Saab 9000 1991 User manual

r • •,
·i
SERVfCE
2:5 Traction Information
M 1991-95
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Handling procedures 4
Tools and equipment
10
Information codes
18
Saab 9000
Diagnostic procedures
28
ETS reference graphs
92
Calibration
128
SERVICE
Final road test
132
MANUAL
Wiring diagrams
135
2:5 Traction Information
) Manual
M 1991-1995
Foreword
TIM is designed to assist and simplify fault tracing
and repair of only the most common TCS problems
on Saab 9000 cars. TIM is not a substitute for the
existing TCS Service Manual, Section 2:5, but
instead a supplement intended to be used in con-
junction with the Service Manual.
Saab Automobile AB
RECYCABLE PAPER
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Warning, Important and 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.
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, 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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PURPOSE
KNOW-HOW
SAFETY
CARE
TCS Information Manual (TIM) 1
TIM
TCS Information Manual
0
?;
To
assist in fault
diagnosis when working on the TRACTION CONTROL
SYSTEM fitted to Saab cars.
Goal -"FIX IT RIGHT FIRST TIME".
You are expected to have a reasonable understanding of how the Traction
Control System works. If you do not, please refer to Service Manual for
an explanation of system operation .
You should take the necessary precautions in your work at all times to
avoid accidents and injury, particularly observing important HEALTH and
SAFETY regulations.
The TIM should be well looked after and regularly updated. Take it with
you when you go to the TRAINING SCHOOL.
Saab 9000
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2 TCS Information Manual (TIM)
General rules for fault diagnosis
Many components that our tests show to be in per-
fect condition are still being replaced.
To avoid the replacement of components in perfect
condition, the following steps should always be
taken.
• If diagnostic trouble codes are obtained, check
the operation of the relevant components or sys-
tem using a Scan Tool as described in Service
Manual 2:5 and/or in this manual. All importers
have been supplied with this Manual. It contains
selected information explaining how to diagnose
faults and rectify them.
• Check the wiring and connectors for continuity,
poor contact, damaged connecting pins, etc. Use
"KONTAKT 61 part No. 45-30 04 520, which is
an aerosol contact cleaner lubricant with good
long-term reliability specially developed for elec-
trical connectors and switches.
• When changing several components at the same
time, make sure that the components really are
defective before fitting replacements.
Saab9000
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Index
Testing procedures
• Customer contact and preliminary inspection (page 4)
• Workshop inspection . . . . . . . . . . . . . . . . . . . . . . . . (page 5)
Before the road test . . . . . . . . . . . . . . . . . . . . . . . . . (page 6)
• Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (page 8)
• After the road test . . . . . . . . . . . . . . . . . . . . . . . . . . . (page 9)
Tools and equipment
• Dos and don'ts of testing . . . . . . . . . . . . . . . . . . . . . (page 1O)
• Saab special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . (page 13)
• Saab recommended tools . . . . . . . . . . . . . . . . . . . . (page 15)
• Quick-reference parts list . . . . . . . . . . . . . . . . . . . . (page 16)
Information codes
• Command codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . (page 18)
• Version codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (page 20)
• Calibration .. . . .. .. .. . . . .. .. . . . . .. .. . .. . . .. . (page 22)
• Diagnostic Trouble Codes (DTCs)
(Quick reference) . . . . . . . . . . . . . . . . . . . . . . . . . . . . (page 23)
Diagnostic procedures
• Component identification and testing . . . . . . . . . . . (page 28)
• Fault diagnosis/replacement of diodes in
the ABS-TC/ABS system . .. .. . .. .. .. . .. .. .. . (page 48)
• Pin and wiring checks·. . . . . . . . . . . . . . . . . . . . . . . . (page 62)
• OTC fault diagnosis charts . . . . . . . . . . . . . . . . . . . . (page 70)
ETS reference graphs
• ETS reference graphs . . . . . . . . . . . . . . . . . . . . . . . (page 92)
Calibration
•
• Kick-Down Cable adjustment . . . . . . . . . . . . . . . . . (page 128)
Calibration (AUT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . (page 129)
Final road test
• Road test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (page 132)
• Re-check for DTC's . . . . . . . . . . . . . . . . . . . . . . . . . (page 133)
• Inform customer of repairs.................... (page 133)
Wiring diagrams
• TCS (man. aut. M91-95) .. .. .. ..... . .. .. .. .. .. (page 135)
Saab9000
Index 3
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4 Testing procedures
Testing procedures
Customer contact and preliminary inspection
Note
Before touching the car, try to obtain as much
information as possible about the nature of the
fault.
