Saab 9000 User manual

Technical data 1
Special tools 11
Technical description 15
Saab 9000 Fault diagnosis 93
Adjustment/replacementof components 307
Connectors and grounding points 333
SERVICE Wiring diagram 342
MANUAL
T2:7 Enginemanagement
----
system
TrionicOBDII
M 1996-
Foreword
This manual contains 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 training of instructors and me-
chanics.
l All particulars and illustrations in this Ser-
vice Manual are based on the version of the
cars prevailing at the time of going to press.
We reserve the right to introduce changes
without prior notice.
Saab Automobile AB
RECYCABLEPAPER

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.
&
WARNING
Warns ofthe 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.
Marketcodes
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

Technical data 1
Te.chnicaldata ,-
Engine control module ................. . 2 Injectors 6
Crankshaft position sensor . . . . . . .. . . . .. . 2 Ignition discharge module . . . . . . .. . . . . . . . 6
Manifold absolute pressure sensor . . . . . . . 3
Intake 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
way catalytic converter) . . . .. . . . . . . . . .. . . 5
Rear heated oxygen sensor (after three
EVAPcanister purge valve . . . . . . . . . . . . . . 8
Fuel pressure regulator . . . . . . . .. . . . . . . . . 9
way catalytic converter) . . . . . . . . . . . .. . . . . 5 Fuel pump............................. 9
Saab 9000

2 Technicaldata
Engine control module
Number of pins
70
Power supply (+30 circuit) pin Nos. 1 and 48
Power supply (+15 circuit) pin Nos. 60
Power ground pin Nos. 24 and 25
Sensor ground (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 crankcase wall
Type Inductive sensor
Resistance, pins 1-2 at 20°c (68°F} Ohms 540±55 ·
Perforated ring number of ribs 58 (60-2)
Distance between sensor and ring mm .0.4-1.3
Saab 9000

Technicaldata 3
V
3---------
2.5 --------"---1----1
2-------------
0.5 ------------
025 50 kPa
75 100 125 150 175
•
Manifold absolute pressure sensor
V
Approx. voltage at 25 kPa (- o.75 approx. 0.48
bar)
50 kPa (- 0.50 bar) approx. 0.95
100 kPa (±0 bar) approx. 1.9
125 kPa (0.25 bar) approx. 2.4
150 kPa (0.50 bar) approx. 2.8
175 kPa (0.75 bar) approx. 3.3
Pressurein kPa is absolutepressure,i.e. 100kPacorrespondstobarometricpressure.
Whencheckingthepressuresensorusingapressure/vacuumpump,somewhatlowervoltagereadingsmaybe
obtainedat highaltitudes.
Powersupply:5 V.
kOhm
Intake air temperature sensor
0 C(Of) kohms V
-30 (-22) 20-30 approx. 4.5
-10(-14) 7.0-11.4 approx. 3.9
20 (68) 2.1-2.9 approx. 2.4
40 (104) 1.0-1.3 approx. 1.5
60 (140) 0.565-0.670 approx. 0.9
80 (176) 0.295-0.365 approx. 0.54
90 (194) 0.24-0.26 approx. 0.41
Powersupply:5 Vthrougha 2.74 kohm resistorin thecontrolmodule.
Saab9000
r

4 Technical data
kOhm
9.2
+···
!
!!t::~==~--,_
0.32 ' ' '
~:~~
::.! :
j ;
II I I
-40 -20 0 20 40
•
Engine coolant temperature sensor
oc
(Of)
kohms V
-30 (-22) 20-30 approx. 4.5
-10 (-14) 7.0-11.4 approx. 3.9
20 (68) 2.1-2.9 approx. 2.4
40 (104) 1.0-1.3 approx. 1.5
60 (140) 0.565-0.670 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
kohms
pins 1-2 1.6-2.4
Idling speed, pins 2-3 0.8-1.2
Wide open throttle, pins 2-3 2.0-3.0
The throttle position sensor's pins are gold-plated.
Power supply: 5 V
V
o
1
o·
20· 30· 40·
so· so·
10·
ao·
90·
V
5±0.1
0.5±0.4
4.5±0.4
Saab 9000
..
-

