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General: Specifications Saab 9-5 II

Oem General Information 15 illustrations ~1320 words

Welded, Brazed, and Riveted Joint Specifications

Note. Please also pay attention to body repair using structural adhesive, equipment recommendations for resistance spot welding machines and equipment recommendation for MIG brazing.

Significant changes to the vehicle design lead to new joining techniques in bodywork production.

Significant changes in the manufacturing process generally result from

  1. The use of pre-painted sheet metal to increase corrosion protection.
  2. The use of higher strength and highest strength sheet metal to increase body rigidity/impact safety while at the same time reducing vehicle weight.

Joining techniques recently introduced in bodywork production include

  1. Laser-welded vehicle roof
  2. Gas-shielded MIG brazing

These new joining methods must be applied/adapted to the special requirements of service based on the new material quality and joining techniques so as to ensure professional bodywork repair.

WARNINGThe specifications named below must be followed. Failure to do so could lead to component damage, such as corrosion or structural damage at the repair area.
  1. Before the start of work, a test weld/brazing is to be carried out on the area to be repaired (similar to a sample paint spray test). This is done by subjecting a sample of the relevant panel joint to a test weld/brazing and seam check. The sample panel must come from the vehicle to be repaired or be a new part.
  2. Structural seams (e.g. butt seam upon part replacement in the area of the front frame) are to be sealed with body sealant after priming. Before installing closure plates, make sure that corrosion protection is applied to areas such as the rear plate and weld seams in cavities. Inaccessible cavities are to be sealed as well. Cavity sealing after painting is mandatory.
  3. The configuration of the welded and brazed joints for metal service parts sometimes differs from the seam configuration or joint specification used in production due to the different joining methods and joining order. For example, slots must be made in certain service parts or body sections in order to create the joint. For these such cases, the service literature explicitly specifies the configuration of the joint.
  4. For certain joining methods or seam geometries, it may be necessary to attach a reinforcing plate at the location of the joint. This plate serves to ensure a high-quality connection that has the same structural properties as a new part. The reinforcing sheet metal is to be taken from the new part remnant or from the component of the sheet metal to be repaired. The service instructions provide information on the configuration and connection to be used for the reinforcing sheet metal. In order to prevent structural breaches, the corners and edges of the reinforcing pate are to be deburred and bevelled.
  5. For structural seams (e.g. butt seams upon part replacement at the front frame), the deck/root seam must not be ground or smoothed. Reason: structural breach of the component upon grinding, notching or heat, uncontrolled reduction in metal thickness.
  6. Specific welding/brazing parameters are to be set for the individual seam areas based on equipment version. This information is to be taken from the equipment manufacturer documentation.
  7. Should a resistance spot welding spot require special settings, such is indicated by entering SPP in field 5. Settings can be found in the parameter lists of the recommended equipment manufacturers. Recommended manufacturers can be found in the newsletter.
  8. No spot weld primer is to be used at joints when using gas-shielded welding methods, such as MAG welding and MIG brazing. Reason: reduction of seam quality through gas emission, causing pore formation, which reduces the strength of the seam.
  9. Rivets are only to be used on metal body parts in combination with the adhesive sealing system. Only waterproof, stainless steel rivets are allowed to be used. Use of aluminum rivets instead of steel is not permitted due to corrosion and insufficient strength.

Technical Specifications

Note. MAG welding must comply with guideline QT 001131.

  1. MIG brazing must comply with guideline GME7834.
  2. Spot welding operations must comply with guideline QT 001130.
  3. The most recently updated version of the guidelines is to be applied.

