Saab 9000 User manual

Saab 9000
Service Manual
M 1985-93
@
2:3 LH Fuel injection system
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Technical data 1
Special tools 11
Technical description 15
Saab 9000 Fault diagnosis 53
Adjustment/replacement of
components 183
SERVICE Connectors and grounding points 245
Wiring diagrams 269
MANUAL
2:3LHFuelinjection
system
M 1985-93
Foreword
This service manual supersedes:
• Service Manual 2:3 Fuel system,
fuel injection engine M1985-1989-
• Service Information 240-1106
• The text dealing with the LH fuel system
in 9000 M1988-91 "News" manuals
Contents subject to alteration without notice.
Saab Automobile AB
RECVCABLE PAPER
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'
Technical data
Special tools
Technical description 15
Saab 9000 Fault diagnosis 53
Adjustment/replacement of
components 183
SERVICE Connectors and grounding points
245
MANUAL Wiring diagrams
269
2:3LHFuelinjection
system
M 1985-93
Foreword
This service manual supersedes:
• Service Manual 2:3 Fuel system,
fuel injection engine M1985-1989-
• Service Information 240-1106
• The text dealing with the LH fuel system
in 9000 M1988-91 "News" manuals
Contents subject to alteration without notice.
Saab AutomobileAB
RECYCABLE PAPER
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Warning, Importantand·Note
The headings "Warning", "Important" and "Note"
occur from time to time in the Service Manual. They
are used to draw the attention of the reader to in-
formation of special interest and seriousness. The
importance of the information is indicated by the
three different headings and the difference between
them is explained below.
WARNING
Warns of the risk of material damage and grave
injury to mechanics and the driver, as well as
serious damage to the car.
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 and labour. This information is
not supplied for.reasons of safety.
Market codes
The codes refer to market specifications
AT
AU
BE
CA
CH
DE
DK
ES
EU
FE
Fl
FR
Austria
Australia
Belgium
Canada
Switzerland
Germany
Denmark
Spain
Europe
Far East
Finland
France
©Saab Automobile AB 1995
Production: Service Support, Saab Automobile AB, Trollhattan, Sweden
GB
GR
IS
IT
JP
ME
NL
NO
SE
us
UC
Great Britain
Greece
Iceland
Italy
Japan
Middle East
Netherlands
Norway
Sweden
USA
US California
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Technical data 1
Technical data
Coolant temperature sensor . . . . . . . . . . 1
Auxiliary air valve M1985 . . . . . . . . . . . 1
IAC valve M1986-. . . . . . . . . . . . . . . . 2
Full-load enrichment . . . . . . . . . . . . . . 2
Fuel pump ................... 3
Fuel tank .................... 3
CO idling .................... 3
Pulse ratio, closed loop LH 2.2 . . . . . . . . 4
Coolanttemperaturesensor
Mass air flow sensor . . . . . . . . . . . . . . 4
Oxygen sensor . . . . . . . . . . . . . . . . . 5
Injectors ..................... 5
Summary of LH components . . . . . . . . . 6
Fuelpressureregulator ............ 9
EVAPca'nisterpurge.valve . . . . . . . . . . 9
Pressureswitch . . . . . . . . . . . . . . . . 9
Tighteningtorques . .. . . . . . . . . . . . . 10o
Designation 9357021(Bosch0280130026)or
_________ 0280130032)(TCScars)
Resistanceat 0°c (32°F) Ohms 5800± 10 %
200C(68°F) Ohms 2600± 7 %
80°C (176°F) Ohms 320 ± 5 %
Note:Temperaturesensor 87 88 200 containstwo parallelcircuits.The abovefigures referto each circuit.
