(831-2456) Discoloured door handles
Symptom: Discoloured door handles.
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TECHNICAL SERVICE BULLETIN
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Bulletin Nbr:
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831-2456
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Date:
...........
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Augusti 2004
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Market:
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all
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Saab 9-3 (9440) M03 within Vehicle Identification Number interval 31021000 - 31058000
The material content of the door handles was changed in the above Vehicle Identification Number range. This can result in the door handles becoming discoloured (white).
In the case of customer complaint, the following procedure must be carried out.
Symptom description
Discoloured door handles.
12 785 560 Door handle front LH
12 786 424 Door handle RH (x2)
12 785 558 Door handle rear LH
All door handles must be replaced.
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To remove, door handle, front
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1.
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The window must be closed. Remove the door trim, in accordance with WIS - 9-3 (9440) - Body - Interior equipment - Door trim, front, 4D
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2.
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Bend the water barrier down slightly. Detach it using 82 93 474 Removal tool.
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3.
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Cars with guard
: Remove the guard's bolts.
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4.
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Cars up to and including Vehicle Identification Number 31030983
: Detach the lock cover from the handle's rod.
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5.
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Cars from and including Vehicle Identification Number 31030984
: Detach the lock cover from the handle's rod.
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6.
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Detach the handle's rod from the clip.
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7.
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Cars with guard
: Remove the bolts from the lock unit.
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8.
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Cars with guard
: Remove the guard by coaxing it out.
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9.
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Undo the upper rear nut from the handle.
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10.
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Turn the lock cylinder anticlockwise and pull out the cylinder from the handle.
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11.
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Unhook the lock cylinder from the lock rod.
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12.
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Remove the handle's nuts.
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13.
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Remove the reinforcement plate.
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14.
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Lift out the handle by:
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14.A.
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Pull out the lower edge of the handle so that the studs release.
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14.B.
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Pull downward to draw out the handle's counterweight.
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14.C.
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Now lift upwards to draw the handle's rod out from the hole.
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To fit, door handle, front
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1.
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Check the handle's gasket, that it is intact and located correctly.
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2.A.
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Insert the handle's rod in the door.
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2.B.
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Angle in the handle's counterweight.
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2.C.
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Angle in the handle's lower edge and insert the studs in the holes.
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3.
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Fit the reinforcement plate.
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4.
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Fit the handle's nuts. Tighten the two lower nuts and screw on the upper one just a few turns.
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5.
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Hook the lock cylinder on the rod.
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6.
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Fit the lock cylinder by pushing in the lock cylinder and turning it clockwise.
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7.
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Tighten the rear upper nut on the handle and lock cylinder.
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8.
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Cars with guard
: Fit the guard in the door. Make sure the handle's rod comes in front of the guard. Lift up the cover at the rear edge so that it is placed between the lock cylinder and the window's U-strip.
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9.
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Cars with guard
: Insert the lock unit bolts and the guard bolt.
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10.
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Cars with guard
: Tighten the bolts.
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11.
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Cars up to and including Vehicle Identification Number 31030983
: Fit the rod to the clip. Lift in the clip and hold the rod down at the same time as fitting the lock cover in order to eliminate play.
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12.
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Cars from and including Vehicle Identification Number 31030984
: Fit the rod in the clip. Close the lock cover to the clip.
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13.
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Check the function of the handle and lock.
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14.
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Fit the water barrier and the door trim, see WIS - 9-3 M03 - Body - Interior equipment - Adjustment/Replacement - Door trim, front, 4D.
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To remove, door handle, rear
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1.
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The window must be closed. Remove the door trim, in accordance with WIS - 9-3 (9440) M03 - Body - Interior equipment - Door trim, rear
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2.
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Bend the water barrier down slightly. Detach it using 82 93 474 Removal tool.
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3.
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Remove the lock's bolts.
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5.
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Remove the clips for the lock cable and the wiring harness.
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6.
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Cars up to and including Vehicle Identification Number 31030983
: Detach the lock cover from the handle's rod.
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7.
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Cars from and including Vehicle Identification Number 31030984
: Detach the lock cover from the handle's rod.
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8.
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Detach the handle's rod from the clip. Lower the lock unit slightly to access the handle's nuts.
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9.
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Remove the nuts from the handle. Take care not to drop any of the nuts.
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10.
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Lift out the handle by:
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10.A.
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Pull out the lower edge of the handle so that the studs release.
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10.B.
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Pull downward to draw out the handle's counterweight.
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10.C.
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Now lift upwards to draw the handle's rod out from the hole.
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To fit, door handle, rear
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1.
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Check the handle's gasket, that it is intact and located correctly.
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2.A.
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Insert the handle's rod in the door.
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2.B.
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Angle in the handle's counterweight.
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2.C.
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Angle in the handle's lower edge and insert the studs in the holes.
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3.
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Fit the handle's nuts.
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4.
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Position the lock. Fit the lock's bolts.
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5.
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Cars up to and including Vehicle Identification Number 31030983
: Fit the rod to the clip. Lift in the clip and hold the rod down at the same time as fitting the lock cover in order to eliminate play.
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6.
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Cars from and including Vehicle Identification Number 31030984
: Fit the rod in the clip. Close the lock cover to the clip.
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7.
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Fit the clips for the wiring harness and the lock cable.
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8.
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Check the function of the handle.
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10.
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Fit the water barrier and the door trim, see WIS - 9-3 M03 - Body - Interior equipment - Adjustment/Replacement - Door trim, rear.
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11.
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Cars with pinch protection
: Carry out calibration of pinch protection, see WIS - 9-3 M03 - Body - Doors and locks - Adjustment/Replacement - Calibration of pinch protection.
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Warranty/Time Information
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In the case of customer complaint and if the car is
within the warranty period
, use the following information to fill out the claim:
Both rear doors
Failed Object: 834 40
Fault/Reason code: 86
Location code: 09 (US=9)
Warranty Type (US): 01
Repair/Action code: 01
Labour Operation (US): 8344002
Labour Operation (CA): B4520
Time: 0.7 hr
Both front doors
Failed Object: 834 41
Fault/Reason code: 86
Location code: 09 (US=9)
Warranty Type (US): 01
Repair/Action code: 01
Labour Operation (US): 8344106
Labour Operation (CA): B4120
Time: 0.8 hr
