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2004 Saab 9-5 Aero

Factory specifications, fluid capacities, torque values, EPA fuel economy and the federal safety record for the 2004 9-5 Aero.

Body PASSENGER CARTransmission Automatic (S5)

The 2004 Saab 9-5 Aero is a passenger car equipped with a five-speed automatic transmission and EPA fuel economy ratings of 17 mpg city, 26 mpg highway, and 20 mpg combined, positioning it as a mid-size offering that balances turbocharged performance intent with everyday usability. With 19 owner complaints on record, the top issue area is the electrical system, and the model year carries two recalls, placing it in a middling-to-cautious zone of the 9-5's reliability history where buyers should expect to scrutinize wiring and module integrity more closely than mechanical components.

Model year2008 2005 2004 2003 2002

Quick specs

Fluid capacities, tune-up values and fuel economy at a glance.

Lug nut torque80 ft-lbsOEM · verified

EPA fuel economy17/26/20 mpgEPA · verified

Fitment & sizes

Replacement part sizes and factory part numbers — battery, bulbs, filters and belts.

From the factory this vehicle uses a BCI 48 · 700 CCA battery, OE oil filter 93186554. Each part links to every other vehicle that shares it, so a part you already stock may fit more of your fleet than you'd expect.

Battery groupBCI 48 · 700 CCAOEM · verified

Tire sizeP215-55HR16OEM · verified

Wheel / rim6.5 inOEM · verified

OE service part numbers OEM · verified

Engine oil filter	93186554
Engine air filter	55560911
Fuel filter	4163853
Spark plug	9399866 alt 9117565
Battery	12827676
Front wiper blades	93196006 alt 93196007
Serpentine belt	4899548 alt 55563222
Thermostat	30577561 alt 9176165
Cabin air filter	32020155

Full specifications

Engine, drivetrain, dimensions and economy.

Engine & drivetrain NHTSA vPIC

Transmission

Automatic (S5)

Dimensions & weight NHTSA vPIC

Overall length	189.4 in
Overall width	70.5 in
Overall height	57.1 in
Wheelbase	106.3 in
Curb weight	2855 lb
Track (front / rear)	59.8 / 59.8 in
Weight distribution (front / rear)	59/41

Ratings & economy EPA / vPIC

EPA city / highway / combined	17 / 26 / 20 mpg
Drivetrain	Front-Wheel Drive
Passenger volume	96 cu ft
Cargo volume	16 cu ft
Recommended fuel	Regular Gasoline

Service quick specs OEM factory data

Capacities, torques and tune-up values from the factory service manual.

Torque lug nuts to 80 ft-lbs, the oil drain plug to 19.0 ft-lbs. The firing order is 1-3-4-2. Note the cylinder-head bolts finish on a torque angle (torque-to-yield) — they stretch permanently and should be replaced, not reused, during any head service.

Lubricants & capacities

Engine Coolant	DEXCOOL OR EQUIVALENT
Power Steering Fluid	USE PENTOSIN CHF11S OR EQUIVALENT

Engine torques

Crankshaft Pulley and/or Damper Bolts	130 ft-lbs
Engine Flywheel Bolts	AT: 70 ft-lbs, MT: 59 ft-lbs
Engine Oil Pan Drain Plug	19.0 ft-lbs
Oil Pump to Cylinder BLock Bolts/Studs	17 ft-lbs

Chassis torques

Lug Nuts	80 ft-lbs
Front Wheel Hub	215 ft-lbs

Ignition

Cylinder Firing Order	1-3-4-2
Curb Idle Speed (No Load)	825 rpm
Spark Plug Gap	0.039 in
Spark Plug Torque	18.0 ft-lbs

Battery & A/C

Refrigerant	R134a
Refrigerant Capacity	1.93 lbs
Oil Group	PAG
Oil Capacity	4.90 oz
Standard BCI Group Number	48
Standard BCI Cranking Performance	700 cca

Service checks

Pressure Test	20-22 psi
Radiator Cap Pressure Relief	20-22 psi
Thermostat Opening Temperature	192 °F
Regulated Fuel System Pressure (Without Vacuum)	43.0 psi
Regulated Fuel System Pressure (With Vacuum)	33.0 psi
Injector Primary Resistance	15.9 @ 68 degreesF ohms

Brakes

Torque Caliper to Bracket	21 ft-lbs
Minimum Pad Thickness	Front: 0.039; Rear: 0.039 in
Rotor Max Parallel Variation	0.0006 in
Rotor Runout Limit	0.003 in
Rotor Minimum Machining	0.984 in / 0.39 in
Rotor Discard at or Under	0.925 in / 0.33 in
Rotor Finish	0.87 μin / 0.32 μin

Multi-step torque procedures OEM · verified

Connecting Rod (Large End) Bearings — tightening sequence 1 stages

15 ft. lbs., Step 2: 70

15 ft. lbs

Cylinder Head — tightening sequence 3 stages

Prep M12 Bolts

1	29.5 ft. lbs.	29.5 ft. lbs
2	44.0 ft. lbs.	44 ft. lbs
3	90 degrees; M8 Bolts	90 degrees
1	16.0 ft. lbs.	16 ft. lbs

Main Bearings — tightening sequence 1 stages

15 ft. lbs., Step 2: 70

15 ft. lbs

Factory maintenance schedule OEM · verified

Normal service, condensed from the factory interval matrix.

Under the factory schedule, replace the spark plugs every 30,000 mi.

