Saab 9000 Service Manual Download Page 241

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Summary of Contents for 9000

Page 1: ......

Page 2: ...tains descriptions of the Trionic 08D II engine management system for model year 1996 Saab 9000 cars The manual is intended for use as a service manual and also as a workbook in connec tion with the t...

Page 3: ...Important Points out the risk of minor damage to the car and also warns the mechanic of difficulties and time wasting mistakes Note Hints and tips on how the work can be done in a way that saves time...

Page 4: ...air temperature sensor 3 Engine coolant temperature sensor 4 Spark plugs _ 7 Idle air control valve 7 Throttle position sensor 4 Boost pressure control valve 8 Front heated oxygen sensor before three...

Page 5: ...round output pin Nos 67 Reference ground engine coolant pin Nos 66 temperature sensor Reference ground front and rear pin Nos 47 heated oxygen sensors Crankshaft position sensor Location Mounted in cr...

Page 6: ...olutepressure i e 100kPa correspondsto barometricpressure Whencheckingthepressuresensorusingapressure vacuumpump somewhatlower voltagereadingsmaybe obtainedat high altitudes Powersupply 5 V kOhm Intak...

Page 7: ...670 approx 0 9 80 176 0 295 0 365 approx 0 54 90 194 0 24 0 26 approx 0 41 110 230 0 14 0 16 approx 0 26 Power supply 5 V through a 2 74 kohm resistor in the control module Throttle position sensor k...

Page 8: ...Pins 3 and 4 are gold plated Bosch LSH25P with electric heating Watts 18 V 0 1 Ohms 2 0 0 5 PTC 0 2 V 0 8 0 6 0 4 0 2 0 _____ ___ _______ ______ 0 80 0 90 1 00 1 10 1 20 Rear heated oxygen sensor afte...

Page 9: ...Maximum permissible difference be tween injectors Ignition discharge module Number of pins Power supply Capacitor voltage lgn tionvoltage max Firing order Ionization voltage Bosch EV1 3E red 4 hole Oh...

Page 10: ...7ES Electrode gap mm in 1 0 0 1 0 0 0 0394 0 00394 0 0 Tightening torque Nm lbf ft 27 20 Idle air control valve Number of windings 1 Winding resistance at 20 c 68 F Ohms 7 7 1 Control voltage PWM 12 V...

Page 11: ...ar Y Basic boost pressure 0 45 0 03 bar y 2 Ohms al 3 PWM 12V 90 Hz PWM 12V 70 Hz Boost pressure bar Gear Ii 1 1 Ii 2 5 X X X X X 0 90 0 49 0 70 y i 0 91 I All versions have basic boost pressure when...

Page 12: ...ressure air side Fuel pum p Capacity at 3 0 bar counterpressure Resistance level sensor Tightening torque screw top Technical data 9 bar 3 0 0 1 connected to intake manifold ml 30s min 700 Ohms 25 370...

Page 13: ...1O Technical data Saab9000...

Page 14: ...70 pin for Saab Trionic BOB 86 11436 ISAT scan tool adapter SDA II 86 11352 Test cable for pin connection 2 sets 4 male pins 86 11410 Test cable for pin connection 2 sets 4 female sockets 86 11386 Te...

Page 15: ...Jumper cable 83 92 912 Sealing pliers 83 94 538 Removal fitting tool for locking ring on turbo unit s operating arm 83 93 514 Pressure gauge 86 10 867 Cable for grounding spark plugs 45 30 14 883 Pres...

Page 16: ...87 91 980 Adjusting tool kick down wire 83 94 405 Test hose fuel flow co IO C I I C I u Special tools 13 I Saab 9000...

Page 17: ...14 Special tools Saab 9000...

Page 18: ...atalyst damaging misfire 66 Ground 29 Fault handling II fuel system Crankshaft position sensor 30 emission related misfire 68 Manifold absolute pressure sensor 31 Intake air temperature sensor 32 Engi...

Page 19: ...16 Technical Description Saab Trionic system overview Saab Trionic engine management system Saab 9000...

Page 20: ...rs or gold plated pins Saab 9000 Service Manual 2 7 EngineManagementSystem Trlonlc080 II M 1996 The Saab Trionic ignition system consists of an igni tion discharge module with four ignition coils one...

Page 21: ...olute pressure sensor 4 Intake air temperature sensor 5 Temperature sensor engine coolant 6 Throttle position sensor 4 l t 5 6 9 Vi 7 Front heated oxygen sensor before three way catalytic converter 8...

Page 22: ...gnals from the crankshaft position sensor the system has sufficiently reliable informa tion for synchronizing spark generation and fuel in jection to the correct cylinder To improve starting performan...

Page 23: ...is occurring in any of the cylinders by analyzing the ion ization currents passing through the spark plugs If knocking occurs ignition is retarded In the event of substantial ignition retardation or...

Page 24: ...cking if any throttle position Technical Description 21 0 b Pre injection As soon as the engine starts to rotate and the elec tronic control module receives pulses from the crank shaft position sensor...

Page 25: ...rolling a solenoid valve which is connected to the turbo wastegate Actual boost pressure is ascertained by the pressure sensor Target boost pressure is calculated by the engine control module mainly o...

Page 26: ...ine These changes may be wear in the engine dirt or leaks in the intake manifold or throttle body The engine control module is programmed to main tain idling speed constant at 850 50 rpm when the engi...

Page 27: ...page 33 8 Throttle position sensor see page 34 9 Front heated oxygen sensor before three way catalytic converter see page 44 10 Rear heated oxygen sensor after three way cata lytic converter see page...

Page 28: ...nsor see page 31 6 Ignition discharge module see page 35 7 Injectors see page 41 8 Boost pressure control valve see page 52 9 Idle air control valve see page 54 10 EVAP canister purge valve see page 5...

Page 29: ...iring are withdrawn through the bulkhead partition The ECM has a 32 bit processor which can perform 2 million calculations per second A number of sensors supply the ECM with informa tion The ECM proce...

Page 30: ...d absolute pressure sensor There are substitute functions for all sensors apart from the crankshaft position sensor When the ignition is switched off ail the sensors sup plied with 5 V are activated f...

Page 31: ...in 60 of the Trionic control module Applying power 15 circuit to pin 60 activates the engine control module The engine will not start unless power is supplied via the 15 circuit 289 15 r 1f159 I 01 l_...

Page 32: ...e control module The leads connected to the crankshaft position sen sor and the leads from the oxygen sensors are also screened via pin 67 of the engine control module The engine will not start withou...

Page 33: ...or va ries with engine speed During idling the voltage is 7 10 V AC and at 2500 rpm it is approx 15 20 V AC However it isthe frequency and not the voltage which is of interest to the ECM The ECM chief...

Page 34: ...oltage to ECM pin 22 The ECM uses pressure and temperature in the in take manifold to calculate the engine load i e how great an air mass each cylinder draws in The fuel in jection time is proportiona...

Page 35: ...The sensor is grounded via pin 67 The volt age across the resistor in the control module is pro portional to the temperature of the intake air In combination with the pressure in the intake man ifold...

Page 36: ...precise temperature measurement The voltage across the resistor in the ECM is proportional to the coolant temperature The voltage is used to determine fuel injection dura tion for pre injection as wel...

Page 37: ...o identify idling partly open throttle and wide open throttle During idling the ECM uses a special ignition control matrix and adjusts the idling speed The closed loop is disconnected at wide open thr...

Page 38: ...it This voltage 400 V is connected to one pole of the primary windings of the 4 ignition coils Four trigger leads are connected to the ignition dis charge module from Trionic ECM pin 9 cyl 1 pin 10 c...

Page 39: ...0 rpm A special ignition control curve is used at idling speed Normal ignition advance is about 0 8 de pending on the engine version If engine speed drops as may happen when the ra diator fan cuts in...

Page 40: ...dead centre This is done as follows One of the poles of the secondary windings of the 4 ignition coils is connected in the usual manner to the spark plugs The other pole is not connected directly to g...

Page 41: ...e control module knows that cylinder 1 has fired When the engine is started the ECM does not know which of cylinders 1 and 4 is in the compression posi tion and ignition consequently takes place on bo...

Page 42: ...vent of persistent knocking the timing will be retarded additionally but not more than a maximum of 12 If ignition timing is retarded by more than a certain amount on all cylinders the quantity of fue...

Page 43: ...turned off and the engine has stopped the main relay remains acti vated for a further 6 seconds The Trionic ECM then grounds all the trigger leads 210 times per second for 5 seconds Each electrode gap...

Page 44: ...y precisely set two jets on each intake valve This makes the fixing of the injectors very important To ensure that this is done properly the injectors are fixed in pairs in special mounts be tween cyl...