Action:
ASK, LOOK AND LISTEN.
ASK
- Talk with the driver of the car and ask him
about the fault.
LISTEN
- When did the fault occur and what were the
symptoms?
- Was the accelerator harder to depress and was
engine response different?
LOOK
Did any warning or indicator lamps come on? .
Saab 9000
TCS
'_ , LOCK I
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LISTEN
- Did the car restart OK?
Workshop inspection
Action:
LOOK and LISTEN.
Note
Carry out a visual inspection of the car but do
not touch anything.
LOOK
Look for broken components and loose connec-
tions under the bonnet.
LISTEN
Listen to the engine. Is it running OK?
Saab 9000
Testing procedures 5
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6 Testingprocedures
LOOK
Look to see if any extra equipment is fitted. If it
is, it may be affecting the TCS. Check that the
mobile phone, anti-theft alarm, etc. are correctly
installed. ·
LOOK
Are any warning or indicator lamps on?
. TCS
;
1
LOCK
Saab-Alarm
I\
CHECK ENGINE
Before the road test
Action:
READ Diagnostic Trouble Codes (DTCs).
CONNECTA SCANTOOL
Plug the scan tool into a data link connector
(green or black) under the right-hand front seat.
Saab 9000
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Testing procedures 7
READ THE DTCs
Carry out fault diagnosis on all systems from
both the green and black data link connectors
and make a note of all the diagnostic trouble
codes.
CLEAR THE DTCs
Clear the trouble codes in all systems but do not
recalibrate any systems at this time.
Power Off test
It has been found that DTCs.
can be generated in
other systems on .
·
models during the ETS
system Power-Off test (performed each time the
ignition is switched off) while the scan tool is still
connected. On all models it is therefore advisable
to terminate scan tool communication before
switching OFF the ignition.
ENTERCOMMANDCODES
Enter command codes according to the DTCs
obtained as described above. Refer to "Com-
mand Codes" on page 18.
I
ISAT
"System reset to zero"
ISAT
"Brake light switch"
Saab 9000
900
I
206
i
;::
;::
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8 Testing procedures
Before the Road Test
A) Reset the trip meter to zero.
B) Note the engine temperature .
During the Road Test
A) Check the boost pressure .
8) Check the Cruise Control system .
C)Check shifting performance (automatic
transmission).
D) Activate the TCS (provoke wheelspin).
E) Watch the warning lamp display.
F) Listen to the sound of the engine.
G) Does the accelerator work OK?
Road test
Saab 9000
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Testingprocedures9
After the Road Test
Action:
the OTCs as described in "Before the
road test".
test
It has been found that OTCs can be generated on
certain models during the ETS system Power-Off
test (performed each time the ignition is switched
off) while the scan tool is still connected. On all
models it is therefore advisable to terminate scan
tool communication before switching OFF the igni-
tion.
NEWCOOES
Proceed to the OTC fault diagnosis charts on page
70 and deal only with these new codes in sequential
order.
NO NEW CODES
Refer to the original codes noted during "Before the
road test". Proceed to the OTC fault diagnosis chart
on page 70 and deal with each code in sequential
order.
Saab 9000
Refer to page 70
OTCfault diagnosis charts.
Refer to page 70
OTCfault diagnosis charts.
.-
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1O Tools and equipment
Tools and equipment
Dos and don'ts of testing
DON'T
Do not use extra leads to make jumper or bridg-
ing connections (when obtaining readings via a
BOB).
DON'T
Never take readings by applying test probes to
the connector side.
(Use a breakout lead, part No. 4066916).
DON'T
Never disconnect any electrical components
when the ignition is switched ON.
Saab 9000
,,
0 00000000
13 22
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Dos and don'ts of testing (contd.)
DON'T
Do not overload your equipment. Remember
what you are testing and select the right scale.
DON'T
Do not charge the battery without disconnecting
it from the car.
DO
Always use a Breakout Box (BOB) when taking
test readings.