Every 6,000 mi	Engine Coolant System (leak inspection)
Every 15,000 mi	Accessory Drive Belt (inspect) · Air Bag System (inspect) · Battery (inspect) · Body Latches, Locks & Hinges (inspect) · Brake Hydraulic System (inspect fluid level) · Brake Line (inspect)
At 30,000 mi	Accessory Drive Belt (inspect) · Air Bag System (inspect) · Brake Hydraulic System (inspect fluid level) · Brake Line (inspect) · Brake Linings (inspect) · Cabin Air Filter (replace)
Every 30,000 mi	Spark Plugs (replace) · Transmission Assembly (inspect)
Every 60,000 mi	Fuel Filter (replace)

Reliability & federal safety record

Owner-reported issues, recalls, investigations and service bulletins on record with NHTSA — an unfiltered look at what owners actually experience.

Owner complaints about the 2004 Saab 9-5 Aero dominate in one area — the electrical system, 8 of 19 reports (42%), well ahead of the next concern. None of this vehicle's 2 recall campaigns target the electrical system, so those reports read as owner-reported wear-and-tear rather than an acknowledged defect. 1 of the reports describe a crash and 1 a fire — a small share of the total, but worth weighing against the electrical system pattern above. These are tallies of what owners actually reported to the federal government, not an editorial score — and higher-selling models naturally rack up more reports.

Open recalls

NHTSA campaigns

Service bulletins

Manufacturer communications

ODI investigations

Office of Defects Investigation

Owner complaints

1 involved a crash · 1 a fire

NHTSA crash-test rating federal NCAP · out of 5 stars

Rollover★★★★★

Owner complaints filed with NHTSA, by component

All 19 complaints on record, top 8 components.

Electrical System8

Tires2

Structure2

Electrical System,Engine,Fuel/Propulsion System1

Air Bags1

Steering,Electrical System,Engine1

Power Train,Electrical System,Fuel/Propulsion System1

Service Brakes, Hydraulic,Engine & Engine Cooling,Electrical System,Exterior Lighting1

Source: NHTSA Office of Defects Investigation complaint database.

Recalls NHTSA · verified

Showing 2 of 2 campaigns on record for this vehicle.

07V087000Fuel System, Gasoline:Delivery:Hoses, Lines/Piping, And FittingsReported 07/03/2007

ON CERTAIN PASSENGER VEHICLES, THE FUEL PUMP RETAINING TABS HOLDING THE FUEL LINES WERE DAMAGED DURING PRODUCTION. Remedy: DEALERS WILL DEVELOP A SECURING BRACKET THAT WILL SECURE THE FUEL LINES TO THE FUEL PUMP EVEN IF THE PLASTIC RETAINING TABS SHOULD BREAK. THE RECALL BEGAN ON JUNE 13, 2007. THIS…

08V160000Seats:Front Assembly:Head RestraintReported 09/04/2008

SAAB IS RECALLING 57,389 MY 2002-2008 9-5 SERIES VEHICLES FOR FAILING TO COMPLY WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 201, "OCCUPANT PROTECTION IN INTERIOR IMPACT." DURING COMPLIANCE… Remedy: DEALERS WILL INSTALL A-PILLAR TRIM WITH IMPROVED ENERGY-ABSORBING CAPABILITY FREE OF CHARGE. THE RECALL BEGAN ON NOVEMBER 25, 2008. OWNERS MAY CONTACT SAAB AT 1-800-955-9007.

Technical service bulletins NHTSA · verified

Showing 5 of 83 bulletins on record with NHTSA.

Bulletin	Date	Component	Summary
PIP5601C	2025-07-18	Unknown Or Other	This PI communicates the requirement to provide a pico file to receive diagnostic…
PIT3271P	2024-09-06	Unknown Or Other	This Preliminary Information communication provides information to the technician about…
General Communication	2024-08-26	Electrical System	Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It…
18-NA-099	2024-06-17	Unknown Or Other	This bulletin provides information for use on a Product Assistance Claim (PAC), which is…
24-NA-098	2024-06-06	Electrical System	This service bulletin provides information for dealers/technicians on Service Programming…

Common OBD-II trouble codes

The most common OBD-II codes for this vehicle's emissions system. These are standardized SAE J2012 definitions, not vehicle-specific fault reports.

P0420

Catalyst system efficiency below threshold — Bank 1

P0300

Random / multiple cylinder misfire detected

P0171

System too lean — Bank 1

P0455

Evaporative emission system leak detected — large leak

P0128

Coolant thermostat below regulating temperature

P0442

Evaporative emission system leak detected — small leak

VIN tools

Decode factory build data for a specific vehicle by VIN.

VIN

Decode a VIN to confirm the transmission and build data for a specific 9-5 Aero. OEM

Build data

Plant, GVWR class, engine and body data for any 17-character VIN.

Recalls

Check open recall campaigns against a specific vehicle by VIN.

Vehicles with shared specs

Find every vehicle that shares this one's battery, bulbs, oil capacity, platform or parts.

Group 48 battery Engine oil filter 93186554 Engine air filter 55560911 Fuel filter 4163853 Spark plug 9399866

Reference guides

Cross-vehicle references for the kinds of data on this page.

Vehicle recalls & TSBs OBD-II trouble codes Torque specifications Maintenance schedules Fluid capacities & specs

Frequently asked

Does the 2004 9-5 Aero have open recalls?

NHTSA lists 2 recall campaign(s) for this model year. Check your specific vehicle by VIN.

What gas mileage does the 9-5 Aero get?

EPA figures are 17 city / 26 highway / 20 combined mpg.