Page 45: ...as begun to rotate coolant tempera ture dependent fuel injection takes place through the 4 injectors simultaneously This enables short start ing times to be achieved If the engine is started and short...

Page 46: ...ans of the front heated oxygen sensor fuel in jection time is corrected so that Lambda 1 0 is ob tained The closed loop is disconnected during heavy acceleration and full load enrichment is activated...

Page 47: ...is connected to pin 23 of the engine con trol module and grounded via pin 47 The engine s exhaust gases pass the oxygen sensor and their oxygen content is measured through a chemical reaction The out...

Page 48: ...y via fuse 28 and grounded via pin 50 of the engine control module The engine control module estimates the temperature of the ex haust gases on the basis of load and engine speed Preheating is disconn...

Page 49: ...dependent on pressure and engine speed It is obtained from the main fuel matrix and must be used to correct the fuel injection duration because the volumetric efficiency of the en gine changes with en...

Page 50: ...is by changing the correction factor for the relevant engine speed and load point in the main fuel matrix so that the re sult will be a fuel injection time of 9 ms In this exam ple the new correction...

Page 51: ...unning within defined load and rpm limits 60 120 kPa and 2000 3000 rpm no point adaptation will take place All points in the fuel matrix are corrected instead This is called global adaptation Inother...

Page 52: ...erature drops below 50 C 122 F and when the estimated exhaust temperature is high To improve exhaust emissions still further the value from the sensor is used to correct the closed loop The most favou...

Page 53: ...f takes place after acer tain delay about a second or so The injectors are re activated when engine speed drops below 1400 rpm Fuel consumption The control module emits a fuel consumption signal from...

Page 54: ...a risk of damage to the engine as a sufficiently low pressure is not achieved in connection with knock control Technical _Description 51 Basic boost pressure should be 0 45 0 03 bar for the R engine...

Page 55: ...justs the boost pressure by alternately grounding pins 26 and 2 As a result of grounding pin 2 a longer time than pin 26 the boost pressure is re duced and conversely the boost pressure is in creased...

Page 56: ...tic transmission Cars with au tomatic transmission have reduced boost pressure Brake light switch When the brake pedal is depressed current B is supplied to the electronic control module on pin 15 and...

Page 57: ...single coil is supplied with current from the main relay The valve is controlled by a 500 Hz PWM signal from pin 49 of the control module The longer the control module keeps pin 49 grounded the wider...

Page 58: ...alve mounted on the vacuum hose between th evapora tive emission canister and intake manifold after the throttle The valve is supplied with current from the main relay and controlled from pin 27 of th...

Page 59: ...31 The relay operates when this pin is grounded If the ignition has been switched off for more than 15 minutes the main relay will operate for 6 seconds when the ignition switch is turned to the ON p...

Page 60: ...l module Grounding pin 56 causes the relay to operate If the ignition has been switched off for longer than 15 minutes the fuel pump relay will operate for 2 se conds when the ignition switch is turne...

Page 61: ...ied to pin 59 of the Trionic control module via the EDU antifrost thermostat and pressure switch The control module then opens the idle air control valve slightly wider to prepare for the forthcoming...

Page 62: ...gnal is used to Ascertain which gear is engaged at the time Activate the SHIFT UP lamp Limit boost pressure in 1st gear all turbo versions except B234E Activate speed limitation by limiting boost pres...

Page 63: ...ool via pin 33 Communication is two way and thus involves both input and output signals The ISAT scan tool can communicate with the Trionic system with the ignition switched on and the engine running...

Page 64: ...t from the 15 circuit It is controlled from pin 32 of the control module and lights up when the igni tion is switched on As soon as the engine control module receives pulses from the crankshaft positi...

Page 65: ...gine control mod ule and tested for 3 seconds when the ignition is switched on A combination of light engine load and high engine revs when the car is being driven will cause the lamp to light up This...

Page 66: ...to compensate for the increase in load Pin 14 is not used on cars with a manual gearbox If a gear position other than P or N is selected the ignition timing will also be temporarily retarded de pendi...

Page 67: ...l in the tank drops below 10 litres the low fuel level lamp in the main instrument display panel lights up At the same time the EDU grounds pin 38 of the Trionic control module This function is used s...

Page 68: ...gnostic II have been monitored Driving a trip see page87 Driving cycle Starting the engine Warm up cycle Starting the engine and then raising engine tempera ture by at least 22 c 40 F to at least 71 c...

Page 69: ...t diagnosis a special code is gener ated at the same time if there is less than 1Olitres of fuel in the tank For the CHECK ENGINE lamp MIL to go out by it self 3 consecutive driving cycles carried out...

Page 70: ...sfire stops CHECK ENGINE light on steady Catalyst damaging misfire does not occur in 3 con secutive driving cycles with similar conditions as when the fault first oc curred CHECK ENGINE light off E C...

Page 71: ...vel that may also have been generated 1 driving cycle carried out under the same conditions as when the fault first occurred or 80 driving cycles without the fault recurring must be completed The CHEC...

Page 72: ...Fault does not occur in 3 consecutive driving cycles with similar conditions as when the fault first oc curred CHECK ENGINE light off E OTC ON 80 OCY 1 E Yes l C E ON 30CY OK C E OFF 1 OCY OK OTC OFF...

Page 73: ...For the diagnostic trouble code to be cleared without further action 40 faultless warm upcycles must be c0mpleted For the CHECK ENGINE lamp MIL to go out by it self 3 consecutive driving cycles must...

Page 74: ...light on Fault does not occur in 3 consecutive driving cycles CHECK ENGINE light off E OTC ON E DCY1 u C E ON 3DCY OK C E OFF f c 40WUC OK Technical Description Fault does not occur in 40 warm up cyc...

Page 75: ...gine load and speed dependent matrix in the electronic control module s memory specifies how many misfires per 200 engine revolutions will dama ge the three way catalytic converter 1 2 34 34 34 34 Whe...

Page 76: ...kPa Yes Saab 9000 Technical Description No Combustion signals from the ignitioncassette during 200 crankshaft revolu tions Number of detected mis fires max number of misfires allowed during 200 cranks...

Page 77: ...rol module s memory specifies how ma ny misfires per 1 000 engine revolutions are neededfor exhaust emissions to reach an illegal level 1 2 1 2 2 When the condit1ons for diagnosis are fulfilled the co...

Page 78: ...kPa Yes E Saab9000 Technical Description 75 No Combustion signals from I the ignition cassette during 1000 crankshaft revolu tions Number of detected mis fires m axnumber of misfires allowed during 10...

Page 79: ...diagnosis are fulfilled and the closed loop has been inthe end position for more than 20 se conds Conditions for closed loop diagnosis Engine running Coolant temperature above 60 C 140 F Closed loop...

Page 80: ...25 for 20 s Fault criteria for short term fuel trim fulfilled Short term fuel trim 25 for 20 s Global adaption 100 Fault criteria for long term fuel trim fulfilled Global adaptation 100 Technical Desc...

Page 81: ...mory A EVAPo o ____ 2 5 6 7 3 __ _ ___ Purging starts and the pulse ratio is increased until a sufficient change in the closed loop or idle speed control can be observed If no change is large enough i...

Page 82: ...d increase flow Short term fuel trim de creases 6 or idle air control decreases 1 Stop purge Function monitored this trip Resume to ordinary purge No Yes 2 3 4 5 Yes 7 9 6 7 No 8 Yes E Saab 9000 Techn...

Page 83: ...ngine revolutions is counted If the number exceeds 14 the diagnosis is OK If the number of transitions is less than 14 two addi tional attempts to obtain a diagnosis OK result this trip will be made I...

Page 84: ...ransitions in 250 crankshaft revolu tions Function monitored this trip No Yes Yes Technical Description 81 No Next event enable criteria are fulfilled during this trip Third attempt to pass test _____...

Page 85: ...he sensor is defective If sensor voltage does not change by more than 0 5 V and does not exceed 0 4 Vin 500 seconds the fault criteria are satisfied V 0 8 0 6 0 4 0 2 0 0 In other respects the sensor...

Page 86: ...or voltage time SensorVoltage 0 4 V and sensor voltage change O SVin 500s Function monitored this trip No Yes Saab 9000 E Technical Description Fault criteria for oxygen sensor 2 activity diagnose ful...

Page 87: ...tive The voltage changes emanating from the rear hea ted oxygen sensor are corrected in regard to engine load and speed and totalled in 50 individual appro ved periods for the front heated oxygen sens...