Auxiliary air valve M1985
Resistanceat 20°c (68°F) Ohms 40-60
Saab 9000
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2 Technical data
Idle air control valve (IAC) M1986-
Resistance at 20°c (68°F), LH 2.2 Ohms
LH 2.4, LH 2.4.1 Ohms
LH 2.4.2 Ohms
Full-load enrichment
Throttle position switch LH 2.2, 2.4, 2.4.1
(throttle valve angle when switch is
closed) degrees (
0)
CO content during simulated full-load
enrichment (not cat.) %
Throttle position sensor LH 2.4.2. V
Ignition on, voltage across pins 2
and 3 V
Saab 9000
20
±
5 (pins 2-1 and 2-3)
7
±
5 (pins 1-2)
12
±
3 (pins 2-1 and 2-3)
approx. 72
4-6 (increases 2-4 %)
0.25 (closed throttle position)
4.0 (wide open throttle)
0
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Fuel pump
Capacity
Fuel tank
cm3/30 s
cm3/30 s
Total capacity, model years 1985-1989 litres (qts)
model years 1990, 1992- litres (qts)
model year 1991 litres (qts)
Fuel remaining when low fuel warning
lamp lights up litres (qts)
min. 900 (Bosch)
min. 700 (Walbro)
68 (71)
66 (69)
62 (65)
approx. 7 (7.4)
CO idling, idling speed 850 rpm (not cat.)
Engine Modelyear CO%
B202 Turbo 1985- 1.3 ±0.3
B202i 1986- 1.0 ±0.5
---
B234i 1991- 1.0 ±0.5
Saab 9000
.Technical data 3
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4 Technical data
Pulse ratio, closed loop LH 2.2
Idling speed 850
±
50 rpm
Engine Modelyear Pulseratio
8202 1985-1988 50/50
Mass air flow sensor
Voltage is proportional to engine load. The greater
the load, the higher the voltage.
Important
A mass air flow sensor of plastic must never be
replaced by a mass air flow sensor of aluminium, or
vice versa.
Saab9000
Remarks
Readings taken with ISAT scan tool and ca-
bles or with pulse ratio meter 83 93 597
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Oxygen sensor
Signal voltage 0-1 V when system in operation. Re-
sistance, preheating 4 ± 2 ohms (at 20°C).
Injectors
Flow capacity
Fuel pressure regulator,
opening pressure (bar)
2.5 (Turbo 1985-86)
2.8 (Turbo 1987-)
3.0 (B202i)
3.0 (B234i
3.0 Turbo (B234)
min.
(ml/30 s)
104
110
90
125
145
Technical data 5
Check that flow capacity is the same for all injec-
tors.
The specified flow rates are valid at room tempera-
ture (20 ± 1°C).
Injector opening duration is proportional to engine
load. The greater the load, the longer the opening
duration.
Saab 9000
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6 Technical data
Summary of LH components
To facilitate the handling of LH control modules, we
have prepared a summary of all existing units.
The summary consists of two tables: Table A for
cars
with
a catalytic converter and Table Bfor those
without.
Table A. Specification, LH fuel injection system
Cars equipped with a catalytic converter
Version Model
1
Engine LH
year Fuel pressure Mass air flow
regulator sensor Injector Control module
Bar Bosch SAAB Bosch SAAB Bosch SAAB Bosch SAAB
9000iM, iA 86-87 8202
2.2
3.0 258 7580160
1
)-009
9390428
-711
7560162
-532 9389768
" 88 " 2.4 " -256 7564123 7538663 " " -552 7538671
89 " " - " -"- -565 7487143
" 90 " " " " " " " " " -584 9119470
" " " " " "
" " " "
-581 9119496
" " 8234 2.4.1 " " - - 9113838 -002 9113721 -579 9113804