The guidelines can be requested from the following address (subject to a fee)

Scheme 1

Scheme 1: Seam Forms
Scheme 1: Seam Forms
CalloutDescription
1Resistance Spot Welding
2Plug Spot Welding
3IOverlapped
IIOffset
110-20 mm (depending on plug) (0.4-0.8 in)
26 mm for sheet metal up to 1.0 mm (0.04 in) 8 mm for sheet metal up to 2.0 mm (0.08 in)
330-40 mm plug weld spacing (1.2-1.6 in)
Quilting Seam Spot Welding/Spot Brazing
IOverlapped
IIOffset
110-14 mm (0.4-0.6 in)
23-5 mm (0.1-0.2 in)
330-40 mm (1.2-1.6 in)

Scheme 2

Scheme 2: MIG Brazing - Slot
Scheme 2: MIG Brazing - Slot
CalloutDescription
4IOverlapped
IIOffset
1At least 15-20 mm (depending on slot size) (0.6-0.8 in)
2See 4.2 Slot Sizes
3Spacing and number of slots (see specification in service instruction)

Scheme 3

Scheme 3: Slot Sizes
Scheme 3: Slot Sizes
CalloutDescription
4I5x18 mm slot (sheet metal thickness up to 0.8 mm) (0.03 in) 6x20 mm slot (sheet metal thickness 0.8-1.2 mm) (0.03-0.05 in) 8x24 mm slot (sheet metal thickness over 1.2 mm) (0.05 in)
II6x8x20 mm slot with pre-drilled spot welds (0.8-1.2 mm sheet metal) (0.03-0.05 in)

Average Adhesive Bead Length/Cartridge Capacity

The cartridge contents of anti-corrosion adhesive sealant kit 93160535/15 05 000 provide an adhesive bead that is about 3.50 m (11 ft) in length on average, depending on the bead thickness.

The cartridge contents of single-component window adhesive 93165025/15 04 815 provide an adhesive bead that is about 3.00 m (10 ft) in length on average, depending on the bead thickness.

Scheme 4

Scheme 4: Seam Form Field
Scheme 4: Seam Form Field

Ignition System Specifications

ApplicationSpecification
MetricEnglish
Firing Order1-2-3-4-5-6
Spark Plug Gap1.1 mm0.043 in
Spark Plug Torque20 Nm15 lb ft

Fastener Tightening Specifications

ApplicationSpecification
MetricEnglish
Accelerator Pedal Position Sensor10 Nm89 lb in
Air Cleaner Element4 Nm36 lb in
Camshaft Position Actuator Solenoid Valve - Exhaust10 Nm89 lb in
Camshaft Position Actuator Solenoid Valve - Intake10 Nm89 lb in
Camshaft Position Sensor - Exhaust10 Nm89 lb in
Camshaft Position Sensor - Intake10 Nm89 lb in
Charge Air Bypass Valve10 Nm89 lb in
Charge Air Bypass Valve Vacuum Tank10 Nm89 lb in
Crankshaft Position Sensor10 Nm89 lb in
Engine Coolant Temperature Sensor20 Nm15 lb ft
Evaporative Emission Canister Purge Solenoid Valve4 Nm36 lb in
Fuel Feed Intermediate Pipe30 Nm22 lb ft
Fuel Feed Pipe (Metal) to Fuel Pump Module30 Nm22 lb ft
Fuel Feed Pipe (Metal) to Intake Manifold7 Nm62 lb in
Fuel Injection Fuel Rail Assembly 1st sequence22 Nm16 lb ft
Fuel Injection Fuel Rail Assembly 2nd sequence22 Nm16 lb ft
Fuel Injection Fuel Rail Fuel Pressure Sensor33 Nm25 lb ft
Fuel Pump Flow Control Module7 Nm62 lb in
Fuel Pump Module15 Nm11 lb ft
Fuel Tank Filler Hose4 Nm36 lb in
Heated Oxygen Sensor - Sensor 142 Nm31 lb ft
Heated Oxygen Sensor - Sensor 242 Nm31 lb ft
Ignition Coil10 Nm89 lb in
Intake Air Pressure and Temperature Sensor7 Nm62 lb in
Knock Sensor - Left Side25 Nm18 lb ft
Knock Sensor - Right Side25 Nm18 lb ft
Manifold Absolute Pressure Sensor4 Nm36 lb in
Spark Plug20 Nm15 lb ft
Throttle Body Assembly10 Nm89 lb in
Turbocharger Wastegate Actuator10 Nm89 lb in
Turbocharger Wastegate Regulator Solenoid Valve10 Nm89 lb in

Prevailing Torque Fasteners

Prevailing torque fasteners create a thread interface between the fastener and the fastener counterpart in order to prevent the fastener from loosening.