Page 88: ...oltage fluctuations are registered Correct voltage fluctua tions on basis of load and rpm Add voltage fluctuations in a memory Voltage fluctuations from 50 periods added togeth er Total below threshol...

Page 89: ...ion discharge module Camshaft position sensor signal from ignition dis charge module Crankshaft position sensor Vehicle speed Battery voltage Brake light switch Outputs EVAP canister purge valve Idle...

Page 90: ...ll be warranted Any faults can be revealed afterwards by requesting a DTC readout When a trip has been made all conditions for On Board Diagnostic II have been fulfilled one by one in the right order...

Page 91: ...oxygen sensor and evaporative emission system Stop the car run the engine at idling speed and proceed as follows select Neutral or Park and apply the handbra ke turn off the A C ACC select ECON do no...

Page 92: ...stic trouble codes Diagnostic trouble code table Saab Trionic 90 92 95 96 Fault diagnosis with fault symptoms 213 Fault diagnosis components 239 Test readings control module connections 276 Before rep...

Page 93: ...CTIVATE INJECTORS IGNITION COILS BOOST PRESS VALVE IACVALVE EVAPVALVE O2S 1 PREHEATING O2S 2 PREHEATING AC RELAY CHECK ENGINE LAMP SHIFT UP LAMP PUMP RELAY MAIN RELAY IDL INGADAPTATION BOOST PRESS RES...

Page 94: ...ange of measurement 40 C 127 C Present intake pressure Range of measurement 0 255kPa Present throttle position as percentage of 5 V Range of measurement 0 100 Internal Trionic status indicating presen...

Page 95: ...FF 12 V MAIN RELAY ON0V OFF 12 V KNOCK CONTROL YES NO IDLE POSITION YES NO Function Input from reversing light switch See Test readings control module con nections pin 13 Input signal from gear select...

Page 96: ...econds at a frequency of 90 Hz The idle air control valve is activated for 10 seconds with a current of 0 6 A The EVAP canister purge valve is activated for 10 seconds at a frequency of 8 Hz The oxyge...

Page 97: ...XXX XXXX PROGRAM VERSION XXX XXXX ENGINE TYPE XX XXX XXXX X SERIAL NUMBER XXX XXXX Function Part number of the Trionic control module Trionic control module program version The Trionic control module...

Page 98: ...141 132 Diagnostic trouble codes P0170 P0171 P0172 136 Diagnostic trouble code P0300 140 Diagnostic trouble codes P0301 P0302 P0303 P0304 148 Diagnostic trouble code P0327 Diagnostic trouble code P033...

Page 99: ...XX P0108 INTAKE PRESSURE OPEN CIRCUIT SHORTING TO B FAULT XX P0110 INTAKE AIR TEMP FUNCTION INCORRECT FAULT XX P0112 INTAKE AIR TEMP SHORT TO GROUND FAULT XX P0113 INTAKE AIR TEMP OPEN CIRCUIT SHORTI...

Page 100: ...xygen sensor Current outside limits Rear heated oxygen sensor All em bracing diagnostic trouble code for oxy gen sensor operation Rear heated oxygen sensor Shorting to battery positive B Rear heated o...

Page 101: ...4 MISFIRING CYLINDER 4 FAULTXXP0327 KNOCK SENSOR OPEN CIRCUIT SHORTING TO B GROUND on FAULTXXP0335 CRANKSHAFT POS SENS FUNCTION INCORRECT P0340 Camshaft positive sensor Malfunction on FAULTXXP0340 P04...

Page 102: ...506 IDLE POSITION ENGINE RPM LOW FAULTXX P0507 IDLE POSITION ENGINE RPM HIGH 188 188 188 c c P0605 Control module Internal fault program fault P1170 Closed loop Malfunction P1171 Closed loop Lean mixt...

Page 103: ...changes P0107 Ignition switch in the ON position 10 kPa for 2 seconds at wide throttle opening P0108 Ignition switch in the ON position 245 kPa for 2 seconds at slight throttle opening 589 2243 67 Di...

Page 104: ...ntinue with point 2 INO 1 Rectify the fault and proceed to point 4 2 Check the pressure sensor s ground connec tion and power supply Turn the ignition switch to the ON position and then back to the OF...

Page 105: ...osition Unplug the pressure sensor s 3 pin connector Connect an ISAT scan tool Select READ FUNCTIONS Select INTAKEPRESSURE The ISAT scan tool reading should be 255 kPa Connect a jumper lead between pi...

Page 106: ...Implementation of driving cycle Drive the car at varying loads and engine rpm for 5 minutes Evaluation of the driving cycle Check whether the diagnostic trouble code has recurred Has the diagnostic t...

Page 107: ...Ignition switch in the ON position 4 96 V for 5 seconds 407 46 67 589 5V 2 74k l p Diagnostic help The temperature sensor reading can be obtained on an ISAT scan tool Turn the ignition switch to the O...

Page 108: ...ic procedure 1 Check the temperature sensor s grounding Unplug the temperature sensor s 2 pin con nector Connect the test lamp to Battery positive B and pin 2 Is the test lamp on IYES I Continue with...

Page 109: ...r s 2 pin con nector Connect an ISAT scan tool Select READ FUNCTIONS Select INTAKE AIR TEMP The reading obtained on the ISAT scan tool should be about 40 C 40 F Connect a jumper lead between pins 1 an...

Page 110: ...trouble code Implementation of driving cycle Drive the car at varying loads and engine rpm for 5 minutes Evaluation of driving cycle Check whether the diagnostic trouble code has recurred Has the diag...

Page 111: ...n switch in the ON position 0 08 V for 5 seconds P0118 Ignition switch in the ON position 4 8 V for 5 seconds 589 p Diagnostic help The temperature sensor reading can be obtained on an ISAT scan tool...

Page 112: ...ic procedure 1 Check the temperature sensor s grounding Unplug the temperature sensor s 2 pin con nector Connect the test lamp to Battery positive B and pin 2 Is the test lamp on IYES I Continue with...

Page 113: ...ensor s 2 pin con nector Connect an ISAT scan tool Select READ FUNCTIONS Select COOLANT TEMPERATURE The reading obtained on the ISAT scan tool should be about 40 C 40 F Connect a jumper lead between p...

Page 114: ...mplementation of driving cycle Drive the car at varying loads and enQ_ine rpm for 5 minutes Evaluation of driving cycle Check whether the diagnostic trouble code has recurred Has the diagnostic troubl...

Page 115: ...r 5 seconds P0123 Engine running 4 96 V for 5 seconds p 45 42 Diagnostic help The throttle position sensor reading can be obtained on an ISAT scan tool Turn the ignition switch to the ON position and...

Page 116: ...power supply Turn the ignition switch to the ON position and then back to the OFF position Unplug the throttle position sensor s 3 pin con nector Take voltage readings on the connector pin 1to B appr...

Page 117: ...N position and then back to the OFF position Unplug the throttle position sensor s 3 pin con nector Connect an ISAT scan tool Select READ FUNCTIONS Select THROTTLE POSITION The reading obtained on the...

Page 118: ...rouble code Implementation of driving cycle Drive the car at varying loads and engine rpm for 5 minutes Evaluation of driving cycle Check whether the diagnostic trouble code has recurred Has the diagn...

Page 119: ...h 20 km h The coolant temperature does not rise by 20 C 36 F from starting temperature or reach 40 C 104 F within 6 minutes and 40 seconds Diagnostic help 50 F 10 C The diagnostic trouble code may be...

Page 120: ...to be placed on the cylinder head without discomfort Connect an ISAT scan tool and contact the EDU Select READ VALUES Select COOLANT TEMPERATURE Start the engine and warm it up at idling speed Feel th...

Page 121: ...stem Select READ FUNCTIONS Select COOLANT TEMPERATURE Note the temperature Contact the EDU Select READ VALUES Select COOLANT TEMPERATURE Note the temperature The difference between the two temperature...

Page 122: ...cle Unplug the temperature sensor s connector from the EDU so that_the radiator fan will run continuously Check that the coolant temperature inthe Trion ic system drops to and stabilizes at about 89 C...

Page 123: ...sensor voltage oscillates at too low a fre quency 592Fa 589 p p H70 1 23 47 67 50 Diagnostic help Operation of the oxygen sensor can be ascertained using an ISAT scan tool Select READ FUNCTIONS Selec...

Page 124: ...electronic control module pin 23 70 or 47 is short circuited to battery positive B in the wiring harness or in one of the oxygen sen sors Check the insulation of the oxygen sensors Unplug the 4 pin co...

Page 125: ...onnect the battery s positive pole to pin 3 of the connector Ignition switch in ON position Connect an ISAT scan tool Select READ FUNCTIONS Select O2S 1 Does the ISAT scan tool show about 1 4 V IYESI...

