Brake: Other Saab 9-2X I

General Purpose Tools

SPECIAL TOOLS SPECIFICATION CHART

PRECAUTIONS

1. Wear working clothing, including a cap, protective goggles, and protective shoes during operation.
2. Before removal, installation or disassembly, be sure to clarify the failure. Avoid unnecessary removal, installation, disassembly, and replacement.
3. Use genuine grease etc. or the equivalent. Do not mix grease etc. with that of another grade or from other manufacturers.
4. Be sure to tighten fasteners including bolts and nuts to the specified torque.
5. Place shop jacks or rigid racks at the specified points.
6. Before securing a part on a vise, place cushioning material such as wood blocks, aluminum plate, or shop cloth between the part and the vise.

15 INCH TYPE & 16 INCH TYPE

Set the vehicle on a lift.

Loosen the wheel nuts.

Lift-up the vehicle, and then remove the front wheel.

Remove the lower caliper bolt.

Raise the caliper body upward and support it.

Note. Do not disconnect the brake hose from caliper body.

Remove the pad.

Scheme 42

Note. If the brake pad is difficult to remove, proceed as follows

Remove the caliper body from support.

Remove the support.

Place a support in a vise between wooden blocks.

Scheme 43

1. Support
2. Wooden blocks

Attach a rod of less than 12 mm (0.47 in) dia. to the shaded area of brake pad, and strike the rod with a hammer to drive brake pad out of place.

Scheme 44

Apply thin coat of Molykote AS880N (Part No. K0779YA010) to the frictional portion between pad and pad clip.

Apply thin coat of Molykote AS880N (Part No. K0779YA010) to the frictional portion between pad and pad inner shim.

Scheme 45

Install the pads on support.

Install the caliper body on support.

Tightening torque

37 Nm (3.8 kgf-m, 27.5 ft -lb)

Note. If it is difficult to push the piston during pad replacement, loosen the air bleeder to facilitate work.

Check the pad thickness A.

Scheme 46

PAD THICKNESS SPECIFICATION

Note. Always replace the pads for both right and left wheels at the same time. Also replace the pad clips if they are twisted or worn. A wear indicator is provided on the inner disc brake pad. If the pad wears down to such an extent that the end of wear indicator contacts disc rotor, a squeaking sound is produced as the wheel rotates. If this sound is heard, replace the pad. Replace the pad if there is oil or grease on it.

Set the vehicle on a lift.

Loosen the wheel nuts.

Lift-up the vehicle, and then remove the front wheel.

Remove the caliper body and support from housing, and suspend it from strut using a wire.

Scheme 47

Remove the disc rotor.

Note. If the disc rotor seizes up within the hub, drive the disc rotor out by installing an 8-mm bolt in holes (B) on rotor.

Scheme 48

Clean mud and foreign particles from the caliper body assembly and support.

Set the vehicle on a lift.

Loosen the wheel nuts.

Lift-up the vehicle, and then remove the front wheel.

Remove the union bolt, and then disconnect the brake hose from caliper body assembly.

Scheme 49

Remove the bolt securing lock pin to caliper body.

Scheme 50

Raise the caliper body, and then move it toward vehicle center to separate it from support.

Remove the support from housing.

Note. Remove the support only when replacing it or the rotor. It need not be removed when servicing the caliper body assembly.

Scheme 51

Clean mud and foreign particles from the caliper body assembly and support.

Install the support on housing.

Tightening torque

80 Nm (8.2 kgf-m, 59 ft-lb)

Apply thin coat of Molykote AS880N (Part No. 32005001) to the frictional portion between pad and pad clip.

Apply thin coat of Molykote AS880N (Part No. 32005001) to the frictional portion between pad and inner shim.

Scheme 52

Install the pads on support.

Install the caliper body on support.

Tightening torque

26.5 Nm (2.7 kgf-m, 19.5 ft -lb)

Replace the brake hose gaskets with new ones, and then connect the brake hose.

Tightening torque

18 Nm (1.8 kgf-m, 13.0 ft -lb)

Bleed air from the brake system.

Clean mud and foreign particles from the caliper body assembly and support.

Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged.

Gradually supply compressed air via the installation hole of brake hose to force the piston out.

Scheme 53

1. Place a 30 mm (1.18 in) wide wooden block here.

Remove the piston boot.

Scheme 54

Remove the piston seal from caliper body cylinder.

