responding change in temperature It is this property that is utiIized by the AC system The refrigerant is circulated round a closed sys tem and a re...

Page 20: ...et low pressure 6 Service outlet high pressure 7 Expansion valve 8 Receiver shell VIR system Cars are at present fitted with two different sys tems which mainly differ in their control function During...

Page 21: ...rator 5 Suction throttling valve 6 Expansion valve _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ t I I I I I H I I I I I Vapour high pressure Liquid high pressure Liquid low pressure Vapour low pressure r I I 1...

Page 22: ...evaporator thereby low ering the temperature The refrigerant is in a liquid state in and im mediately downstream of the expansion valve However as soon as the pressure drops the re frigerant starts to...

Page 23: ...ded with a sight glass which shows if there is sufficient refrigerant in the system The service outlet for the low pres sure side of the system is located at the top of the VIR assembly I it o Saab 90...

Page 24: ...High pressure outlet 7 12V connection 8 Field coil 9 Magnetic clutch 10 Crankshaft Compressor The compressor pressurizes and directs the refri gerant through the system The pressure and temperature in...

Page 25: ...sation During this process heat is given off and then diffused by the air passing over the fins of the condenser This heat that has been removed in the process of converting agasto liquid is the same...

Page 26: ...00 9 Cirkulation diagram 1 Compressor 2 Condenser 3 Receiver shell 4 Expansion valve 5 Evaporator 6 Temperature sensitive expansion valve body 7 Compensating hose 8 Anti freezing thermostat 9 Temperat...

Page 27: ...r the system will be flooded and the refrigerant will not vaporize The increase in pressure will prevent the refrigerant vaporizing and there will also be insufficient room for it to expand If too lit...

Page 28: ...overheating The switch is wired in series with the power supply to the compressor clutch If the refrigerant pressure should drop below 40 Ib in2 2 8 kgf cm2 which could occur if the system contains i...

Page 29: ...e refrigerant and forces it through the system The pressure and temperature increases occurring in the compres sor enable condensation of the refrigerant to take place in the condenser The compressor...

Page 30: ...condensation During this process heat is given off and then diffused by the air passing overthe fins of the condenser This heat that has been removed in the process of converting a gas to liquid is th...

Page 31: ...nsists of a separate valve housing located between the compressor housing and the cylinder head The valves open and close as a result of the pressure differences caused by the reciprocating movement o...

Page 32: ...vidual swash plates located between the compressor housing and the cylinder heads The valves are opened and closed by the pressure differences created by the action of the pistons Service valves for t...

Page 33: ...GLOVES WHEN HANDL ING THE FILTER 1983 models onwards The cover is incorporated in the filter casing and secured by four plastic clips To remove the cover turn the clips a 1J4 turn clockwise or anti cl...

Page 34: ...emove the control rod from between the water valve and the control knob by sliding the rod forward as far as it will go so that it comes free from the knob Next pull the rod back to free it from the w...

Page 35: ...ke sure there is room for the water va Ive to pass be tween the heater housing and the steering column unhook the brake pedal return spring and depress the pedal slightly 10 Remove the capillary tube...

Page 36: ...he 1980 models To change the temperature control valve 1 Remove the bottom section of the facia 2 Remove the left hand speaker grille 3 Disconnect the two water hoses from the valve in the engine comp...

Page 37: ...ture control valve 2 Temperature control valve 8 Connect the coolant hoses in the engine compartment to the valve 9 Top up with coolant and pressure test and vent the system Check it for tightness 10...

Page 38: ...ecirculation damper 2 550 mm centre facia outlet 3 50 750 750 mm outer facia outlet 4 400 mm defroster 5 500 mm floor damper left hand I I J C 6 550 mm floor damper right hand Vacuum hoses Note If the...

Page 39: ...and both speaker defroster grilles 3 Remove the four facia retaining screws 4 Tilt the panel towards the rear and discon nect the electrical connections and the hqses from the air distribution control...

Page 40: ...ng screws for the right hand defroster damper housing I 10 Remove the fan motor retaining screws and lift out the motor Fit the fan motor in the reverse order Note The four screws retaining the switch...