2.4.2
II II II II II II II
-905 7872237
ti ti II ti ti
-905 7872237
8202 2.4 -"- - -711 7560162 -584 9119470
--
-+- ---- - ---- _ __ - --- ---- - -------- -- ------ ---- ------ --- --- -----
9000 86 8202 2.2 2.5 -257 !9375643 -712 7560170 -531 9389750
;
-- ---------- --- -- -- -- --!--- ------- ---•--------- --- ----· --- ---------
9000 LA
B) " - - "
-11- -"- -"- - - " - - "
-539 9391178
9000 LA 88
1 -"- -"-
1
-"-
-255 7564131 -"- ·
11
- -"-
-"- " "
7486905 7538655
-
11-
-+--_,,_---- 8978355
II
-586 9119488
-583 8787079
9000 LM, LA 91 " " " "
11
- - " " "
-940 9126194
II II
8234 2.4.2 3,0 -524 9131061 •009 8857153 -908 8857187
9000
11 11 11 " - - " " 11 11
1
11
-910 7872260
II
8202 -704 7486905 -013 7538655 -712 7560170 9126202
2.4 3.0 -706 -011 -711 -584 9119470
" " 8234 2.4.2 " " " -019 9113838 -002 9113721 -905 7872237
II
s202 -940
9000
" " " " "
11
" " " "
-941 9126202
9000 LM, LA
11
8234 2.4.2 3.0 -524 9131061 -012 9113846 -009 8857153 -908 8857187
II II II
-910 7872260
man+aut TCS
9000iM, iA 93 8202 2.4
II
-706 7486921 7538663 7560162 -584 9119470
2.4.2
---- -
---- - - -- ··-·-
- ------ · -
-
--·--· -·
- -- -
-"- -706 7486921 -019 9113838 -002 9113721 -905 7872237
9000iM, iA 93 *) " " -706 7486921 -019 9113838 -002 9113721 -960 4300224
9000L 90-9-3 8202 2.4 " -706 7486921 -013 7538655 -712 7560170 -940 9126194
137kW) ---- ------- - -
9000L 93 8202 - - 2.5 -704 7486905 -013 7538655 -712 7560170 -940 9126194
9000L 93 8202 " " -704 7486905 -013 7538655 -712 -941 9126202
Catalytic converter repositioned more forward US, SE
1, alum. 100°
2/4.7, plastic, 120°
2/4.7, plastic, 155°
2/6.4, plastic, 155°
Control
Control
Air filter in engine bay
Air filter in wheel housing
(US/Cal)
Control
L Turbo engine
i fuel injection engine
M manual gearbox
A automatic transmission
Saab 9000
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Table B. Specification, LH fuel injection system
Cars not equipped with a catalytic converter
Version Model Engine
year
9000iM, iA 86 8202
" 87 "
" 88 "
9000 iM 89-90 "
9000iA " "
9000 iM, iA 91 "
9000 iA " 8234
9000iM, iA 92 8202
9000iA, iM " 8234
9000 LM 85 8202
" 86 "
" 87 "
---- ----- ---- --------
9000 LA " "
--- ---------- -
9000 LM, LA 88 "
------------------ ------- -- --·---
9000 LM 89 "
-·--------- --- - ---------
9000 LA " "
9000 LM 90 "
9000 LA " "
9000 LM, LA 91 "
9000 LM, LA ·92 8202
9000 LM, LA 93 8202
9000iA, iM 93 8202
9000iA, iM 93 8234
1, alum. 100°
2/4.7, plastic, 120°
2/4.7, plastic, 155°
Control
L Turbo engine
i fuel injection engine
M manual gearbox
A automatic transmission
LH Fuel pressure Mass air flow
-- sensor
- -----
Bar Bosch SAAB Bosch SAAB
---------- ---- ---·---- ------------·- ---------·------
2.2 3.0 -258 7580160 9390428
" " " " " "
" " " " 2) 7591183
" " -706 7486921 " "
" " " " " "
2.4.2 " " " 7872385
" " " " " "
2.4.2 3.0 -706 7486921 -022 7872385
" " " " " "
2.2 2.5 -225 7518681 9375643
" " -257 7580152 " "
" 2.8 -265 7568058 " "
--· ------- --- ------- ------------
" " " " " "
----. ,--- -- -------- -------- ---·---
" " " "
- - - - ---- -
- - " -705 7486913 8978280
- ---- --- -- --
" " " " "
- - !