Saab 9000
Tools and equipment 11
t
,, •J ••• ,
I
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12 Tools and equipment
Dos and don'ts of testing (contd.)
DO
Do bear in mind the possibility of extra equip-
ment, such as
- car phone
- theft alarm
- etc. affecting the TCS.
DO
Take test readings more than just once to con-
firm the results. Perhaps check with an oscillo-
scope.
REMEMBER
Poor quality tools give poor quality results!
Saab 9000
Saab-Alarm
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SAAB
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Tools and equipment 13
Saab Special Tools
[CJ]
,GB88,
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Scan tool 86 1
O834
BOB cable (ASR) 86 11 139
Capacitor cable 86 11 048 ·
Saab Diagnostic Adapter (SDA) 86 11 188 (old)
Saab Diagnostic Adapter II 86 11 436 (new)
BOB cable (ETS) 86 11 014
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Breakout Box (BOB) 86 11
006
Saab 9000
I
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14 Tools and equipment
Saab special tools (contd.)
ffl
'
'
.
J_iL
JV
Pressure/vacuum gauge (45)-30 14 883 Pressure gauge 83 93 514
Blanking plug 83 94 587 Blanking plug 83 94 595
Breakout cable 40 66 916
Saab 9000
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Tools and equipment 15
Saab Recommended Tools
+TRIG
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-TRIG
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Saab 9000
¢ =1,2Voc
Hz
ms
%
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16 Tools and equipment
Quick-reference parts list
Component Part No. Part No. of Modification/identification
replacement (as of chassis No./week)
component
ETS control module
M91 4022653 8827149
M92 4159182 8827909
M93 4300075 8828097 Modified ETS control module in
production as of week 9250
(502 stamped on module
connector) (P1025299/9306).
M931/2 4300539 8828378 Modified ETS control module
software self-test routine in
production as of week 9311
(113 stamped on module
connector) (P10~0656/9312). -~
M941/2 4392601 8828386 Gold plated.
M95 4302378 4610721 Gold plated.
ASR control module 4159190 8827974
M92/93
TC/ABS control module
M91 4190492 8827594 Manual
M92 4195293 8827693 Manual
M92 4107363 8827628 Auto
M93 4199626 8828089 Manual
Throttle body See page 21 for correct throttle
2.0 8982001 body.
2.3 9109075 Redesigned throttle sensor {due
M93 4197927 to wear problem) in production
as of week 9303
{P1025892/w9310).
M941/2 9169699 Gold plated.
M941/2 9170705 Gold plated, can replace
9169699.
8822348*
Accelerator pedal position (APP) 4015194 (M) Sealed lea_
ds in 5-pin APP
sensor 4161238 (A) sensor connector
(P1032318/w9315).
M941/2 4301685
(M)
Gold plated.
Kick-down actuator 4161220 Modified KO-actuator (due to
retracted pins) in production as
of 9304 (043 stamped on
metallic part) (P1028966/w9310}.
Kick-down bracket 4163317 Reinforced KO-actuator bracket
(cable connection)
(P1020737/w9250).
C/CLAMP 4163333
* 8822348 is a supplementary kit for changing to a throttle body with
gold-plated connector contacts. See which throttle body is suitable for
the relevant model year,
page 21.
Saab9000
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,
Component
Safety valve
Rubber bushing
Brake/clutch switch
Brake light switch
Limp Home cable
2.3 M91
2.3 M91
2.0 M91
2.3 M94 engine No. 166911-
Non-return valve
Engine coolant temperature
sensor
ETS Main Relay
Charge air bypass control valve
Charge air bypass valve hose
set
TCS on/off switch
M95 man
Modified carpet on RHD cars as of
Part No.
4015202
7973456
4350443
9505462
4022737(LHD)
4018313(RHD)
8980922(LHD)
4526711(RHD)
4301669
8788200
8522310
4019253
4021218
4439477
Part No. of
replacement
component
P1029694/w9311 See page 47.
Saab 9000
Tools and equipment 17
Modification/identification
(as of chassis No./week)
Screened safety valves as of
week 9304 (stamped on valve
body) (P1024304/w9305) .
Modified (longer) cable fitted, +5
mm LHD, +10 mm RHD,
together with throttle body
9170705.
Red-white body with integrated
filter (P1040435/w9323).
Bosch/He Ila
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