Saab 9000 1985 User manual

jxh
Saab 9000
Service Manual
M 1985-95
@
2:3 Fuel and air induction syste·m

jxh
Technical data
1
Special tools
5
Technical description 7
.Saab 9000 Air induction system 23
Fuel system 37
SERVICE
MANUAL
2:3 Fuel and
air induction system
M1985-1995
Foreword
This service manual replaces:
• Parts of service manual 2:3 LH Fuel injection
system M1985- 1989-
• Service Information 234-030
234-1057
234-1156
234-1157
234-1257
234-1361
We reserve the r_ightto make changes without
notice.
Saab Automobile AB
RECYCABLE PAPER

jxh
Warning, Important and Note
The headings "Warning", "Important" and "Note"
occurfromtimeto time in the ServiceManual.They
are used to draw the attentionof the readerto in-
formation
of
special interest and seriousness.The
importance
of
the information is indicated by the
threedifferentheadingsandthedifferencebetween
them is explainedbelow.
. &
WARNING
Warnsoftheriskofmaterialdamageandgrave
injury to mechanicsand the driver, as well as
seriousdamageto the car.
Important
Pointsout the risk of minordamageto 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 informationis
not suppliedfor reasonsof safety.
Marketcodes
The codes referto marketspecifications
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 1994
Production: Service Support, Saab Automobile AB, Trollhättan, 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

jxh
Technical data
Engine management system
For information about Trionic and Motronic engine
management systems, see service manuals.
Fuel pressure.B202i, B204i, B234i
System pressure bar (psi)
Residual pressure (after 20 mins) bar (psi)
Fuel pressure B202LTT, B234LTT
System pressure bar (psi)
Residual pressure (after 20 mins ) bar (psi)
Fuel pressure B202T, M1985-86
System pressure bar (psi)
Residual pressure (after 20 mins) bar (psi)
Fuel pressure B202T, M1987-
System pressure bar (psi)
Residual pressure (after 20 mins ) bar (psi)
Fuel pressure B234T
System pressure bar (psi)
Residual pressure (after 20 mins ) bar (psi)
Fuel pressure V6
System pressure bar (psi)
Residual pressure (after 20 mins ) bar (psi)
Fuel tank
Total volum.e,year models 1985-1989 liters (qts)
year models 1990, 1992- liters (qts)
year model 1991 liters (qts)
Volume when fuel lamp starts to .light liters (qts)
3,0 (43)
about 2.3 (33)
3,0 (43)
min 2.3 (33)
2,5 (36)
about 1.8 (26)
2,8 (40)
min 2.1 (30)
3,0 (43)
about 2.3 (33)
3,0 (43)
min 2.3 (33)
68 (71)
66 (69)
62 (65)
about 1
o
(10.6)
Saab9000
Technicaldata 1

jxh
2 Technicaldata
Fuel pump
Walbro
Capacity at 3.0 bar counterpressure
Resistance M1990-M1991,
fuel level sensor full tank
Resistance M1990-M1991
fuel level sensor empty tank
Resistance M1992-M1995-,
fuel level sensor full tank.
Resistance M1992-M1995-
fuel level sensor empty tank
Bosch
Capacity at 2.5-3.0 bar counterpressure
Resistance, fuel level sensor
full tank
Resistance, fuel level sensor
empty tank
Fuel filter
Filter volume
Average porosity of paper insert
1/30s min0.7
Ohms 340-360
Ohms 3Q-40
Ohms 360-380
Ohms 28-38
1/30s min0.9
Ohms 2,6-3,8
Ohms 68,2-69,2
0
liters 0,6
Sµm
Saab9000

jxh
Fuel pressure regulator, test readings
System pressure
+0.2 (+2.9)
+0.4 (5.8)
+0.6 (8.6)
barometric pressure
-0.6 (8.6)
-0.4 (5.8)
-0.2 (2.9)
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)
Turbo
-1986
bar (psi) 2.5 (36)
2.7 (39)
2.9 (42)
3.1 (45)
bar (psi) 2.5 (36)
1.9 (28)
2.1 (30)
2.3 (33)
Saab9000
Technical data 3
Turbo B202i 1986- V6
1987- B2341990-
B2041994-
B202LTT
B234LTT
2.8 (40) 3.0 (43) 3.0(43)
3.0 (43) 3.2 (46)
3.2 (46) 3.4 (49)
3.4 (49) 3.6 (52)
2.8 (40) 3.0 (43)
2.2 (32) 2.4 (35)
2.4 (35) 2.4 (35)
2.6 (37) 2.8 (40)

jxh
4 Technical data
Injectors, flow capacity
LH
Fuel pressure regulator, opening pressure (bar) 2.5
Turbo-86
Flow capacity . ml/30s 104
Trionic
Flow capacity, aspirating engine ml/30s 127± 10
Flow capacity, turbo engine ml/30s 176± 14
Motronic
Flow capacity ml/30s 109±9
Saab 9000
2.8 3.0 3.0
Turbo 87- i/S Turbo
110 90 145