Scheme 55

1. Piston seal

Remove the guide pin and boot from caliper body.

Clean the caliper body interior using brake fluid.

Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.

Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.

Apply a coat of specified grease to the boot and install the piston boot to the groove on ends of cylinder.

Grease

NIGLUBE RX-2 (Part No. 32005002)

Insert the piston into cylinder.

Scheme 56

1. Piston
2. Piston boot

Position the boot in grooves on cylinder and piston.

Scheme 57

1. Piston
2. Piston boot
3. Caliper body
4. Piston seal

Apply a coat of specified grease to the lock pin and guide pin outer surface, cylinder inner surface, and boot grooves.

Grease

NIGLUBE RX-2 (Part No. 32005002)

Install the lock and guide pin boot on support.

Scheme 58

1. Pin boot
2. Lock pin or guide pin
3. Apply grease.

14 INCH TYPE

Set the vehicle on a lift.

Loosen the wheel nuts.

Lift-up the vehicle, and then remove the rear wheel.

Remove the lower caliper bolt.

Scheme 59

Raise the caliper body upward and support it.

Note. Do not disconnect the brake hose from caliper body.

Remove the pad.

Note. If the brake pad is difficult to remove, use the same procedure as for front disc brake pad.

Scheme 60

Set the vehicle on a lift.

Loosen the wheel nuts.

Lift-up the vehicle, and then remove the wheels.

Disconnect the brake hose from caliper body assembly.

Remove the bolt securing lock pin to caliper body.

Scheme 61

Raise the caliper body and move it toward vehicle center to separate it from support.

Remove the support from housing.

Note. Remove the support only when replacing it or the rotor. It need not be removed when servicing the caliper body assembly.

Clean mud and foreign particles from the caliper body assembly and support.

Install the support on housing.

Tightening torque

52 Nm (5.3 kgf-m, 38.3 ft -lb)

Apply thin coat of Molykote AS880N (Part No. 32005001) to the frictional portion between pad and pad clip.

Install the pads on support.

Install the caliper body on support.

Tightening torque

37 Nm (3.8 kgf-m, 27.5 ft -lb)

Replace the brake hose gaskets with new ones, and then connect the brake hose.

Tightening torque

18 Nm (1.8 kgf-m, 13.0 ft -lb)

Bleed air from the brake system.

Remove the boot ring.

Scheme 62

1. Boot ring

Remove the piston boot.

Scheme 63

Place a wooden block in caliper body as shown in the figure to prevent the piston from jumping out and avoid being damaged.

Gradually supply compressed air via the installation hole of brake hose to force the piston out.

Scheme 64

1. Place a 30 mm (1.18 in) wide wooden block here.

Remove the piston seal from caliper body cylinder.

Scheme 65

Remove the lock pin sleeve and boot from caliper body.

Remove the guide pin boot.

Clean the caliper body interior using brake fluid.

Apply a coat of brake fluid to the piston seal and fit piston seal in groove on caliper body.

Apply a coat of brake fluid to the entire inner surface of cylinder and outer surface of piston.

Insert the piston into cylinder.

Apply a coat of specified grease to the boot and fit in groove on ends of cylinder and piston.

Grease

NIGLUBE RX-2 (Part No. 32005002)

Install the piston boot to caliper body, and then attach boot ring.

Scheme 66

1. Piston boot
2. Boot ring
3. Piston seal
4. Caliper body

Apply a coat of specified grease to the guide pin, outer surface, sleeve outer surface, cylinder inner surface, and boot grooves.

Grease

NIGLUBE RX-2 (Part No. 32005002)

Scheme 67

1. Pin boot
2. Lock pin or guide pin
3. Apply grease.

Install the guide pin boot on support.

Install the lock pin boot on support, and then insert the lock pin sleeve into place.

Checking without gauges

This method cannot determine the exact portion which has failed, but it can provide a rough understanding of the nature of failure if checking is conducted in accordance with the following procedures.

Air tightness check

Start the engine, and run it for 1 to 2 minutes, then turn it off. Depress the brake pedal several times applying same pedal force as that used in ordinary braking operations. The pedal stroke should be greatest on 1st depression, and it should become smaller with each successive depression. If no change occurs in the pedal height while in a depressed state, the brake booster is faulty.

Scheme 68

1. OK
2. NOT OK
3. 1st
4. 2nd
5. 3rd

Note. In the event of defective operation, inspect the condition of check valve and vacuum hose. Replace them if faulty and conduct the test again. If no improvement is observed, check precisely with gauges.