Page 126: ...ds 60 C 140 F or for at least 1 minute if this tempera ture is reached earlier Depress the accelerator for a second or so and then let the engine run at idling speed for 30 seconds Do this twice again...

Page 127: ...he oxygen sensor s heating circuit current can be ascertained using an ISAT scan tool Select READ FUNCTIONS Select O2S 1 PREHEATING With the engine hot the ISAT scan tool should show a heating current...

Page 128: ...int 3 2 5min 1 8 4 0Q 2 Check the oxygen sensors heating circuit re sistance The engine should have been switched off for at least 5 minutes Check fuse 28 and change it if necessary Unplug the 4 pin c...

Page 129: ...ower supply Unplug the oxygen sensor s 4 pin connector Start the engine and run it at idling speed Connect the test lamp to pin 1 and 8 8 and pin 2 Does the test lamp light up in both cases IYES I Cha...

Page 130: ...f driving cycle Drive the car at varying loads and engine rpm for 5 minutes Evaluation of driving cycle Check whether the diagnostic trouble code has recurred Has the diagnostic trouble code recurred...

Page 131: ...47 70 67 51 Diagnostic help Operation of the oxygen sensor can be ascertained using an ISAT scan tool Select READ FUNCTIONS Select O2S 2 At full load the ISAT scan tool should show a reading of 0 7V A...

Page 132: ...ctronic control module pin 23 70 or 47 is short circuited to battery positive B in the wiring harness or in one of the oxygen sen sors Check the insulation of the oxygen sensors Unplug the 4 pin conne...

Page 133: ...Connect the battery s negative pole pole to pin 3 of the connector Ignition switch in ON position Connect an ISAT scan tool Select READ FUNCTIONS Select O2S 2 Does the ISAT scan tool show about 1 4V I...

Page 134: ...for at least 1 minute if this temperatu re is reached earlier Connect an ISAT scan tool Select READ FUNCTIONS ____ Select 02S 2 Drive the car and check that the ISAT scan tool readings are 0 7 Vat fu...

Page 135: ...47 70 67 51 Diagnostic help The oxygen sensor1 s heating circuit current can be ascertained using an ISAT scan tool Select READ FUNCTIONS Select O2S 2 PREHEATING With the engine hot the ISAT scan tool...

Page 136: ...h point 3 2 5mln 1 8 4 0 l 2 Check the oxygen sensors heating circuit re sistance The engine should have been switched off for at least 5 minutes Check fuse 28 and change it if necessary Unplug the 4...

Page 137: ...ygen sensor s 4 pin connector Start the engine and run it at idling speed until the coolant temperature is above 50 C 122 F Connect the test lamp to pin 1 and B B and pin 2 Does the test lamp light up...

Page 138: ...driving cycle 5Min Drive the car at varying loads and engine rpm for 5 minutes Evaluation of driving cycle Check whether the diagnostic trouble code has recurred Has the diagnostic trouble code recurr...

Page 139: ...ure sensor closed loop misfiring Conditions Ignition switch in ON position P0170 All embracingDTC P0171 Adaptation 100 P0172 Adaptation 100 R 1 Ill Diagnostic help Ifthe adaptation fault occurred on a...

Page 140: ...tic trouble codes using t e ISAT scan tool P1416 P0105 P0135 P0441 P0445 P1170 P1172 Are any of the above diagnostic trouble codes present IYES I Continue fault diagnosis for the relevant diagnostic t...

Page 141: ...0 5 kPa respectively the ISAT scan tool readings may be somewhat lower at high alti tudes The measurement is intended to detect any shift in the operating range of the pressure sensor Are the readings...

Page 142: ...e car at 2000 3000 rpm and a load of 60 120 kPa for about 1 minute Since throttle position changes should be avoided as level a road as possible should be chosen Evaluation of the driving cycle Connec...

Page 143: ...e of misfiring could be Low fuel level in the tank If this is the case it will be Indicated by diagnostic trouble code P1416 also being generated a fault in the fuel system low fuel pressure purge val...

Page 144: ...trouble codes using the ISAT scan tool P1416 P0105 P0135 P0170 P0172 P0335 P0441 P0445 P0505 P0507 P1170 P1172 Are any of the above diagnostic trouble codes present IYES I Continue fault diagnosis fo...

Page 145: ...re is plausible Using an ISAT scan tool check that the opera tion of the pressure sensor is plausible With the ignition switch in the ON position the read ing obtained on the ISAT scan tool should be...

Page 146: ...the spark plugs is missing or that spring travel is inadequate the connector for moisture and corrosion Is the ignition discharge module OK 1YES I Continue with point 4 INOI Rectify the fault and proc...

Page 147: ...ivation time is re quired the command must be repeated Check that each activated spark plug produces a spark Is a spark produced IYES I Continue with point 6 INO I Change the ignition discharge module...

Page 148: ...ge all spark plugs and continue with point 7 INO I Continue fault diagnosis as described in Service Manual 2 1 Basic engine 7 7 Check the fuel system Carry out fuel pressure and fuel flow measure ment...

Page 149: ...e Drive the car at different engine rpm and vary ing loads especially at high revs while the en gine is warming up Evaluation of driving cycle Check whether the diagnostic trouble code has recurred Ha...

Page 150: ...Fault diagnosis 147 I Saab9000...

Page 151: ...alytic converter to be damaged Ifthe number of misfires exceeds the matrix value a diagnostic trouble code will be generated If misfiring occurs in more than one cylinder the cyl inder in question acc...

Page 152: ...in ON position Select ACTIVATE Select IGNITION COILS Select IGNITION CYL 1 CYL 2 CYL 3 or CYL 4 Select the cylinder concerned Activation of an ignition coil takes place for 1O se conds at 200 Hz If a...

Page 153: ...e low Then activate the ignition coil concerned by means of an ISAT scan tool command Trigger lead 10 pin connector pin No cylinder No 1 2 2 3 3 4 4 5 N i 0 The test lamp should light up for 10 second...

Page 154: ...on Check the trigger lead in question for continuity see table below Check the lead for continuity shorting Trigger lead 10 pin con Control mod cylinder No nector pin ule pin No No 1 2 9 2 3 10 3 4 11...

Page 155: ...spring for the spark plugs is missing or that spring travel is inadequate the connector for moisture and corrosion Is the ignition discharge module OK IYES I Continue with point 5 INO I Rectify the fa...

Page 156: ...dule must be positioned with the ignition coils facing down during the test so that the transformer oil will provide good insulation in the high voltage part of the ignition coils 6 Check the operatio...

Page 157: ...000 ODDO 0000 0000 O c J 1 3 8 Check the power supply B of the injector concerned Check the voltage by connecting the test lamp to pin 1 of the relevant injector s connector and 8 Connect an ISAT scan...

Page 158: ...d flash at a frequency of 1O Hz for 1Oseconds Repeat the command in the event of uncertainty Does the test lamp flash IYES I Continue with point 1o INO I The test lamp flashes or remains on continu ou...

Page 159: ...02 P0303 P0304 contd 11 Check the relevant injector s fuel delivery flow Measurethe deliveryflow See Adjustment re placementof components Is the delivery flow OK IYES I Continuewith point 12 INOI Chan...

Page 160: ...driving cycle Drive the car at different engine rpm and vary ing loads especially at high revs while the en gine is warming up Evaluation of driving cycle Check whether the diagnostic trouble code ha...

Page 161: ...p A knock signal reading can be obtained using an ISATscan tool Select READ FUNCTIONS Select KNOCK SENSOR The ISAr scan tool should show a reading of be tween O and 2 55 V depending on the level of th...

Page 162: ...7 and battery negative B The multimeter should be connected alternately to battery positive B and battery negative B When connected to battery positive B the_meter should indicate a positive voltage a...

Page 163: ...nock signal s lead Checkthe continuityof the leadbetweenpin 7 of the ignitiondischargemoduleand pin 44 of the control module Checkthe leadfor open circuitand shorting Are the test readings OK IYES I C...

Page 164: ...Try fitting a replacement ignition discharge module and after a repetition of the driving cycle check whether the diagnostic trouble code is generated afresh INO I The remedial measure taken was corre...

Page 165: ...h 30 km h Engine speed 1500 rpm Brakes not applied The sensor reads an incorrect number of ribs teeth per crankshaft revolution 589 p Diagnostic help The diagnostic trouble code often indicates an int...

Page 166: ...of the sensor s connector Check the resistance of the sensor across pins 1 and 2 Nominal resistance is 540 55 ohms Check for possible stray currents between the signal lead and screened lead across pi...