jxh
Specialtools 5
Special tools
83 94 397 Wrench, fuel pump (Walbro)
M1988-89.
83 94 330 Wrench, fuel pump (Bosch)
83 93 886 Diagnostics cable
83 94 405 Testhose for checking fuel flow.
83 94 462 Wrench,fuelpump (Walbro)
M1990-
(45) 30 14883 Pressure tester
Saab 9000

jxh
6 Specialtools
83 95 121 Extension, fuel pressure adaptor, V6 83 94 744 Adapter, fuel pressure and
fuel flow, V6.
83 93 852 Measuring equipment, fuel pressure
83 93 860 Hose kit (spare part)
83 93 878 Nipple (spare part)
83 94 546 Installation tool, fuel line.
Saab9000

jxh
Technical description 7
Technical description
Engine management system
General •••.•..•...••....•.••...•..•
7
Air induction system 4 cyl,
turbo engine -M1987 and i/S-M1988 .. 8
Air induction system 4 cyl,
turbo engine M1988- and i/S M1989- .. 9
Air induction system V6 M1995- ..... 1
O
Fuel system:
8202 .............................. 11
B234 .......................... . 12
Fuel pump assemblies:
Bosch ..••...•...•............•.... 13
Walbro, negative ejector •............ 13
Walbro, positive ejector ............•. 14
Engine management system
General
The Saab 9000 engine management systems usean
electric fuel pump to draw fuel from the fuel tank and
generate fuel pressure in the system. The pressure
level is determined by the pressure regulator, which
keeps fuel pressure constant in relation to the pres-
sure in the engine's air intake (4 cylinder engines
only). The quantity of fuel injected is therefore gov-
erned only by time the injector is open and not by
pressure variations in the intake manifold.
The fuel is injected by injectors (solenoid valves)
mounted in the intake manifold near the inlet valves
and connected to a common fuel rail.
Injector opening time is controlled by electrical con-
trol pulses from the control module.
For detailed description of the engine management
system, see the service manual for each system.
Components:
Fuel pump, Bosch ..•.•...•.•.•.•... 15
Fuel pump, Walbro negative ejector .•. 16
Fuel pump, Walbro positive ejector .... 17
Fuel filter ...•.......•.............. 18
Fuel rail ............•..........•... 18
Pressure regulator ...........•...... 19
Pulsator ................•.......... 19
Injectors ...................••....•. 20
Intake air temperature sensor ........ 20
Mass air flow sensor 4 cyl ...•.•...•. : 20
Mass air flow sensor V6 •...•.••....• 21
Air cleaner .........••.............. 21
Saab 9000

jxh
8 Technical description
Air induction system 4 cyl turbo engine, manual gearbox, until M1987
4 cyl i/S until M1988
2
1. Aircleaner
2. Connecting pipe
3.
Mass
air flow sensor
4. Rubber gaiter
5. Throttle body
The induction system consists of air cleaner, con-
necting pipe (i/S), mass air flow sensor and rubber
gaiter. The induction system is connected the
throttle body.
The quantity of air used by the engine passes
through the induction system where a filter removes
dust particles.
The air cleaner (air collection chamber) also func-
tions as an intake air silencer.
The mass air flow sensor measures the mass of air
consumed by the engine. The signal from the mass
air flow sensor is processed by the control module
which monitors the engine's fuel mixture require-
ment.
Saab 9000
1

jxh
Air induction system 4 cyl, turbo engine M1988-
4 cyl i/S M1989-
1
4
1. Mass air flow sensor
2. Plastic pipe (connecting pipe)
3. Filter cartridge
4. Inner air cleaner housing
5. Outer air cleaner housing
6. Air pipe
The induction system consists of air cleaner, mass
air flow sensor, filter and air cleaner housing.
The quantity of air used by the engine passes
through the induction system where a filter removes
dust particles.
The air cleaner (air collection chamber) also func-
tions as an intake air silencer. The mass air flow sen-
sor measures the composition of air consumed by
the engine.
The signal from the mass air flow sensor is pro-
cessed by the control module which monitorsthe en-
gine's fuel mixture requirement.
The filter element is mounted in the left-hand wheel
housing.
Saab9000
Technical description 9
5

jxh
10 Technical description
Air induction system V6 M1995-
2
1. Air intake pipe
2. Resonator
3. Air cleaner consisting of:
4. Filter element
5. Air collection chamber
6. Intake air temperature sensor
7. Mass air flow sensor
8. Connecting hose
9. Throttle butterfly
The induction system consists of air intake pipe with
-resonator (sound-absorbing plastic chamber), air
cleaner, rubber elbow, mass air flow sensor and con-
necting hose. The induction system is connected to
the throttle.body.
The quantity of air used by the engine passes
through the induction system where a filter removes
dust particles.
The V6 has a variable induction system. For further
information on this and on the mass air flow sensor,
see service manual 2:7 Engine Management Sys-
tem.
Saab9000
5

jxh
Fuel system, 8202
2
4
3
1. Fuel pump
2. Fuel filter
3. Fuel line
4. Fuel rail
5. Injector
6. Pressure regulator
7. Cold-starting valve
(certain versions only)
8. Roll-over valve
(M1985-88 only)
Saab9000
Technical description 11
5
6
8