Page 41: ...d Ifthe car has been involved in a collision a care ful inspection must be made of all components that could have been damaged Pay special at tention to soldered joints Bent or cracked pipes must alwa...

Page 42: ...n the refrigeration oil from the old compres sor and measure the volume Completely drain the new compressor as well Thereafter re charge the new compressor with the same volume of oil as that drained...

Page 43: ...eye with large quantities of cold water from the tap preferably for about fifteen minutes If any discomfort remains sight is impaired orvi sion misty rush to a doctor or hospital Warning If a refrige...

Page 44: ...long the line Identify all possible causes and then decide which is the most likely Perform all the simple checks first Note that the possible causes aT e not liste d in any order of probability Sympt...

Page 45: ...with refrigerant deteriorating Alternatively deterioration at high ambient temperature X Air in the system Bubbles visible in Drain the system change the receiver and sight glass refrigerant X Frostin...

Page 46: ...the unit and check that the If not discharge the system and re system is sealed charge it I I The system cools normally The system still cools insuf ficiently or not at aiL Connect the high and low p...

Page 47: ...netic clutch Check the pressure on the high I pressure side Idling speed 1500 r p m Faulty compressor switch Low pressure on the high pressure side High pressure on the high pressure side 142 psi 10...

Page 48: ...refrigerant Check the radiator fan pressure switch on the high Check the system for leaks pressure side It should start the radiator fan within Seal the leaks 3 minutes Discharge the system See page...

Page 49: ...esent I Check voltage supply Check voltage at con H Voltage present for fault using wiring neetion L of the fuse diagram page Check compressor switch No voltage wiring Fuse blown Wiring correct Defect...

Page 50: ...5000 Thermometer Closely fitting protective goggles and gloves Valves with extension pieces for connection to the hoses are recommended These minimize re frigerant losses when charging the system Impo...

Page 51: ...ll require a special connector Connect the yell Ow hose between valve Eand the refrigerant cylinder Do not open the valve on the cylinder Charging the measuring cylinder If the measuring cylinder is n...

Page 52: ...um gauge should not rise To check that the measuring cylinder is tightly sealed After the pump has been running for about a minute close the ballast valve Let the vacuum pump continue to run for a fur...

Page 53: ...mark maximum charge 2250 g Close all valves after charging When changing the refrigerant cylinder Purge the air from the hose between the refriger ant cylinder and the measuring cylinder Draining the...

Page 54: ...valves Recon nect the hose to the vacuum pump Charging the refrigerant Before starting work read through the safety precautions carefully Check that a sufficient quantity of refrigerant is in the mea...

Page 55: ...to the high pressure side of the compressor marked Dis Connect the blue hose to the low pressure side of the compressor marked Sue Open the valves on the compressor Start the vacuum pump and open the...

Page 56: ...pump to raise the vacuum again Check the vacuum by opening valve G Note the reading on the vacuum gauge The reading should be below 5 mbar To test for leaks in the system Close valve G the gauge must...

Page 57: ...any leaks Final charging of the system Before finally charging the system all refrige rant in the system must be drained and a vacuum must be raised in the system by the vacuum pump Proceed as follow...

Page 58: ...ve 1 Vacuum pump switch 2 Ballast valve Close valve A Check that valve G is closed Switch offthe vacuum pump Rotate the scale on the measuring cylinder to the same reading as that on the gauge above R...

Page 59: ...ty of refrigerant in accordance with the specification Close valves F S C and D Switch offthe heating ofthe measuring cylinder Shut off the valves at the compressor in the car Check that all valves on...

Page 60: ...Supply airtemp measured about 20 mm inside one of the outer facia outlets approx 15 30 C 5min If the specified temperature is not achieved Check that no engine coolant leaks when the temperature cont...

Page 61: ...erant Temperature control Distribution control ACswitch Facia outlets Recirculation damper Recorded operating conditions Saab 900 as from the 1984 models Ambientair temp measured atthe front of the bu...