Page 167: ...fil ings swart etc that the perforated ring isfirmly secured to the crankshaft by prising it gently with a screw driver while the crankshaft is rotated that the perfo rated ring is not skew buckled o...

Page 168: ...ery positive B and pin 2 of the connector Battery positive B and pin 3 of the connector Does the test lamp light up in both cases IYES I Continue with point 4 INO I Repair or replace the appropriate l...

Page 169: ...he control module sensor input Check the lead between pin 1 of the connector and pin 41 of the control module Is the lead OK IYES I Change the crankshaft position sensor and then continue with point 5...

Page 170: ...d than 31 mph 50 km h Rev up the engine to maximum rpm for at least 5 seconds without touching the brake pedal Evaluation of driving cycle Check whether the diagnostic trouble code has recurred Hasthe...

Page 171: ...More than 5000 engine revolutions since starting No camshaft position signal 589 346 17 II 17 Diagnostic help The cause of the fault could be incorrect or defective spark plugs wrong type sooty damag...

Page 172: ...n the Trionic system Obtain readouts of all diagnostic trouble codes using the ISAT scan tool P0105 P0135 P0170 P0172 P0300 P0304 P0335 P0441 P0445 P1170 P1172 Are any of the above diagnostic trouble...

Page 173: ...module s1Q pin connector Ignition switch in ON position Takevoltagereadingsonthefemaleconnector sockets pin 8 to batterynegative 8 pin 9 to batterynegative 8 The readingsobtainedshouldbe about 1oV Are...

Page 174: ...ether the diagnostic trouble code has recurred Has the diagnostic trouble code recurred IYES I Try fitting a replacement ignition discharge module and after a repetition of the driving cycle check whe...

Page 175: ...ngine speed rpm x load kPa 60 000 260 000 Coolant temperature 60 C 140 F Rear heated oxygen sensor 0 4 V at any time in this driving cycle I CHECKENGINE 0 6 1 0 3 ov Rear heated oxygen sensor voltage...

Page 176: ...procedure 1 Check the exhaust system Start the engine and run it at idling speed Check the exha ust system for leakage between the engine and the rear heated oxygen sensor Any leakage IYES I Rectify t...

Page 177: ...n or loose contacts in the connector Is the cable OK IYES I Change the three way catalytic converter and continuewith point 3 INO I Rectifythe fault and proceedto point 4 3 3 CJ __________ ___ 3 Check...

Page 178: ...25 56mph 40 90km h for 4 minutes se lect a gear that will keep engine speed at 2000 3000rpm Since throttle position changes should be av oided as level a road as possible should be chosen Evaluation...

Page 179: ...d changes Steady idling speed Additional fuel from purging 10 of engine fuel needs and no change in closed loop or idle speed control when purging activated Diagnostic help The diagnostic trouble code...

Page 180: ...lve hose from the in take manifold Connect the pressure vacuum pump and create a vacuum The pressure must not rise Does the pressure rise IYES I Repair or replace the hose connected to the valve or th...

Page 181: ...o the hose again and create a vacuum A steady flow should now be obtained from the evap orative emission canister via the valve the sound of the valve pulsating can also be heard in the hose Is a stea...

Page 182: ...earlier Depress the accelerator a second or two and then run the engine at idling speed for 30 se conds Repeat three times Evaluation of the driving cycle Connect an ISAT scan tool Select READ ON OFF...

Page 183: ...ng Conditions Purge valve active P0443 All embracing OTC P0444 Open circuit for more than 2 seconds P0445 Short circuit to ground for more than 2 se conds J37 321 30 230 21 Diagnostic help 589 p p The...

Page 184: ...nplug connector H6 5 located behind the right hand direction indicator Take a resistance reading inthe male connector across pins 5 and 6 Nominal resistance is 26 3 ohms Is the resistance reading OK I...

Page 185: ...s the test lamp on _ IYES I Continue with point 3 INO I Repair or replace the lead between pin 6 and crimped connection J37 and continue with point 4 3 3 Check the valvers ground connection Check the...

Page 186: ...ntil the temperature of the coolant exceeds 60 C 140 F or for at least 1 minute if this tempera ture is reached earlier Drive the car for 5 minutes at varying engine rpm and loads Evaluation of the dr...

Page 187: ...N position vehicle speed 168 mph 270 km h P0502 brake pedal not depressed engine speed 1800 rpm intake manifold pressure 60 kPa no vehicle speed signal for 4 seconds Above conditions fulfilled and the...

Page 188: ...re 1 Check the speedometer ODDO DODO ODDO 00 J Drive the car and check that the speedometer indicates a plausible speed Does the speedometer indicate a plausible speed IYES I Continue with point 2 INO...

Page 189: ...ON position Connect the test lamp to pins 39 and 1 of the fe male connector Rotate the wheel Does the test lamp flash IYESI Continue with point 3 _ INO I Check the lead between pin 2 of the speedo met...

Page 190: ...ation of driving cycle Drive the car at varying engine rpm and loads for 5 minutes Evaluation of driving cycle Connect an ISAT scan tool Select READ FUNCTIONS Select CAR SPEED Check that the ISAT scan...

Page 191: ...ry Engine coolant temperature 60 C 140 F Throttle position sensor indicates idling speed Engine speed is above 1200 rpm or below 700 rpm Normal idling speed cannot be achieved 30 230 J67 Diagnostic he...

Page 192: ...ir through the idle air con trol valve by pinching off the air hose using a pair of pliers Idling speed should drop drastically Has idling speed dropped IYES I Continue with point 2 INO I Continue fau...

Page 193: ...valve s 2 pin connec tor Start the engine and run it at idling speed Connect the test lamp to pin 2 of the female connector and a good grounding point on the engine The test lamp should light up Is t...

Page 194: ...the test lamp to pin 1 of the female connector and battery positive B The test lamp should light up Remove fuse 23 The test lamp should now shine weakly or go out altogether Has the test lamp gone out...

Page 195: ...iving cycle Stop the car apply the handbrake and run the engine at idling speed Switch off the NC and all electrical equip ment If the car has automatic transmission select position P Allow the engine...

Page 196: ...Fault diagnO iS 193 I Saab9000...

Page 197: ...he control module s program does not coincide with that programmed by the supplier iio i H70 1 289 22 c L G7P 589 1 60 25 48 24 Diagnostic procedure 1 Check the control module If the diagnostic troubl...

Page 198: ...r at varying loads and engine rpm for 5 minutes Turn the ignition switch ON and OFF 1O times Evaluation of driving cycle Check whether the diagnostic trouble code has recurred Hasthe diagnostictrouble...

Page 199: ...ctive P1170 All embracing DTC P1171 Closed loop 25 for more than 20 sec P1172 Closed loop 25 for more than 20 sec 592Fa 589 p p 67 H70 1 23 47 67 50 Diagnostic help Ifthe closed loop fault has arisen...

Page 200: ...ing the ISAT scan tool P1416 P0105 P0135 P0441 P0445 Are any of the above diagnostic trouble codes present IYES I Continue fault diagnosis for the relevant diagnostic trouble code INO I Continue with...

Page 201: ...pressure of 0 6 bar and then create a vacuum of 0 6 bar Use a pressure gauge and a pressure vacuum pump The ISAT scan tool should show readings of 160 5 kPa and 40 5 kPa respectively the ISAT scan too...

Page 202: ...al 1 5 V dry battery in good condition Connect the battery s positive pole to pin 4 of the connector Connect the battery s J Ositive pole to pin 3 of the connector Ignition switch in ON position Conne...

Page 203: ...urge valve closes when no current is applied to it that there is no air leakage in the exhaust system ahead of the front heated oxygen sensor or its mounting Is there a relevant cause of the fault IYE...

Page 204: ...t the engine and run it at idling speed until the temperature of the coolant reaches 60 C 140 Run the engine at idling speed for another 5 minutes Evaluation of driving cycle Check whether the diagnos...

Page 205: ...odes is gen erated P0170 P0171 P0172 P1170 P1171 P1172 P0300 Ill H I P1416 P0170 P0172 P1170 P1172 P0300 Diagnostic help Diagnostic trouble code P1416 is not a fault in the lit eral sense If there is...

Page 206: ...codes in the Trionic system Obtain readouts of all diagnostic trouble codes using the ISAT scan tool When any of the following di gnostic trouble codes is generated the reason is probably because the...

Page 207: ...e goes far into the red zone The pressure switch has opened Conditions The control module has reduced boost pressure by the maximum amount The pressure switch has opened p p 54 231 22AI s I 2 Diagnost...