Technicaldata 5
•
V
0.8
0.6
--------
--------
0.4
0.2
C\I
co
0
-;:.
~
0.80 0.90 1.00 1.10 1.20
co
v
').,
C\I
(.)
Front heated oxygen sensor (before three way catalytic converter)
Type
Rating, heating element
Control range
Resistance at 20°c (68°F), pins 1-2
Pins 3 and 4 are gold-plated.
Bosch LSH25Pwith 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 (after three way catalytic
converter)
Type
Rating, heating element
Control range
Resistance at 20°c (68°F), pins 1-2
Pins 3 and 4 are gold-plated.
Bosch LSH25PLwith electric heating
Watts 18
V 0-1
Ohms 2.0 +0.5 (PTC)
-0.2
Saab 9000

6 Technical data
Injectors
Type
Design
Resistance at 20°c (68°F)
Flow capacity
Maximum permissible difference be-
tween injectors
Ignition discharge module
Number of pins
Power supply
Capacitor voltage
lgn~tion
voltage, max.
Firing order
Ionization voltage
Bosch EV1-3E, red
4-hole
Ohms 12.0±0.35
ml/30S· 176±14
ml 18
10
V 12
V 400
V 40000
1-3-4-2
V 80
Saab 9000

Technicaldata 7 I
Spark plugs
Manufacturer NGK
Type BCPR 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 500 Hz
Idling speed, warmed-up engine 850±50 rpm
Saab9000

8 Technical data
Boost pressure control valve
Number of windings
Resistance per winding ?1t
20°C (68°F)
Control voltage, <2500 rpm
Control voltage, >2500 rpm ·
Engine version
'----,---__. ---- - ·-- --~ -- -= ----·--
R
B234E, manual, 3500 rpm
:1
X
1;
B234E, automatic, 4000 rpm
X
B234L, manual, 3500 rpm
X
B234L, automatic, 4000 rpm 0,49
<-
B234R, manual: 3500 rpm
CCC
X
= Basic boost pressure 0.40±0.03 bar.
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 the brake pedal is depressed.
EVAP canister purge valve
II
Pressure
I
switch op-
i
eration
0,65
0,65
.1,35
1,35
1,35
Type Bosch TEV2
Characteristic feature Closed at zero current
Resistance at20° C (68°F) Ohms 26±3
Control voltage PWM 12V 8 Hz
Saab 9000
CJ>
co
~
I
C\I
(.)
Speed limitation
--
-
-- -
·-
149 mph (240 km/h)
149 mph (240 km/h)
149·mph (240 km/h)
0
CJ>
,:::
i
"<t
C\I
(.)
-
~

Fuel pressure regulator
Fuel pressure
Pressure, air side
Fuel pum.p
Capacity at 3.0 bar counterpressure
Resistance, level sensor
Tightening torque, screw top
Technicaldata 9
bar 3.0+0.1
connected to intake manifold
ml/30s min 700
Ohms 25-370
Nm (lbf ft) 75 (55)
Saab 9000
C\I
O'>
-;:::.
~
..,.
C\I
(..)
I-

1
O Technicaldata
Saab9000

Specialtools
Special tools
86 11 170 Test cable, 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 Test spark plug
86 11857 Testlamp
Saab 9000
11
I

12
Specialtools
83 93 886 Jumper cable
83 92 912 Sealing pliers
83 94538 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 Pressure/vacuum pump
Saab 9000

87 91 980 Adjusting tool, kick-down wire
83 94 405 Testhose, fuel flow
co
IO
C\I
I'-
~
~
C\I
u
Special tools 13
I
Saab 9000