Page 62: ...o achieve effective cooling The switch is connected in parallel with the conventional thermostatic switch in the cooling system and breaks the cir cuit when non pressurized The operating range for the...

Page 63: ...couplings with re frigeration oi I Charge the system with refrige rant See the section on discharging and charg ing Changing the desiccant bag and clean ing the filter VIR unit Drain the system of ref...

Page 64: ...compressor and the VIR assembly before this is connected Lubricate all pipe coupl ings with refrigeration oil For tightening torques see the Technical specification Changing the suction throttling va...

Page 65: ...arge the refrigerant from the system see the section on discharging and charg ing Disconnect the refrigerant hoses from the compressor and the dryer receiver VIR assembly 2 Release the bottom row of s...

Page 66: ...cm2 the radiator fan will cut out pro vided that the engine coolant temperature is not so high that the fan has been energized by the thermocontact The pressure switch operation can be c hecked by run...

Page 67: ...cover 3 Remove the compensating hose from the outlet hose 4 Remove the two self tapping screws holding the expansion valve capillary tube mounting and bend it out of the way 5 Remove the inlet hose fr...

Page 68: ...of insulating material has been fitted to the temperature sensor coil above the evaporator outfet pipe This has been done to prevent the pipes from coming into contact with one another thus giving ri...

Page 69: ...For particulars of tightening torques see the Technical specifications Always use a restraining tool when releasing and tightening the couplings Charge the system with refrigerant Replacing the anti...

Page 70: ...ator try to solve the problem by locating the capillary tube as described below Carefully withdraw the capillary tube and fit it as shown in the drawing Wrap a piece of tape 130 mm from the end ofthe...

Page 71: ...oblems on the evaporator try to solve the problem by locating the capillary tube as described below Carefu Ily withdraw the capi lIary tube and fit it as shown in the drawing Wrap a piece oftape 130 m...

Page 72: ...art To identify the evaporator as from the 1984 models Evaporator as from the 1984 models Copper Borletti Aluminium Sanden Borletti evaporator The flange nut at the connection to the evaporator is mad...

Page 73: ...se restraining tools 4 Remove the four bolts retaining the evaporator and withdraw the evaporator Refit in the reverse order For particulars ofthe tightening torques see the Technical specifications T...

Page 74: ...dure for changing a hose is the same for all hoses 1 Disconnect the negative battery lead 2 Drain the refrigerant from the system in ac cordance with the instructions given elsewhere in this section 3...

Page 75: ...ree engine mounting retain ing bolts the centre bolt need only be backed off Jack up the engine as far as it will go 8 Lift out the compressor with the engine mounting Refit in the reverse order Lubri...

Page 76: ...ning system t t2 i6 the retaining nut from the compres s or shaft Tool Sleeve 8393241 Hook wrench 8393266 3 Remove the compressor clutch retainer Tool Puller 83 93 258 Hook wre ch 83 93266 4 Remove th...

Page 77: ...tion the rotor in the compressor so that the clutches electrical terminals are upper most when the compressor is installed Note The three guides on the rotor which shouId be fit ted into the aperture...

Page 78: ...it the circlip 4 Fit the key and press the retainer onto the shaft as far as it will go Caution Do not use J a hammerto drive on the retainer as this can damage the compressor 5 Use tool 8393308 and b...

Page 79: ...d the rotor is 0 5 1mm 6 Fit the shaft nut and tighten it to a torque of 15 Nm 11 0 Ibf ft The clutch clearance can be adjusted without removing the shaft nut Compressor as from the 1981 models Also C...

Page 80: ...oil into a suitable ves sel Measure the volume of oil drained If a new compressor is to be fitted drain the oil from the compressor Sankyo compressor 2 Add 0 3 dl of oil to the measured volume of oil...

Page 81: ...or removed 1 Mount the compressor in a vice 2 Remove the retaining nut from the compres sor shaft Tool 3 4 in socket 19 mm Special tool 8393373 As from 1984 models the compressor is equip ped with a s...