All Metal Prevailing Torque Fasteners

These fasteners accomplish the thread interface by a designed distortion or deformation in the fastener.

Nylon Interface Prevailing Torque Fasteners

These fasteners accomplish the thread interface by the presence of a nylon material on the fastener threads.

Metric Prevailing Torque Fastener Minimum Torque Development

ApplicationSpecification
MetricEnglish
All Metal Prevailing Torque Fasteners
6 mm0, 4 Nm4 lb in
8 mm0, 8 Nm7 lb in
10 mm1, 4 Nm12 lb in
12 m2, 1 Nm19 lb in
14 mm3 Nm27 lb in
16 mm4, 2 Nm37 lb in
20 mm7 Nm62 lb in
24 mm10, 5 Nm93 lb in
Nylon Interface Prevailing Torque Fasteners
6 mm0, 3 Nm3 lb in
8 mm0, 6 Nm5 lb in
10 mm1, 1 Nm10 lb in
12 mm1, 5 Nm13 lb in
14 mm2, 3 Nm20 lb in
16 m3, 4 Nm30 lb in
20 mm5, 5 Nm49 lb in
24 mm8, 5 Nm75 lb in

English Prevailing Torque Fastener Minimum Torque Development

ApplicationSpecification
MetricEnglish
All Metal Prevailing Torque Fasteners
1/4 in0, 5 Nm4.5 lb in
5/16 in0, 8 Nm7.5 lb in
3/8 in1, 3 Nm11.5 lb in
7/16 in1, 8 Nm16 lb in
1/2 in2, 3 Nm20 lb in
9/16 in3, 2 Nm28 lb in
5/8 in4 Nm36 lb in
3/4 in7 Nm54 lb in
Nylon Interface Prevailing Torque Fasteners
1/4" 0, 3Nm3 lb in
5/16" 0, 6Nm5 lb in
3/8" 1Nm9 lb in
7/16" 1, 3Nm12 lb in
1/2" 1, 8Nm16 lb in
9/16" 2, 5Nm22 lb in
5/8" 3, 4Nm30 lb in
3/4" 5Nm45 lb in

Scheme 5

Scheme 5: Fasteners (Europe)
Scheme 5: Fasteners (Europe)