Loaded air tightness check

Depress the brake pedal while engine is running, and turn off the engine while pedal is still depressed. Keep the pedal depressed for 30 seconds; if no change occurs in the pedal height, the brake booster is functioning normally; if the pedal height increases, it is faulty.

Note. If faulty, check precisely with gauges.

Checking with gauges

Connect gauges as shown in the figure. After bleeding air from pressure gauges, proceed to each check.

Scheme 69

1. Pressure gauge
2. Vacuum gauge
3. Adapter hose
4. Vacuum hose
5. Pedal force gauge

Start the engine and keep it running until a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg) = point A is indicated on vacuum gauge. Do not depress the brake pedal.

Scheme 70

1. Pressure gauge
2. Vacuum gauge

Stop the engine and watch the gauge. If the vacuum drop range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15 seconds after stopping engine, the brake booster is functioning properly.

If defective, the cause may be one of those listed below.

1. Check valve malfunction
2. Leak from vacuum hose
3. Leak from the shell jointed portion or stud bolt welded portion
4. Damaged diaphragm
5. Leak from valve body seal and bearing portion
6. Leak from plate and seal assembly portion
7. Leak from poppet valve assembly portion

Start the engine and depress brake pedal with pedal force of 196 N (20 kgf, 44 lb). Keep the engine running until a vacuum of 66.7 kPa (500 mmHg, 19.69 inHg) = point B is indicated on vacuum gauge while the pedal is still depressed.

Scheme 71

1. Pressure gauge
2. Vacuum gauge
3. Pedal force gauge
4. Depress

Stop the engine and watch vacuum gauge.

If the vacuum drop range is less than 3.3 kPa (25 mmHg, 0.98 inHg) within 15 seconds after stopping engine, the brake booster is functioning properly.

If defective, refer to " AIR TIGHTNESS CHECK ".

If any fault is found on brake booster, replace the brake booster with a new one.

Lack of boosting action check

Turn off the engine, and set the vacuum gauge reading at "0". Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the standard value listed.

LACK OF BOOSTING ACTION CHART

Boosting action check

Set the vacuum gauge reading at 66.7 kPa (500 mmHg, 19.69 inHg) by running engine. Then, check the fluid pressure when brake pedal is depressed. The pressure must be greater than the standard value listed.

CHECKING BOOSTING ACTION

Procedure

Master Cylinder

Note. If the master cylinder is disassembled or reservoir tank is empty, bleed the master cylinder. During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. The brake pedal operating must be very slow. For convenience and safety, two people should do the work.

Loosen the wheel nuts, jack-up the vehicle, support it with rigid racks, and remove the wheel.

Disconnect the brake line at primary and secondary sides.

Put a plastic bag cover on master cylinder.

Carefully depress and hold the brake pedal.

Scheme 72

Close the outlet plug with your finger, and then release the brake pedal.

Scheme 73

Repeat step 4) and 5) until the brake fluid is completely bled from outlet plug.

Remove the plastic bag.

Install the brake pipes to master cylinder.

Tightening torque

15 Nm (1.5 kgf-m, 10.8 ft -lb)

Bleed air from the brake line.

Note. During the bleeding operation, keep the brake reservoir tank filled with brake fluid to eliminate entry of air. The brake pedal operating must be very slow. For convenience and safety, two people should do the work.

Make sure that there is no leak from the joints and connections of brake system.

Fit one end of vinyl tube into the air bleeder and put the other end into a brake fluid container.

Scheme 74

Scheme 75

1. Master cylinder
2. Hydraulic unit
3. Proportioning valve

Slowly depress the brake pedal and keep it depressed. Then, open the air bleeder to discharge air together with the fluid.

Release the air bleeder for 1 to 2 seconds.

Next, with the bleeder closed, slowly release the brake pedal.

Repeat these steps until there are no more air bubbles in the vinyl tube.

Allow 3 to 4 seconds between two brake pedal operations.

Note. The brake pedal operating must be very slow.

Tighten the air bleeder securely when no air bubbles are visible.

Air bleeder tightening torque

8 Nm (0.8 kgf-m, 5.8 ft-lb)

Perform these steps for the brakes connecting to secondary chamber of master cylinder, first, and then for the ones connecting to primary chamber. With all procedures completed, fully depress the brake pedal and keep it in that position for approx. 20 seconds to make sure that there is no leak evident in the entire system.