Page 208: ...whether the fault is a control fault or a basic engine turbo fault Disconnect the air hoses marked W and C from the boost pressure control valve and con nect them to each other with a length of pipe...

Page 209: ...J 27c J 29c J 31c J 11 5 3 Check fuse 5 Is the fuse OK IYES I Continue with point 4 INO1 Continue with point 6 4 Check the air hoses Inspect the valve s three control hoses making sure that they are i...

Page 210: ...heck the resistance of the valve Takeresistance readings in the valve s connec tor across Pins 1 and 2 Pins 2 and 3 Nominal resistance is 3 1 ohm in both cases Are the readings OK IYES I Continue with...

Page 211: ...epair or replace the lead if necessary Continue with point 9 8 _______ 1 l 0000 0000 0000 0000 00 J 8 Check the lead connected to pin 1 of the valve Ignition switch in ON position Plug in the valve s...

Page 212: ...3000 rpm 6 times Eva_luationof the driving cycle Check whether the diagnostic trouble code has recurred and whether the pressure switch has ______ opened during the driving cycle Has the diagnostic tr...

Page 213: ...2 to Omph 35 to Okm h Each brake application shorter than 10 seconds No status change on the input from the brake light switch P1576 Short circuit to battery positive B P15TT Short circuit to ground o...

Page 214: ...Continue with point 2 Continue fault diagnosis as described in Service Manual 3 2 Electrical system bra ke lights Then carry out a final check in accordance with point 2 2 Final check Clear the diagno...

Page 215: ...212 Fault diagnosis Saab 9000...

Page 216: ...226 Low boost pressure 232 Fault diagnosis components 239 Ignition 240 Main relay 244 Fuel pump relay fuel pump 250 DRIVE 256 A C 260 Engine speed 264 Fuel consumption 266 Reversing light switch 267 C...

Page 217: ...2 Ill CHECKENGINE 1 2 Check the CHECK ENGINE lamp MIL gnitionon Check the fuel level Check that the CHECK ENGINE lamp MIL lights up and stays on Is the CHECK ENGINE lamp on IYES I The control module i...

Page 218: ...nsert fuse 23 Ignition switch in the ON position check that the test lamp lights up for about 6 seconds and then goes out Does the test lamp light up for 6 seconds IYES I The main relay is OK INOI See...

Page 219: ...ration of the fuel pump relay as follows Ignition switch in the OFF position Remove fuse 23 for 5 seconds Insert fuse 23 Ignition switch in the ON position listen for the sound of the fuel pump workin...

Page 220: ...is present Is power supplied to the injectors ___ IYES I The power supply is OK INOI Check the leads up to crimped connection J67 Does the ignition discharge module produce sparks IYES I The ignition...

Page 221: ...xcessively high engine temperature Connect an ISAT scan tool Contact the Trionic system Select READ FUNCTIONS Select COOLANT TEMPERATURE Read off the engine coolant temperature Then contact the EDU Se...

Page 222: ...ow a reading of about 102 kPa NOTE the reading is dependent on air pressure Fi rstbuild up a positive pressure of 0 6 bar and then create a negative pressure of 0 6 bar Use a pressure gauge and pressu...

Page 223: ...will cause misfiring under full load conditions Too small a gap will result in lumpy idling and hesitant running under light load conditions 5 Inspect the spark plug insulator tips Check the colour of...

Page 224: ...Fault diagnosis 221 I Saab9000...

Page 225: ...222 Fault diagnosis Poor performance Conditions No diagnostictroublecodes Saab9000...

Page 226: ...nt on air pressure First build up a positive pressure of 0 6 bar and then create a negative pressure of 0 6 bar Use a presure gauge and pressure vacuum pump The ISAT scan tool should show readings of...

Page 227: ...ct O2S 1 When the car is driven at wide open throttle the ISAT scan tool should show a reading of 0 5 V Is the ISAT scan tool reading correct The fault is probably in the fuel system No I See Fault di...

Page 228: ...on discharge module Repeat the activities described in point 3 Does the ISAT scan tool sill show ON IYES I The fault is probably due to an inferior grade of fuel Refit the original ignition discharge...

Page 229: ...n the engine has to cope with a sudden load demand in connection with the engagement of high urrent electrical equipment such as the A C ACC power steering electrically heated rear window or on cars w...

Page 230: ...ld drop drastically Has engine speed dropped IYES I Continue with point 2 INO I Continue fault diagnosis by checking Incorrectly adjusted throttle Air leakage after throttle Rectify as necessary and c...

Page 231: ...IAC VALVE Check visually that the valve rotates without tending to bind Is the control valve OK IYES I Continue with point 4 INO I Change the idle air control valve and then continue with point 6 4 A...

Page 232: ...ny changes in engine load Depending on the trouble continue fault diag nosis with Fault diagnosis DRIVE on page 256 Fault diagnosis other trouble Continue as described below Try changing the idle air...

Page 233: ...d all electrical equip ment If the car has automatic transmission select position P Allow the engine to stabilize its idling speed for 10 sec Switch on the NC and all electrical equip ment If the car...

Page 234: ...Fault diagnosis 231 I Saab9000...

Page 235: ...auge gives a low reading Conditions No diagnostic trouble codes Diagnostic help Note Cars with a manual gearbox have basic boost pres sure in 1st gear The APC valve can be activated with the ISAT scan...

Page 236: ...When the car is driven at wide open throttle the ISAT scan tool will show the cause of the fault Does the ISAT scan tool shown BOOST PRESSURE IYES I Continue with point 2 INO I The ISATscan tool show...

Page 237: ...hat it is connected to the wastegate Drive the car When driving at wide open throttle from low engine rpm the pressure switch should open before 3000 rpm is attained Does the switch open IYES I Contin...

Page 238: ...d Are the air hoses OK JYES I Continue with point 5 INO I Rectify any fault discovered Fault diagnosis 235 5 5 Check the power supply Ignition switch in ON position Check that the valve is supplied wi...

Page 239: ...l probably also be damaged Ifa new val ve is then fitted it will inevitably be rendered unser viceable In the event of a short circuit both valve and control module must therefore be changed at the sa...

Page 240: ...Plug in the valve s connector Select ACTIVATE Select BOOST PRESS VALVE A loud buzzing sound should be heard Can a sound be heard IYES I Change the boost pressure control valve INO I Check the lead be...

Page 241: ...contd 9 Check functionality ______ 0000 0000 0000 0000 OD Drive the car on test and check whether the fault symptoms persist Do the fault symptoms persist IYES I Proceed to page 282 INO I The remedia...

Page 242: ...omponents Ignition 238 Main relay 242 Fuel pump relay fuel pump 248 I DRIVE 254 A C 258 Engine speed 262 Fuel consumption 264 Reversing light switch 265 CHECK ENGINE lamp MIL and SHIFT UP lamp 266 Dia...

Page 243: ...240 Fault diagnosis Ignition Symptom of fault Engine will not start 30 230 Saab 9000 346 229 589 12 10 11 9 0 C I co _ C I u...

Page 244: ...nd connection Connect a test lamp to battery positive B and pin 6 of the ignition discharge module s connec tor Is the test lamp on IYES I Continue with point 2 INO I Check and rectify the wmng includ...

Page 245: ...ibed in Fault diagnosis main relay on page 244 _____ ll 0000 0000 0000 0000 ooc i WARNING The electronic ignition system generates up to 40 000 Volts Such voltages can prove fatal to people with weak...

Page 246: ...cable 86 10 867 Activate each separate ignition coil using the ISAT scan tool Sparks should be produced on each spark plug that is activated Are sparks obtained IYES I Change the spark plugs and conti...

Page 247: ...244 Fault diagnosis Main relay Symptom of fault Engine will not start 30 230 589 H70 1 p 31 oo ooo oo 00 0 Saab 9000...

Page 248: ...a fre quency of 1 Hz If a longer activation time is required the command will have to be repeated Listen for the sound of the main relay and idle air control valve working They should both click at a...

Page 249: ...wer Unplug the ignition discharge module s 10 pin connector Connect a 12 V 60 W bulb to pin 1Oand battery positive B Does the idle air control valve click IYES I Continue with point 3 INO I The fault...

Page 250: ...87 and crimped connection J37 and the lead between pin 30 and battery positive B Repair or replace the leads if necessary Fault diagnosis 247 l ODDO DODO ODDO 4 Check the main relay DODO ooc i Remove...

Page 251: ...amp on IYES I Continue with point 6 INO I Check the lead between pin 86 and battery positive 8 Repair or replace it if necessary 6 6 Check the main relay s connection to ground Check and if necessary...

Page 252: ...Fault diagnosis 249 I Saab 9000...