" " " I "
--- -
" " " ! --
-- - -I i
2.4.2 " " --7872393
" 2.8 -705 -018 17872393
" 2.8 -705 7486913 I -018
" 3.0 -706 7486921 -022 7872385
" 3.0 -706 7486921 -022 7872385
Saab 9000
Technical data 7
Injector Control module
------ ··----- -------------------
Bosch SAAB Bosch SAAB
--------- ----------- ------ -- --
-711 7560162 -530 9388513
" " " "
" " -553 7591498
" " -574 9114711
- - " -567 7487127
" " -903 7872203
-002 9113721 -907 7872229
-711 7560162 -903 7872203
-002 9113721 -907 7872229
7560170 -519 9388471
" " -534 9389545
" " -548 9393463
--- ----- ------ -··---
" " -540 9391186
------------ ------ ------------ -- -
" " " "
------------ --· ·-· -------
" " -575 9114729
---- ----- --------------- --
" " -555 8975294
" " -587 9119520
- - ---588 9119538
" " -904 7872211
-712 7560170 -904 7872211
-712 -904 7872211
-711 7560162 -903 7872203
-002 9113721 -907 7872229
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8 Technical data
Table C. Specification, LH components
Component LH system Car version Bosch Saab
2.2 2.4 2.4.1 2.4.2
Temperature sensor
X
9000 Turbo cat. aut M87-88 -055 7563562
Temperature sensor
X
TCS -032 8788200
Temperature sensor
X X X X
Others -026 9357021
Oxygen sensor
X X
9000i M87-M89 -009 7525603
Oxygen sensor
X X X
9000i M90-M91, 90_00i M86, 9000 -028 9392762
Turbo M85-M91
Oxygen sensor
X X
M92- -245 9132564
Oxygen sensor
X X X X
9000 Turbo, Brazil -095 9129743
Oxygen sensor
X X X X
9000 Turbo, Brazil and ME M92 -258 4164323
Knock sensor
X
All 9358037
Knock sensor
X X X X
All -006 7568801
--- ·--- - ---------
-
.
-- -----·--- ----
--- -------
--·· ··
-
-- -
-- --
-- ---
-- --- - - --- .
--
--
--- --- ---
----- -
··---
-- ---- --· -- ·-----
Knock sensor
X X X X
DI electronic ignition 7585755
-------- -- --- --- -
··- -·------
- -
- - -
- - --- --- ---- ·--
Throttle position
X X X
All except 2.4.2 -300 7501612
switch I
Throttle position
X
2.4.2 8857195
sensor
IAC valve
X
M86- -502 7516792
IAC valve
X X
2.4 M88-, 2.4.1 M90 -516 7586019
IAC valve
X
8234 Turbo M91- -526 8787996
----- -- -- ---------- -- -- -- -·-- ----
----- ----- -- .
- -·-·· - --·-
--- --·----- --- -
....
·· ·---- -
------·---- ---------------------- -- -
··- -
-- --
.....
.
----
···---
...
----
IAC valve
X
Other 2.4.2 -505 8857179
- --
-
··- · -·
-· -
·--
------ - ·--
- ------- --
-- --- --- - ------ --
------ --
- --·····- -
---- ----
Auxiliary _air valve
X
M1985 -107 8357832
-- - --- -- --- ----
·---
-
·--------- - ---- - -- ----- ·-------- --·-·-----
-
-- -·
.
--- ---- - --- - --- --· - ----
Cold-starting valve
X
9000icat. -432 7486129
Evaporative emission
X
Cat. cars. ME market 7532054
canister
- -
--
-
--· ···--
- ·
-- - - -· · ··
···--·· ·-··---
----- --···
-- - -
-
------
-- -- - ---- --------·- -- -- -- -- - --
------- ---- ··---- --- ------------
------ -- -- -- --- -
- -- ·
·-
····-· ----- -·---
Evaporative emission
X X X
All 7539216
canister excl. purge
valve
EVAP canister purge
X X X
All -157 7539257
valve
Charge air bypass
X X X X
All Turbo -103 9390022
valve engine serial No. G122319, inclusive
Saab 9000
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Fuel pressure regulator, test readings
Nominal system
Turbo
-1986 Turbo
1987-
pressure, bar (psi) 2.5 (36) 2.8 (40)
Tolerance range:
2.5 + 0.25/-0.15 bar (36 + 3.6/-2.3 psi)
2.8 + 0.25/-0.15 bar (40 + 3.6/-2.3 psi)
3.0 + 0.25/-0.15 bar (43 + 3.6/-2.3 psi)
1986-
B234 1990-
3.0 (43)
Technical data
Permissible tolerance when checking with garage equipment and due allowance made
for temperature, grade of fuel, instrument error and calibration: +5%.
EVAP canister purge valve
Type Bosch TEV
Characteristic feature
Resistance at 20°c (68°F)
Control voltage
Pressure switch
Tripping pressure
Open without current
ohms
V
bar {psi)
Saab9000
45±5 %
13
O± 0.05 (not cat.)