Check the pedal stroke.

While the engine is idling, depress the brake pedal with a 490 N (50 kgf, 110 lb) load and measure the distance between brake pedal and steering wheel. With the brake pedal released, measure the distance between pedal and steering wheel again. The difference between the two measurements must not be more than specified.

Scheme 76

1. Steering wheel
2. Toe board

Specified pedal stroke

Saab 9-2X 2.0T Aero AT model

105 mm (4.13 in)

Except Saab 9-2X 2.0T Aero AT model

90 mm (3.54 in)

When depressing brake pedal with a 490 N (50 kgf, 110 lbf) load.

If the distance is more than the specifications, there is a possibility that air is in the brake line. Bleed the brake line until pedal stroke meets the specification.

Operate the hydraulic control unit in the sequence control mode.

Recheck the pedal stroke.

If the distance is more than specifications, there is a possibility air is in the inside of hydraulic unit. Repeat above steps 2) to 9) above until pedal stroke meets the specification.

Add brake fluid to the required level (MAX. level) of reservoir tank.

As a final step, test run the vehicle at low speed and apply brakes relatively hard 2 to 3 times to ensure that brakes provide normal braking action on all four wheels without dragging and uneven braking.

Separate the brake pipe from brake hose.

(Always use the flare nut wrench and be careful not to deform the flare nut.)

Pull out the clamp to remove brake hose.

Remove the bolt at strut and union bolt.

Scheme 77

1. Brake hose
2. Brake pipe

Separate the brake pipe from brake hose.

Note. Always use the flare nut wrench and be careful not to deform the flare nut.

Remove the clamp and union bolt.

Scheme 78

1. Brake pipe
2. Brake hose
3. Brake hose clamp

Secure the brake hose to strut.

Tightening torque

32 Nm (3.3 kgf-m, 23.6 ft -lb)

Install the brake hose to caliper using a new gasket.

Tightening torque (Union bolt)

18 Nm (1.8 kgf-m, 13.0 ft -lb)

Scheme 79

Position the disc in straight-forward direction and route brake hose through hole in bracket on wheel apron side.

Temporarily tighten the flare nut to connect brake pipe and hose.

Fix the brake hose with clamp at wheel apron bracket.

While holding the hexagonal part of brake hose fitting with a wrench, tighten the flare nut to the specified torque.

Tightening torque (Brake pipe flare nut)

15 Nm (1.5 kgf-m, 10.8 ft -lb)

Bleed air from the brake system.

Pass the brake hose through hole of bracket, and then lightly tighten the flare nut to connect brake pipe.

Insert the clamp upward to fix brake hose.

Install the brake hose to caliper using a new gasket.

Tightening torque (Union bolt)

18 Nm (1.8 kgf-m, 13.0 ft -lb)

While holding the hexagonal part of brake hose fitting with a wrench, tighten the flare nut to the specified torque.

Tightening torque (Brake pipe flare nut)

15 Nm (1.5 kgf-m, 10.8 ft -lb)

Scheme 80

1. Brake pipe
2. Brake hose
3. Brake hose clamp

Bleed air from the brake system.

MT MODEL

Remove the steering shaft.

Disconnect the connectors (for stop light switch, etc.) from pedal bracket.

Remove the clevis pin which secures the lever to push rod.

Remove the nut which secures the clutch master cylinder.

Remove the accelerator pedal.

Remove the bolts and nuts which the secure pedal bracket.

Scheme 81

AT MODEL

Disconnect the ground cable from battery.

Remove the instrument panel lower cover from instrument panel.

Remove the clevis pin which secures the brake pedal to brake booster operating rod. Also disconnect the stop light switch connector.

Remove the four bolts and four nuts which secure the brake pedal to pedal.

Scheme 82

1. Clevis pin
2. Snap pin
3. Operating rod

Remove the brake switch.

Remove the clutch pedal.

Remove the clutch master cylinder bracket.

Scheme 83

Remove the bushing, spring and stopper.

Scheme 84

1. Stopper
2. Bushing
3. Brake pedal
4. Brake pedal spring

Remove the brake pedal pad.

Remove the brake switch.

Unbolt, and then remove the brake pedal.

Scheme 85

Remove the bushing, spacer and spring.

Scheme 86

1. Plug
2. Stopper
3. Brake pedal
4. Brake pedal spring

Remove the brake pedal pad.