Page 253: ...250 Fault diagnosis Fuel pump relay fuel pump Symptom of fault Engine will not start 271 p GS Saab 9000...

Page 254: ...uency of 1 Hz If a longer activation time is required the command will have to be repeated Listen for the sound of the fuel pump relay and fuel pump working They should both be heard working at a freq...

Page 255: ...IYES I Continue with point 4 INO I Continue with point 5 4 Check the fuel pump relay Unplug the fuel pump relay Connect a jumper lead between pins 30 and 87 on the relay holder Does the fuel pump work...

Page 256: ...ins 1 and 2 of the 4 pin male connector Select ACTIVATE Select PUMP RELAY 0000 ODDO 0000 0000 ooc i The test lamp should flash at the rate of 1 Hz once a second Does the test lamp flash IYES I Change...

Page 257: ...se blow IYES I Check and if necessary rectify the wiring harness between fuse 14 and pin 1 of con nector H4 4 INO I Change the fuel pump 7 ___ 0000 0000 DODD 0000 OD 85 7 Check the fuel pump relay Unp...

Page 258: ...nding point Is the test lamp on IYES I Continue with point 9 INO I Check and if necessary repair or replace the lead between pin 86 of the relay holder and battery positive B 9 56 9 Check the fuel pum...

Page 259: ...256 Fault diagnosis DRIVE Symptom of fault Engine idling speed drops when the selector lever is moved away from P or N Conditions Fuse 9 is intact Saab 9000 589 p 239 I I I I I I I 31 I J IAIITJ J30...

Page 260: ...lect DRIVE 1 ___ 1 l 0000 0000 0000 0000 OOc J Move the selector lever from P and N to another gear position to check for the presence of an in put signal Is the ISAT scan tool reading correct IYES I...

Page 261: ...t up when the selector lever is in any position except P and N Functionality OK IYES I Continue with point 3 INO I Check and if necessary repair or replace the lead between pin 14 of the Trionic contr...

Page 262: ...automatic transmission select position P Allowthe engine to stabilize its idling speed for 10 sec Switch on the A C and all electrical equip ment If the car has automatic transmission select position...

Page 263: ...so be in perfect working or der Functions Definitions Information to the effect that the compressor is to be engaged A C IN is received by the Trionic control module on pin 59 The control module prepa...

Page 264: ...the Trionic system The ISAT scan tool should show ON and engine speed should increase slightly Fault diagnosis 261 Conditions fulfilled IYES I Continue with point 2 INOI The fault is situated before t...

Page 265: ...mpressor clutch should now both be heard Conditions fulfilled IYES I No electrical fault present INO I The fault is probably after Trionic i e be tween pin 54 and the compressor Continue fault diagnos...

Page 266: ...Fault diagnosis 263 I Saab9000...

Page 267: ...264 Fault diagnosis Engine speed Output signal to main instrument display panel Symptom of fault Tachometer does not work 47 I I 1 1 H70 1 I 2 I h17d l58 I I I Saab 9000 589...

Page 268: ...Fault diagnosis 265 2 Check the output signal Plug in the Trionic control module Unplug the main instrument display panel s connector Start the engine and run it at idling speed Take a frequency readi...

Page 269: ...ross pins 8 and 21 With the engine warmed up and running at idling speed a reading of 7 1 Hz should be obtained Is the reading OK IYES I Continue fault diagnosis as described in Service Manual 3 2 Ele...

Page 270: ...11 405 430 IJot 0 0 7 J 31 r 7 MAN J 2 Check the reversing light Check that the reversing light comes on when reverse gear is engaged Is the reversing light OK IYES I The fault is in the lead between...

Page 271: ...not light up or are on constantly when not activated by the control module Note that the SHIFT UP lamp is tested for 3 seconds each time the ignition switch is turned to the ON posi tion Conditions N...

Page 272: ...KENGINE Diagnostic procedure 1 Check the lamps Connect an SAT scan tool Ignition switch nON position Select ACTIVATE Select CHECK ENGINE LAMP and SHIFT UP LAMP Do the lamps flash IYES I Functionality...

Page 273: ...ay panel CHECK ENGINE lamp MIL Between pin 32 of the Trionic control module and pin 12 of the EDU SHIFT UP lamp Between pin 55 of the Trionic control module and pin 14 of the main instru ment display...

Page 274: ...Fault diagnosis 271 I Saab 9000...

Page 275: ...munication ISAT scan tool input and output signals Symptom of fault No contact with the Trionic control module via the ISAT scan tool Conditions ISAT scan tool communication with the Trionic sys tem i...

Page 276: ...Take voltage readings inthe data link connector across pin 16 and a good grounding point B pin 16 and pin 4 B pin 16 and pin 5 B Are all readings OK IYES I Continue with point 2 INC I Check fuse 23 I...

Page 277: ...on Take a voltage reading in the data link connec tor across pin 7 and a good ground point 6 5 V Is the voltage reading OK IYES I Continue with point 3 INO I Check the wiring between pin 7 of the data...

Page 278: ...ON position Connect an ISAT scan tool Contact the Trionic system l 00001 0000 0000 0000 OOC J The ISAT scan tool should show the Trionic menu Is contact established IYES I The remedial measure taken...

Page 279: ...mmon sense should tell you whether a reading is correct or not If any test reading is obviously incorrect use the wiring diagram to trace the leads connectors or components which you consider ought to...

Page 280: ...Function In Test condi Across Test reading Out tions 1 PK WH 30 in 850 50 rpm B to 1 0 5 V 2 GN BK Boost pressure control out 850 50 rpm 2 25 90 Hz valve 17 5 1 9 ms LP HI LO 3 GN Injector 1 out 850...

Page 281: ...LOp 13 WH Reversing light switch in 13 25 ov 53 267 Gear R 13 25 B 53 267 14 OG DRIVE in P N 14 25 ov 63 256 R D 1 2 3 14 25 B 63 256 15 VT Brake light switch in brake pedal 15 25 ov 53 210 not depre...

Page 282: ...0 rpm 850 50 rpm 1000 1500 rpm 850 50 rpm warmed up engine and valve active Start the en gine engine running and CHECK ENGINE lamp MIL out ISATscan tool not connected ISAT connected 850 50 rpm CC acti...

Page 283: ...n 850 50 rpm 44 25 50 100 mV 39 158 LP PLO 45 GN BN Throttle position sensor in 45 67 idling 0 5 V 34 112 see also tech nical data 46 WH BK Intake air temperature in 40 C 104 F 46 67 1 5 V 32 104 sens...

Page 284: ...re 67 BK Sensor ground out 68 YE WH Engine coolant tempera in ture sensor 69 70 GN Rear heated oxygen sen in sor oxygen sensor 2 Test condi tions 850 50 rpm A CON 850 50 rpm A C OFF when ignition swit...

Page 285: ...Service Manual 3 2 Electrical system wiring diagrams as a refer ence 3 In connection with removing and fitting the control module bear in mind its sensitivity to electrostatic discharges See page 283...

Page 286: ...n such a way that the connector pins come into contact with foreign objects Before unpacking a new control module ground the packaging to the car body Open the packaging as shortly as possible before...

Page 287: ...284 Fault diagnosis Saab 9000...

Page 288: ...anister purge valve 291 Fuel pressure regulator 304 Idle air control valve 292 Throttle cable Kick down wire adjustment 305 Injectors 293 Main relay fuel pump relay 306 Checking injector flow capacity...

Page 289: ...odule slightly upwards 4 Disconnectthe braided grounding strap and lift up the control module 5 Undo the catch to release the connector and then remove same To fit i Check the part number of the new c...

Page 290: ...xpansion tank filler cap to release the pressure in the cooling system Screw the cap back on again 2 Unplug the connector and remove the sensor To fit Fit in reverse order Tightening torque 13 Nm 9 5...

Page 291: ...s Important Note how the wiring is run and the points where the cable ties are fastened 2 Snip the cable ties and remove the wiring 3 Remove the sensor retaining bolt and remove the sensor Note how th...

Page 292: ...her hose from the throttle body 3 Remove the position sensor retaining screws and remove the sensor 1 2 0 lO co q C I _________________ ___ To fit 1 Make sure that the O ring is correctly positioned a...

Page 293: ...it by means of the locknut This will leave a clearance of about 0 05 mm 0 002 in between throttle valve and throttle body 4 Check that the length of the throttle cable does not prevent the throttle v...

Page 294: ...the wheel housing trim and the front sec tion of the wing liner 4 Unplug the connector and disconnect the hoses 5 Remove the purge valve Note Note the position of the valve C t LO co co t C I To fit...