14 Specialtools
Saab 9000

TechnicalDescription 15
Technical Description
Saab Trionic system overview . . . .. . . . . . . 16 Relays . .. . . . .. . . . . .. . . . . . .. . . . . . . . . . . . 56 I
Main components of the Saab Trionic A/C compressor ............ : . . . . . . . . . . . 58
system . . . . .. . . . . . . . . . . . . .. . . . .... . . .. . 18 Vehicle speed . . . . .. . . .. . . . . . . . . .. . . . . . . 59
Ignition system, knock control . . . . . . . . . . . . 19 ISAT scan tool communication . . . . . . . . . . . '60
Fuel injection ............. ·.. . . . . . .. . . . . 21 CHECK ENGINE lamp . .. .. . . . . . . .. . . . . 61
Boost pressure control . . . . . . . . . . . . . . . . . . 22 SHIFT UP lamp
Idle speed control . . . . . . . . . . . . . . . . . . . . . . 23 (cars with manual gearbox) . . . . . . . . . . . . . . 62
DRIVE ...................... ·.......... 63
Engine control module inputs . . . . . . . . . . . . 24 Low fuel level . . .. . . . . . . . . . . . . .. . . . . . . . . 64
Engine control module outputs . . . . . . . . . . . 25 OBD II diagnostics
Terms and definitions . . . . . . . . .... .. . . . . . . 65
Engine control module . . . . . . . . . . . . . . . . . . 26
ECM power supply . .. . .. . . .. . . . . . . . . . . . 28 Fault handling, (I) Catalyst 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
Engine coolant temperature sensor . . . . . . . 33
Fault handling, (Ill) comprehensive
components .. : . . . . . . . . . . . . . . . . . . . . . . . . 70
Fault criteria, catalyst damaging misfire . . . 72
Fault criteria, emission-related misfire . . . . 74
Throttle position sensor . . . . . . . . . . . . . . . . . 34 Fault criteria, fuel system . . . . . . . . .. . . . . . . 76
Ignition discharge module . . . . . . . . . . . . . . . 35 Fault criteria, fuel evaporation . . . . . . . . . . . . 78
Fuel injection . . . . . . . . . . . . . . . . . . .. .. . . . . 41 Fault criteria, oxygen sensor 1 . . . . . . . . . . . 80
Basic boost pressure . . . . . . .. . . . . . . . . . . . 51 Fault criteria, oxyge.nsensor 2 . . . .. . . . . . . 82
Boost pressure control . . . . . . . . . . . . . . . . . . 52 Fault criteria, catalyst . . . . . . . . . .. . . . . . .. . 84
Idle speed control . . . . . . . . . . . . . . . . . . . . . . 54 Fault criteria, other components/functions 86
Fuel evaporation . .. . . . . . . . .. . . . .. . . . . . . 55 Driving a trip . . . . . .. . . .. . . . . . . . . .. . . . . . . 87
Saab9000

16 Technical Description
Saab Trionic system overview
Saab Trionic engine management system
Saab 9000

TechnicalDescription 17
Saab Trionic system overview (contd.)
The Saab Trionic is an engine management syste!'Tl
which controls ignition timing, fuel injection and boost
pressure from one and the same electronic control
module.
The Saab Trionic system was introduced in 1993 on
Saab 9000 models fitted with the B234L engin~.
Model y~ar 1996 and later cars for the USA market
are equipped with the On-Board Diagnostic II sys-
tem, entailing the following component changes:
• Oxygen sensor also after the three-way catalytic
converter
(rear heated oxygen sensor)
• A number of sensors are fitted with different con-
nectors or gold-plated pins.
Saab 9000
Service Manual
2:7EngineManagementSystem
Trlonlc080 II
M 1996-
The Saab Trionic ignition system consists of an igni-
tion discharge module with four ignition coils, one for
each spark plug. The ignition system is of capacitive
type. Since ,he spark plugs are used as sensors to
detect combustion and knocking, neither camshaft
position sensors nor knock sensors are needed. The
system also supports efficient detection of misfiring,
which is an On-Board Diagnostic II system require-
ment.
Fuel injection is sequential and regulated by the in-
take manifold pressure. Boost pressure control is ef-
fected by means of a solenoid valve connected to the
turbo unit's wastegate. The Saab Trionic engine
management system designed by Saab has tremen-
dous development potential. ·
Saab 9000
I