0.95 ± 0.03 (cat.)
9
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O Technical data
Tightening torques
Torque (Nm) Torque (lbfft) Size
Intakemanifold 22 16
MB
Knocksensor 20 15
Ignition_dischargemodule 11 8
M6
Sparkplugs 28 20.7
Other bolts 5 3.7 M5
10 7.4
M6
----- - - --
20 15
MB
40 30
M10
Saab 9000
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Specialtools
Special tools
30 14883 Pressure/vacuum pump
83 93 514 Boost pressure gauge
83 93 852 Pressure gauge equipment, fuel pressure
83 93 886 Cable, LH fault diagnosis. For running fuel
pump.
83 93 894 Cable, LH fault diagnosis
83 94 223 LH system tester
Saab 9000
I
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12 Specialtools
83 94 264 Cleaning equipment, injectors.
· 83 94 272 Cleaning agent
83 94 314 Wrench, 8202 CO setting
83 94 322 Spanner, throttle butterfly
83 94 405 Test hose, fuel flow measurement
83 94 504 Cable for lamp flash codes. 1
O
pole, LH 2.4
Saab 9000
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83 94 587 Plug, turbo hose
83 94 595 Plug, turbo hose
86 10834 /SAT scan tool
Specialtools 13
86 11 006 Breakout Box (BOB)
86 11 147 Test cable, 25 pole
86 11 154 Test cable, 35 pole
Saab 9000
0
CX)
C\I
I
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14 Special.tools
86 11345 Diagnostics cable (jumper lead with switch)
86 11 352 Test cable, male terminals
86 11410 Test cable, female terminals
87 11857 Test lamp
87 91 980 Adjusting tool, wire, 4-cyl.
30 04 520 Kontakt 61
Saab 9000
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Technical description 15
Technical description
LH system, general .... .
LH 2.2. .......... .
LH 2.4............. .
Identification of LH systems
Location of components . . . . . . . . . .
Sensors .................. .
Principle of operation, all systems . . . . . . . . . . . . . . . . . . . .
Mass air flow sensor . . . . . . . . . . . . . . . . .
General ...
Description . .
Burn-off ....
Control module
Temperature sensor. . . ............... .
Oxygen sensor. . . . . . . . . . . . . . . .
Throttle position switch . . . . . . . . . . . . . . . . . . . . . .
Throttle position sensor. . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary air valve . . . . . .....
Idle air control valve, LH 2.2 (IAC valve) ..
Idle air control valve, LH 2.4, 2.4.1 and 2.4.2 (IAC-valve) . .
EVAP canister purge valve . . . . . . . .
Cold starting valve 9000i, cat. (LH 2.4).
Engine starting. . . . . . . . . .
Warming up the engine . . . . . .
Safety factors .......... .
Limp Home driving conditions . .
PRE-IGNition enrichment . .
Fuel shut-off . . . . . . . .
Electronic EGA system ..
Saab 9000
. 16
. . 18
19
.. 20
. 21
..... 22
. . 23
.... 29
29
. 30
. 32
. .• 33
...... 35
. ... 36
.. 37
. 38
. ... 39
. . 40
. 41
... 43
. 44
. ... 45
. 46
. 47
. 48
...... 49
... 50
.. 51
I
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16 Technical description
LH system, general
LH2.2
The Bosch LH-Jetronic (Luftmassenmesser
Hitzdraht) air mass meter with hot filament sensor
(mass air flow sensor) is a fuel injection system in
which the best properties of different fuel injection
systems are combined with
mass air flow sensing,
i.e. the density of the air is taken into account.
The LH-Jetronic system measures the air mass
used by the engine, taking the composition of the air
(temperature, pressure and humidity) into account
as it flows through the mass air flow sensor.
This system gives an exact measure of the amount
of oxygen supplied to the engine by the air massand
determines the amount of fuel needed for efficient
combustion.
The system has the following advantages:
• Compensates for different temperature condi-
tions.
• Adjusts the amount of fuel to the amount of oxy-
gen in the air when driving at high altitudes.
• Few components.
• Low weight.
• Few moving parts.
· • Good means of adapting the amount of fuel to ac-
tual needs (warm-up phase/acceleration phase).
Saab 9000
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