Page 295: ...tle cable guide 3 Disconnect the idle air control valve s hoses from the thr ttle body 4 Pull the valve out of its holder and remove the hoses 5 Unplug the valve s connector 6 Lift out the valve and r...

Page 296: ...he vicinity To remove 1 Remove the fuel injection rail retaining bolts 2 Carefully lift up the fuel injection rail complete with injectors Have some paper or the like handy to absorb and mop up the fu...

Page 297: ...ical equipment No smoking anywhere in the vicinity 1 Remove the fuel rail with injectors as described in points 1 4 on the previous page 2 Start the fuel pump by connecting a jumper lead between fuses...

Page 298: ...hen screw the filler cap back on again 4 Disconnect the throttle body preheating hoses and plug the ends of the hoses 5 Disconnect the crankcase breather hose 6 Disconnect the idle air control valve h...

Page 299: ...t the throttle cable and Cruise Control cable and on cars with automatic transmission the kick down wire 3 Only cars with automatic transmission Check and adjust the kick down wire see page 305 4 Reco...

Page 300: ...of access Remove the connector from the bracket Important Note how the wiring is run and the points where the cable ties are fastened 2 Snip the cable ties and remove the wiring 3 Remove the oxygen se...

Page 301: ...oints where the cable ties are fastened 2 Snip the cable ties and remove the wiring 3 Raise the car and remove the oxygen sensor To fit Important Before fittin_g lubricate the threads of the oxygen se...

Page 302: ...nt replacement of components 299 Manifold absolute pressure sensor To remove 1 Remove the pressure sensor 2 Unplug the connector and disconnect the hose from the sensor To fit Fit in reverse order Saa...

Page 303: ...300 Adjustment replacement of components Intake air temperature sensor e To remove 1 Unplug the connector 2 Remove the sensor To fit Fit in reverse order Saab 9000 co j 3 co ___ _...

Page 304: ...ector 2 Remove the ignition discharge module s 4 retain ing bolts 3 Remove the spark plugs To fit Check the electrode gap on the spark plugs Itshould be 1 0 mm Fit in reverse order Tightening torque s...

Page 305: ...2 Fit in reverse order 0 C LO co co SI C I 2 Remove the 4 bolts 3 Lift up the ignition discharge module 4 Turn the ignition discharge module upside down and remove the 8 screws Tightening torque ignit...

Page 306: ...t the fuel pump by connecting a jumper lead between fuses 14 and 18 using special tool 83 93 886 4 Check the reading at barometric pressure It should be 3 bar 5 Use the pressure vacuum pump to incr_ e...

Page 307: ...caused by short circuits and when connecting and discon necting leads etc on electrical equipment No smoking anywhere in the vicinity To remove 1 Start by cleaning the area round the regulator and th...

Page 308: ...nt with the casting seam on the throttle body 3 Slacken the stop nut on the throttle cable and press the guide downwards until the wide open throttle position is felt the wide open throttle posi tion...

Page 309: ...306 Adjustment replacement of components Main relay fuel pump relay l U U CX CX I C I _ __________ JO The main relay holder is located under the airbag on the passenger s side Saab 9000...

Page 310: ...ve s control hoses 8 3 Remove the screws securing the boost pressure control valve to the car body C To fit C LO t LO co co t C J __ 1 Position the control valve correctly and tighten the screws C 2 F...

Page 311: ...he correct boost pressure is 0 40 0 03 bar 4 If basic boost pressure is outside the permissible limits continue as described in Adjustment of ba sic boost pressure 5 Remove the boost pressure gauge 3...

Page 312: ...ed to grip it as close to the threads as possible Rotate the end piece care fully so that no burrs will be left on the push rod 1 Undo the end piece s locknut and break the seal 2 Remove the circlip a...

Page 313: ...push rod from the valve s operating lever 3 Make sure that the operating lever can move free ly Change the wastegate valve if it is defective Diaphragm unit 4 Check that the push rod can move freely...

Page 314: ...y out adaptation on an uphill gradient Repeat the procedure until maximum nominal boost pressure in regard to the fuel grade used etc is at tained p Cars with automatic transmission Accelerate at as w...

Page 315: ...312 Adjustment replacement of components Charge air bypass valve To remove 1 Remove the control hose from the valve 2 Undo the two hose clips and remove the valve To fit Fit in reverse order Saab 9000...

Page 316: ...ts 313 Connectors and grounding points Control module Saab Trionic 080 II 589 289 Control module anti theft alarm 289 508 Control module Cruise Control 508 Switch brake lights 29 Saab 9000 29 l1Bl X r...

Page 317: ...314 Connectors and groundingpoints Switch reversing light 31 Indicator lamp SHIFT UP 47K Relay fuel pump 102 Tachometer 110 Saab9000 31 47K 110 m X a __ ______ __ J...

Page 318: ...r speedometer 132 Time ielay relay radiator fan 156 Antifrost thermostat 171 Boost pressure control valve 179 Connectors andgrounding points 315 Saab 9000 132 1 2 3 I E E 171 179 0 co C I __ ________...

Page 319: ...groundingpoints Engine coolant temperature sensor 202 Throttleposition sensor 203 Injector cyl 1 cyl 2 cyl 3 cyl 4 2060 b c d EDU 210 Saab 9000 202 203 1 2 3 E E 206 2 1 2 1 2 3 4 1 2 1 2 G E 00 1 v C...

Page 320: ...ngine management system 229 Transmission range switch automatic transmission 239 Heated oxygen sensor 271 592Fa Heated oxygen sensor 271 592Ra Saab 9000 239 1 2 3 4 5 rYE7 fGNl rYEl 271 592Fa H4 16 27...

Page 321: ...eglerventil tomglmg 272 Ur uftningsventil kolfilter 321 Motor briinslepump med integrerad matarpump 323 Liigesgivare vevaxel 345 Saab 9000 272 1 2 fBDlf1illl lB QJ j 321 323 1 2 EJE 3 4 345 H3 9 C co...

Page 322: ...346 Re ii backljus 405 Temperaturgivare insugningsluft 407 Tryckgivare inloppsror 431 Kontaktdon ochjordpunkter 319 346 H10 18 10 9 8 7 6 EJ 8 EJE EJ 5 4 3 2 1 407 431 3 2 1 E 1 t a a t I ________ __...

Page 323: ...320 Connectorsand groundingpoints H2 19 H4 4 H6 S H10 1 Saab 9000 H2 19 H4 4 1 2 3 4 BEJ H6 5 6 5 4 fGvlIYElg lBQJ EJ GEJ 3 2 1 H10 1...

Page 324: ...23 H10 25 H16 1 Connectors andgrounding points 321 H10 15 10 9 8 7 6 leul iGNliBUl lBQJ lYt J LJ EJ EJEJ 5 4 3 2 1 H10 23 444 H10 25 1 2 3 4 5 EJ EJEJ EJEJ 6 7 8 9 10 H16 1 445 D X v N L _ _________ S...

Page 325: ...5 G C JEJBDDBC JrnJGJ BEJG EJEJB EJ 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 Br J B BEl BEJGJEJ GJEJ J B EJ 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 2...

Page 326: ...Kontaktdon och jordpunkter 323 GB G24 Saab 9000 co co co co C J I...

Page 327: ...top of intake manifold EDU In main instrument display panel Main relay engine management sys tem In main fuse box under passenger airbag Transmission range switch automatic transmission Under the cen...

Page 328: ...owards main instrument display panel main wiring harness J 34 About 115 mm from SRS control mod ule branch towards main fuse box main wiring harness J 37 About 60 mm from relay position H pin 2 in mai...

Page 329: ...___J 1 o t s o H M N aO Z C g a o t r S OMM N D 901 1 J l o 7H Ml N a c ae ao 9 I I 2 r co s o HM NO eeoa IO 1 JtO J c c o rl sc o HMf LA 0 1 ___ sc o HIIN L L J IJ I 1 4111 V slV Cl r co I I W t I 9...

Page 330: ...E V C 8L I 1 I C 11 6 I I 0 I 0 0 J 0 g 0 o H o 0 q 0 z I J z z G 1 0 C I C I 0 l s o ta ea ss t o 0 t tc 1 ee o ne i ei 1 6 I s o HMtne ga a a j 0 ID IO 0 z G 0 I C I 6 I sc o 1e 0 0 I 0 0 J i ID CJ...

Page 331: ...SaabAuto Trollhatt mobile AB an Sweden Printed in Sweden Graphic Systems AB G bg 1995 26402 cri 0 j 0 I 0 c 5 O a C Q a Q c C C w co I co C z 0 C i Cl 0 0...

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