The last 9-5 sedan of the first generation rolled off the Trollhättan production line at the beginning of July 2009, and the last wagon was assembled on February 1, 2010. Between the summer of 1997, when 9-5 production began, and 2010, 252,236 sedans, and 231,357 wagons were built. The total production 483,593 units, was narrowly beaten by its predecessor, the 9000, of which 503,000 were built.
Production equipment for the first-generation 9-5 was sold by General Motors to BAIC of China in 2009.
The first-generation 9-5 was powered by Saab's B205 and B235 straight-4 engines, and from 2002 in Europe by an Opel Ecotec X22DTH 2.2 diesel engine (Saab D223L), replaced in 2006 by Fiat's 1.9 JTD 16V diesel straight-4. A turbocharged version of the GM 54° V6 engine, designated by Saab as B308, had a unique asymmetrical low-pressure turbocharger and was available from 1999 to 2003. This engine was available only with an automatic transmission, and cars with this engine installed are distinguishable by their twin tailpipes. The V6 was only available on Arc, SE, and Griffin models. In 2004, the V6 engine was replaced by a high pressure turbo straight-4 engine producing 220 hp (160 kW). By 2006 this engine was producing 260 hp (190 kW) even in the non-Aero or non-sport models (US models).
The B205 & B235-based 9-5 models have suffered a high rate of engine failures due to engine oil sludge. This primarily affected the 1999–2003 models. Saab refined the engine's positive crankcase ventilation system (PCV) for the 2004 and later model years and required use of fully synthetic oil, virtually eliminating the problem. Additionally, SAAB created update kits to retrofit to the 1999–2003 cars since they cannot be easily modified to accept the 2004 and later system. Mounting complaints by 9-5 owners forced GM to offer an eight-year warranty on the engine in 4-cylinder models for original owners, provided the owner can produce proof that they followed the manufacturer's oil change intervals. Saab recommended the use of fully synthetic or synthetic-blend oil as a preventative measure.
The 9-5 was available with an Aisin AW 4-speed (50-42LE) automatic transmission saab reference FA47; from 1997 until 2001, when a new Aisin AW unit replaced the dated four-speed automatic with a five-speed automatic. A five-speed manual transmission is fitted as standard to the base models and the Aero. Six-speed manual transmission was not offered in first-generation 9-5s.
In 2005, an updated version of the 2.0 L turbocharged I4 was introduced in the European market together with the 2006 9-5. The engine was sold as 2.0T BioPower, optimized to run on E85 producing 132 kW (180 hp) at 5500 rpm. There was also a 2.3T BioPower version sold from 2007. It was also introduced in Australia.
There is a Saab 9-5 E100 Concept, based on the turbo 2.0.
The 9-5 introduced Saab's Active Head Restraints (SAHR), which moved up and forward to prevent whiplash when the car was struck from the rear. This feature won technology and safety awards in Australia, Denmark, and the United Kingdom. The Saab 9-5 also was one of the first cars to have extensive side-crash protection.
The front seats featured torso airbags and head airbags even on the earliest models, which few contemporary vehicles did in the late 1990s. The basic structure included a robust passenger safety cage, front and rear deformation zones, reinforced door posts and pillars, as well as the "Pendulum B-Pillar", which combined high-strength low-alloy steel at chest and head height with tailored blank steel at the floorpan, designed to direct the crash forces down toward the floor. The design was proven by the Insurance Institute for Highway Safety (IIHS) to protect occupants in side crashes, even without the addition of curtain airbags or rear side airbags. From 2002, ESP (electronic stability control) was included as standard.
Another Saab feature, the "Night Panel", permitted dousing of the instrument panel lighting, except for essential information, for less distraction when driving at night. Once activated, only essential information such as current speed is displayed except, for example, if the car requires fuel or the engine overheats.
In the United States OnStar was available, and provided as standard equipment in selected 9-5's from 2001 onward.
The 9-5 had various comfort features both as standard and cost options over the years.
While early models frequently had dash mounted cassette decks, CD changers were standard features on many cars and in-dash satellite navigation was also available. Factory-fitted phone kits were similarly optional.
Many models featured leather or part-leather upholstery and both front and rear heated seats were also available. A few models were shipped with the optional ventilated seats.
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