Page 82: ...tion system air conditioning system 4 Remove the key from the shaft 5 Remove the bearing circlip Tool Universal circlip pliers Remove the rotor circlip Tool Universal circlip pliers 6 Place pulley 83...

Page 83: ...Heating and ventilation system air condItioning system J4 1 f 7 Remove the rotor 8 Remove the screws holding the coil onto the compressor 9 Remove the screw and clip retaining the cable Saab900...

Page 84: ...o refit 1 Shims for cgjjpsting clutch clearance Refit tlte same numberof shims aswere removed 2 Fit the cOil Note Make sure that the dowel in the coil is aligned with the hole in the compressor cas in...

Page 85: ...5 Fit the circlip for the bearing and the circlip for the rotor Fit the key 6 Place the compressor clutch retainer on the shaft Place adaptor 83 93 415 in position Use a hammer to drive home the retai...

Page 86: ...rings should be positioned with their sealing sides away from each other Place driver 8393407 in position with the spacer Ensure that the spacer is corre ctly positioned so that the pressure is exerte...

Page 87: ...r head from the valve housing using a gasket scraper Note The mating surfaces must be kept completely unmarked 3 Carefully detach the valve housing from the compressor using a gasket scraper 4 Remove...

Page 88: ...ng on the compressor Note The dowels should be located in the holes in the compressor 4 Fit the gasket between the valve housing and the cylinder head 5 Refit the cylinder head Note The dowels should...

Page 89: ...he compressor in a vice To dismantle 1 Undo and remove the centre nut on the crankshaft Tool Holder 83 93 655 2 Remove the hub and shoe assembly Tool Puller 8393662 Note that the shims may remain insi...

Page 90: ...ssembly by hand Note Do not use any tools 6 Remove the screw and clip retaining the cable 7 Remove the screws retaining the coil in the compressor To reassemble 1 Refit the field assembly securing it...

Page 91: ...the felt washer on the crankshaft Tool Sleeve 8393704 4 Fit the pulley assembly by hand Note Do not use any tools 5 Fit the tab washer and bearing nut Tightening torque 30 Nm 22 1Ibf ft Tool Socket83...

Page 92: ...nd 0 70 mm If the clearance is not within the specified limits remove the hub assembly and adjust the number of shims It should be possible to insert a 0 3 mm feeler gauge freely all the way round a 0...

Page 93: ...l Pliers 8393696 5 Remove the crankshaft seal by engaging the special key in the slots in the seal see illu stration and then turning it clockwise Note Since two types of crankshaft seal are used chec...

Page 94: ...itioning system 6 Remove the crankshaft seal 0 ring 7 Lubricate a new 0 ring with oil and then fit it Note Always use a new 0 ring 8 Fit the protective sleeve onto the crankshaft Tool Sleeve8393712 9...

Page 95: ...e the crankshaft seal with refrigera tion oil 11 Slide the crankshaft seal onto the sleeve and then fit it by turning the special key anti clockwise Tool 8393688 2 lug 8393738 3 lug 12 Fit the sealing...

Page 96: ...n _ 4t __ 14 Fit the key in the keyway To change the front cylinder head gas ket Clarion compressor 1 Remove the cylinder head screws 2 Carefully prise off the head taking care not to scratch or score...

Page 97: ...tting the cylinder head 5 Fit the cylinder head 6 Tighten the cylinder head bolts Tightening torque 15 Nm 1 1 0 Ibf ft Note If both cylinder heads have been removed always tighten the front head to th...

Page 98: ...tem 2 Carefully prise off the head taking care not to scratch or score either of the flanges 3 Always fit a new head gasket 4 Fit a new 0 ring after first lubricating it with refrigeration oil Note th...

Page 99: ...service valve complete Tighten the cylinder head screws evenly symmetrically in sequence Tightening torque 15 Nm 11 0 Ibf ft Note If both cylinder heads have been removed always tighten the front hea...

Page 100: ...ment panel 1 Connect the yellow hose between the upper outlet on the solenoid valve and the vacuum outlet on the heater box 2 Connect the blue hose between the middle outlet on the solenoid valve and...