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Scheme 8

Scheme 8
Scheme 8

Scheme 9

Scheme 9
Scheme 9

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11

Scheme 12

Scheme 12
Scheme 12

Scheme 13

Scheme 13
Scheme 13

Scheme 14

Scheme 14
Scheme 14

Scheme 15

Scheme 15
Scheme 15
  1. Fillister Head Screw with Inner TORX
  2. Flat Bolt with Inner TORX
  3. Cheese-Head Screw with Inner Hex - Rolled-In Washer
  4. Hex Bolt
  5. Hex Bolt with Inner TORX
  6. Fillister Head Screw with Cross Recess
  7. Fillister Head Screw with Cross Recess
  8. Flat Head Screw with Inner TORX
  9. Hex Nut - Metal
  10. Special Nut - Plastic
  11. Blind Rivet
  12. Plug - Herringbone Profile
  13. Clips
  14. Plugs - Conical, Round, Colored
  15. Clips - Square, Light
  16. Snap Button - Black
  17. Cover Cap - Round, Colored
  18. Spring Clip - Light
  19. Spring Clip - Dark
  20. Spring Clip
  21. Stop Nut
  22. Hex Nut with Rolled-In Washer
  23. Flat Head Screw with Cross Recess
  24. TORX Bolt with Collar
  25. Cheese-Head Screw with Inner TORX with Rolled-In Washer
  26. Hex Bolt with Rolled-In Washer
  27. Hex Bolt with Rolled-In Washer
  28. Hex Bolt with Rolled-In Washer
  29. Fillister Head Screw with Cross Recess
  30. Hex Nut with Washer
  31. Special Plastic Nut without Thread
  32. Clip with Screw-In Fastening
  33. Terminal
  34. Body-Bound Rivet - Thick
  35. Body-Bound Rivet - Thin
  36. Fastening Clip
  37. Fastening Clip
  38. Body-Bound Rivet - Long
  39. Door Bolt
  40. Hollow Pin
  41. Collar Bolt - Hex
  42. Snap Button Nut with Inner TORX
  43. Rivet Nut
  44. Fastening Plug
  45. Hex Bolt
  46. Cap Nut - Plastic
  47. Plastic Screw Hook
  48. Plastic Nut
  49. Fastening Ring - Seat Pad
  50. Hex Bolt with Rolled-In Washer
  51. TORX Bolt with Rolled-In Washer
  52. TORX Bolt with Rolled-In Washer
  53. TORX Bolt with Rolled-In Washer
  54. Fillister Head Screw with Inner TORX
  55. Clip - Round, Light
  56. Clip - Elongated
  57. Cheese-Head TORX Bolt
  58. Fillister Head TORX Bolt
  59. Cheese-Head TORX Bolt - Steering Crossmember
  60. Washer - Steering Crossmember
  61. Tolerance Screw - Steering Crossmember
  62. Spring Clip
  63. Weld Stud
  64. Insertion Pin
  65. Body-Bound Rivet - Square
  66. Body-Bound Rivet - Round
  67. Fastening Plug
  68. Fastening Plug - Insertion Screw
  69. Fastening Plug
  70. Nut
  71. Fastening Plug
  72. Spring Nut
  73. Flat-Ended Screw with Cross Recess
  74. Bolt
  75. Self-Tapping Screw with Washer
  76. Terminal
  77. Terminal
  78. Sheet-Metal Clamp - Cable Laying
  79. Sheet-Metal Clamp - Cable Laying
  80. Sheet-Metal Clamp - Cable Laying
  81. Velcro Fastening
  82. Plug - Plastic
  83. Plug - Drainage
  84. Bracket - Plastic
  85. Flat-Head Screw - Cross Recess
  86. Hex Bolt with Rolled-In Washer
  87. Flat-Head Screw - Cross Recess
  88. Fillister Head Screw - Cross Recess, Washer
  89. Hex Bolt - Long
  90. Cheese-Head Screw - Long, Inner TORX
  91. Cheese-Head Screw - Short, Inner TORX
  92. Collar Nut
  93. Clip - Inner Paneling
  94. Clip - Cable
  95. Fastening Plug - Narrow
  96. Fastening Plug - Wide
  97. Collar Bolt - Washer
  98. Hex Bolts - Washer
  99. Rear Quarter Window Fastening Nut - Plastic
  100. Body-Bound Rivet
  101. TORX Bolt with Hex
  102. Philips Screw - Fillister Head
  103. Hex Bolt - Cross Recess
  104. Clips with Screw-In Fastening
  105. TORX Bolt
  106. Spring Clip
  107. Rivet Nut - Opel Fix
  108. Blind Rivet Nut
  109. Plastic Clip - Seat Occupancy Detection System
  110. Plastic Clamp
  111. TORX Bolt
  112. Clips
  113. Plastic Spring Nut
  114. Sill Panelling Clips
  115. Sliding Glass Sunroof Fastening Bolt
  116. Fastening Clip
  117. Fastening Clip
  118. Fastening Plug
  119. Fastening Clip
  120. Retaining Clamp
  121. Gloves
  122. Safety Glasses
  123. Cover Strip Fastening Clip

Component Fastener Tightening Caution

WARNINGReplacement components must be the correct part number for the application. Components requiring the use of the thread locking compound, lubricants, corrosion inhibitors, or sealants are identified in the service procedure. Some replacement components may come with these coatings already applied. Do not use these coatings on components unless specified. These coatings can affect the final torque, which may affect the operation of the component. Use the correct torque specification when installing components in order to avoid damage.

Torque Reaction Against Timing Drive Chain Caution

WARNINGA wrench must be used on the hex of the camshaft when loosening or tightening in order to prevent component damage. Failure to prevent the torque reaction against the timing drive chain can lead to timing drive chain failure.

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