jxh
12 Technical description
Fuel system, B234 i/T
5 7A
2 3
1. Fuel pump
2. Fuel filter
3. Fuel line
4. Pulsator
5. Fuel rail
6. Injector
7. Pressure regulator
Turbo engines
engines
8. Cold-startin9 valve
(certain versions only)
Saab9000
II
II
II
======')

jxh
Fuel pump assemblies
Bosch
1. Fuel pump
2. Feed pump
3. Fuel level sensor
2
Walbro, negative ejector
1. Non-return valve in pump unit
2. Two versions of roll-over valve
in return line
Saab 9000
Technicaldescription 13

jxh
14 Technical description
Fuel pump assemblies (contd.)
1
2
Walbro, positive ejector
1. Non-return valve in feed line
2. Roll-over valve in return line
1
2
Walbro, positive ejector with
integrated fuel level sensor
1. Non-return valve in feed line
2. Roll-over valve in return line
Saab 9000

jxh
Bosch fuel pump
The fuel pump (1), housed inside a container (2) in
the fuel tank, is an electric rotary pump. The pump
and motor are sealed and cannot be dismantled for
overhaul. The fuel pump incorporates a relief valve
that opens if the pressure exceeds a certain level. A
non-return valve on the pressure side of the pump
prevents the pressure in the fuel line from dropping
immediately if the ignition is switched off.
An electric feed pump (3) supplies the container with
fuel from the tank. The container acts as a pressure
vessel and because the main fuel pump isalways fed
with fuel under pressure, no air bubbles will form.
Saab 9000
Technical description 15
3

jxh
16 Technical description
Walbro fuel pump, negative ejector
1. Main pump
2. Ejector pump
3. Filter
4. Reservoir
5. Pump delivery line
The fuel pump is mounted inside a plastic reservoir
which is clamped between the top and bottom of the
tank. It is located at the bottom by ribs on the bottom
of the tank and secured at the top by a screw top.
Movement in the tank is absorbed bythe spring inthe
fuel pump. In the main, the operation and design of
the pump isthe same as earlier fuel pumps with main
and feed pump. However, in the Walbro pump, the
feed pump has been replaced with an ejector driven
by the flow of return fuel.
The function of the ejector is to supply fuel to the
pump. As the main pump is located in the reservoir,
fuel supply is assured during cornering andaccelera-
tion, even when only a small quantity of fuel remains
in the tank.
The pump unit, with the ejector part at the bottom, is
seated in a sump in the bottom of the tank. This en-
sures fuel to the ejector pump, even when there is a
small quantity of fuel in the tank and the car is on a
steep slope.
6. Return line
7. Screw top
8. Seal
9. Spring
If fuel runs out, the following quantity of fuel is re-
quired for the pump to once again draw fuel.
1 Car tilting 10% forward and 10% to the right.
Fuel quantity 5 liters.
2 Car tilting 10% to the right. Fuel quantity
5 liters.
3 Car on flat ground. Fuel quantity 2.6 liters.
4 When the car is tilting to the left, fuel fills the
sump where the pump is located which means
that the engine receives fuel until the tank is
as good as empty.
Saab 9000

jxh
Walbro fuel pump, positive ejector
1. Main pump
2. Ejector pump
3. Filter
4. Reservoir
5. Pump delivery line
The fuel pump is located inside a plastic container
which is clamped between the top and bottom of the
tank. At the bottom, it is centered with ribs onthe bot-
tom of the tank and at the top it is secured with a
screw top.
Movement inthe tank is absorbed bythe spring inthe
fuel pump. In the main, the operation and design of
the pump isthe same as earlier fuel pumps with main
and feed pump. However, in the Walbro pump, the
feed pump has been replaced with a positive ejector
driven by flow of fuel from the pressure line via a T
joint. The pump is an electric rotor pump.
The function of the ejector is to supply fuel to the
pump. As the main pump is located in the reservoir,
fuel supply isassured during cornering andaccelera-
tion, even when only a small quantity of fuel remains
in the tank.Pump and motor are sealed and cannot
be dismantled for overhaul.
A non-return valve on the pressure side of the pump,
located inthe connecting nipple to the pump lid, pre-
vents the pressure in the fuel linefrom dropping im-
mediately after the engine is switched off. The fuel
tank level sensor is mounted on the fuel pump con-
tainer via a jointed arm.
Technical description 17
<
8
6. Return line
7. Screw top
8. Seal
9. Spring
If fuel runs out, the following quantity of fuel is re-
quired for the pump to once again draw fuel.
1 Car tilting 10% forward and 10% to the right.
Fuel quantity 5 liters.
2 The car is tilted 10% to the right.
Fuel quantity 5 liters.
3 Car on level ground.
Fuel quantity 2.6 liters.
4 When the car is tilted to the left, the sump in
which the pump is located fills and the engine
can be supplied with fuel until the tank is as
good as empty.
Saab 9000