Page 101: ...y When the compres sor cuts in the solenoid acts on the butterfly preventing it from returning fully to the idling stop thereby maintaining a correct idling speed The device may be adjusted To check a...

Page 102: ...ssor cuts in the specially calib rated valve opens to maintain a correct idling speed The valve is not adjustable Fuel Injection engines as from the 1984 models not applicable to the Turbo 16 for the...

Page 103: ...itched in the engine speed will be increased to compensate for the increased load See circuit diagram under Electrical sys tem Delayed cutting In of the AC on starting only U S A 1986 models On aII ca...

Page 104: ...d is primarily intended to ensure that the engine re ceives adequate cooling If the temperature goes above 230 F 115 C the thermocontact will break the circuit to the compressor s magne tic clutch An...

Page 105: ...x 37 Radiator fan motor 38 Radiator fan relay 39 Radiator fan thermoco ntact 57 3 pin connector 59 2 pin connector 142 Solenoid fuel injection engines 142 Solenoid carburettor engines not Sweden 161 C...

Page 106: ...is primarily intended to ensure that the engine re ceives adequate cooling If the tem perature goes above 230 F 115 C the thermocontact will break the circuit to the compressor s magne tic clutch An o...

Page 107: ...iator fan motor 0 38 Radiator fan relay r t 39 Radiator fan ther mocontact 0 57 3 pin connector I 59 2 pin connector ll I mmmIn mmmmmm m I 137 Venturi switch ao 142 Solenoid fuel injection engines f 1...

Page 108: ...outlet and regulates the operation of the compressor clutch A time relay 167 only fitted in cars with automatic transmission which is activated by thro ttle switch 137 breaks the circuitfor about 20 s...

Page 109: ...dels 22 Fuse box 37 Radiator fan motor 38 Radiator fan relay 39 Thermocontact fan 57 3 pole connector 59 2 pole connector 60 1 pin connector 142 Solenoid valve 155 Radiator fan relay AC 161 Compressor...

Page 110: ...or outlet and regulates the operation of the compressor clutch A time relay 167 only fitted in cars with automatic transmission which is activated by throttle switch 137 breaks the circuit for about 2...

Page 111: ...s 22 Fuse box 37 Radiator fan motor 38 Radiator fan relay 39 Thermocohtact fan 57 3 pole connector 59 2 pole connector 60 i pin connector 142 Solenoid valve 155 Radiator fan relay AC 161 Compressor by...

Page 112: ...e fan relay 1 56 which starts the radiator fan 37 The anti frost thermostat 171 opens and closes the circuitto the magnetic clutch depend ing on thetempefature on the surface ofthe con denser The pres...

Page 113: ...an motor 39 Thermostatic switch for radiator fan 59 Two pin connector 142 Solenoid valve 150 AC switch 155 Fan relay for auxiliary fan motor 156 Fan relay standard fan motor 166 Pressure switch for ra...

Page 114: ...temperature of the evaporator fins Pressure switch 166 breaks the circuit if the pressure in the system falls below 2 1 kgf cm2 which will happen ifthere is an insufficientquan tity of refrigerant in...

Page 115: ...1_ __ J 172 59 0 39 f l LJ lJJ 9 75 T_l _ C5_ _ Fim 511an Grbn Gul Vii Rod BIA G A r u Schwafl Grun Gclb WeiR ROI 61 u Glav culeu NOlf Ved Jaune Blanc Rouge Blou Gus COIQLIT Black Green Vellow Whilp...

Page 116: ...I I I r...

Page 117: ...9 854 59 854 60 854 61 854 20 854 67 854 77 854 80 854 84 854 85 854 87 Air conditioning AC system Operation General repair instructions AC compensation See idling speed compensation Absorption agent...

Page 118: ...on To change the clutch See the relevant compressor Ventilation air filter 854 30 854 1 854 9 854 30 854 44 854 48 854 14 854 38 854 88 854 39 42 854 41 Saab900 854 32 854 36 37 854 34 854 32 Lubricat...

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Page 120: ...Saab Automobile AS Trollhattan Sweden...

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