PRE-RELEASE
(811-2101) Soft top cover latch jams due to deformed hinge
| SERVICE INFORMATION | |
| Bulletin Nbr: | 811-2101 |
| Date: ........... | September 1999 |
| Market: | all |
| Soft top cover latch jams due to deformed hinge |
| Cars concerned |
Saab 9-3 Convertible M98-M99 up to and incl. chassis no. X7063257.
| Background |
The soft top cover hinges flex when the soft top is in motion and when the soft top cover is opened and closed. This flexing occurs mostly when the soft top cover starts to open and causes the soft top cover to move forward, jamming the soft top cover latch pins in the latches. As a result, the breakpin in the soft top cover operating mechanism may break.
To reduce the flexing, a new hinge has been introduced for fitting after customer complaint as described below.
| Materials |
48 56 415 Hinge assembly, left (CA: 30582848)
48 56 423 Hinge assembly, right (CA: 30582849)
79 75 568 Bolt (x 4) (CA: 30509244)
51 16 967 Damper, soft top cover (x 2) (CA: 30582772)
82 35 178 Blind rivet (x 2) (CA: 30510074)
51 07 859 Wiring harness, soft top cover (CA: 30583079)
| Procedure |
| 1. |
Loosen and fold down the luggage compartment upholstery. Place some protection on the boot lid.
Remove the covering on the soft top cover. Operate the soft top to its raised position (closed) with the fifth bow raised (upright) and soft top cover open (upright). |
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| 2. |
Measure the distance on the hinge to the upper nut.
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| 3. |
Unplug the connectors for the microswitches and the latch motor. Cut off the cable ties.
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| 4. |
Remove the nuts and bolts securing the soft top cover to the hinges. Lift away the top cover.
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| 5. |
Remove the soft top cover seal.
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| 6. |
Loosen the soft top storage from the edge.
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| 7. |
Loosen the outer end on the hinge springs using an Apex screwdriver without Torx bit or a suitable pipe.
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| 8. |
Remove the wiring harness from the left hinge.
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| 9. |
Fold down the rear seat backrest and release the hydraulic pressure by opening the hydralic valve.
Fold down the hinges and open the boot lid. |
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| 10. |
Mark the position of the left hinge on the body and remove the left hinge.
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| 11. |
Lift away the rod with the springs.
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| 12. |
Mark the position of the right hinge on the body and remove the bolts securing the hinge.
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| 13. |
Pull out the hinge from the joint.
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| 14. |
Drill out the blind rivets securing the dampers and remove them.
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| 15. |
Fit the new dampers.
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| 16. |
Transfer the washers and clip nut from the old hinges to the new ones.
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| 17. |
Press the right hinge in the joint and adjust according to marking. Fasten the hinge.
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| 18. |
Fit the rod with the springs.
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| 19. |
Fit the left hinge and tighten according to markings.
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| 20. |
Close the boot lid and attach the springs with an Apex screwdriver without Torx bit or a suitable piece of pipe. Fit the new wiring harness.
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| 21. |
Fit the storage bag on the sheet metal flange and press the soft top cover seal in place.
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| 22. |
Fit the soft top cover in accordance with earlier measurement. Use the new bolts 79 75 568 on the impact member.
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| 23. |
Plug in the connector and fit a new cable tie. Close the hydraulic valve.
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| 24. |
Operate the soft top for one cycle, checking its fit and making sure the soft top cover and fifth bow lock correctly.
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| 25. |
Carry out any necessary adjustments according to WIS.
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| 26. |
Fit the covering on the soft top cover and vacuum the car to remove any cuttings.
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| 27. |
Lower the soft top cover and open the boot lid. Refit the luggage compartment trim.
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| 28. |
Connect the diagnostics tool and erase any diagnostic trouble code.
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| Warranty/Time information |
Failed Object: 81420
Fault/Reason code: 72
Location code (US): 09
Warranty Type (US): 01
Repair/Action code: 01
Work procedure (US): 81420 (CA: B3595 - B3623)
Time: 1.1 hrs
