Professional Documents
Culture Documents
SERVICE MANUAL
rER
MJ~
[E
U l
t;
:2 ~3
Fuel system
," I
240
(240- .
(240-6
f[JJ]e~ ~y~~em
~ Iri1n<C~B )Q1l llllgJ ~ flil@
M
~981-93
1 - - - - - - - - . - -....----.." . - -
,:;....
Units
The basic and derived units used throughout the Service Manual are in
accordance with the SI system. (Systeme Internatio.nal d'Unites)
For users not familiar with the SI units. some non-Continental units are
given in brackets after the respective SI unit.
The following symbols and abbreviations are used:
51 unit
Millimeter (0101)
Kilograms (kg)
Newton (N)
Newtonmeter (Nm)
Atmosphere (bar)
Liter (I)
Celcius
eq
Conversion factors
1 in = 25.4 mOl
1 tb = 0.45 I<g
1 Ibf = 4.45 N
11bfft = 1.36 Nm
1 psi = 0.07 bar
1 US Iiq qt = 0.83 UKqt
of
"
= C x 9/5 +
32
1 0101 = 0.039 in
1 I<g = 2.20 Ib
1 N = 0.231bf
1 Nm = 0.74 Ibf ft
1 bar = 14.5 Ibf/in 2
1 r = 1.05 Iiq qt
1 USgal = 0.83 UKgal
C = eF - 32) x 5/9
m<
ES
EU
FE
FI
r"
...
FR
Austria
Australia
Belgium
Canada
Switzerland
Germany
Denmarl<
Spain
Europe
Far East
Finland
France
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
Fuel system,
8201 fuel injection engine. . . . . 022-1
Fuel system,
8202 fuel injection engine. . 022-4
022-1
022-'11
Other engines
bar (psi)
5:1-5.8 (74-84)
4.5-5.2 (65-75)
bar (psi)
5.3-5.5 (77-80)
4.7-4.9 (68-71)
bar (psi)
'1.5 (2'1.5)
'1.5 (21.5)
bar (psi)
3.4-3.8 (46-55)
3.4-3.8 (46-55)
bar (psi)
2.4-2.8 (35-41)
Turbo,
Other
'1981-82
...085
'1983
...084 (US)
'1982-
... 102
1984-
-1982
1982
...084 (US)
1983
...011
1983-84
1984-
1985-
...020
Saab 900
022-2
Technical data
Croll1tro~
PJll'essu.urs 9
(CO~dJ
eli1goll1e
bar
bar n--,---.-----.~-r_-,----r:;;;::;r__;r~
(ps i) n--+--+--+---+---t----t----;
(psi)
11----1---1--+---1--1-+--1--+--+---1
2.5 1I----I---I--+---I--t--+--I--"I---I----1
3.0 II-------~-I---+--+--t-...,
(36,3)
(43.5) If--+--+--+--t--
11---+---+----+--+-+-1---:
2, a II--+--+--+---+--+::
2 .5 11--I---t--+----t7rr
(36.3) Il--+__+--h
{29,O,ll------+---+--l-_
1,5
2.0 n--t---1-7.
(29.0) 11--1----'
'1.5
rr----,-----.---,--~-r__.------.----,...-____r__,
Il--f--+-----,
(2.:1,8}'l------f-
!1--.J-~+--+-_j__+_+-+__+-.
(21.8)
1, 0 I l - - - - f (114,5)11---1---1---1---+_+--+---+--+--+_ ~
en
1.0
(14.5)
:=b~b=:b:=~='==:=h=='="==d===(f)
O5
lb.
10
(50)
20
(68)
30
(86)
40C
(104) (oF)
\b=~.b="=="==d=d=~'=~
10
(7,'3)
(50)
20
30
(68)
(86)
40C
(104)
("11=
111
070
102
bar ...-.----.-----.~-r__.------,-~~--;
(ps i) II----I----f--l---f-----+-----i-
3.0 I-+---t--+--t----/---+
(43.5) II-----I---I--I--+_+_~
Date code
2.5
D---+--+--+----/-~
(36.3) Il----l____+--l____~&'_+__+__l____t____l
2.0 II--+----I--~
Bosch No.
(29.0) 11--+---+----,1
1.5 1l--+--1~
r-(21 .8) n--t--*ii'-+--t--+---+----+----+---+----ti
'r
(f)
1.0 lb=d=~~~::be='==='=='==!==l
(14.5)
10
20
30
40C
(50) (68) (86) (104) (oF)
Bosch No. 0'438140: 084 (with green c%ur code)
136
Opening pressure
bar (psi)
3.0-4.1 (44-60)
3.7 (53.7)
Tightness test*
bar (psi)
2.4 (35)
2.7 (39.2)
0437502012
0437502056
Bosch No.
Saab 900
Technical data
022-3
Nm (Ibf ft)
4.7-5.3 (3.5-3.9)
Nm (Ibf ft)
4.7-5.3 (3.5-3.9)
Nm (Ibf ft)
5.0-5.5 (3.7-4.1)
Nm (Ibf ft)
3.2-3.8 (2.3-2.8)
Nm (Ibf ft)
13-15 (9'.6-11.0)
M8 bolts
Nm (Ibf ft)
10-12 (704-8.9)
M10 bolts
Nm (Ibf ft)
13-15 (9.6-11.0)
M12 bolts
Nm (Ibf ft)
20-24 (14.8-17.7)
M14 bolts
Nm (Ibf ft)
15-20 (11.0-14.8)
Nm (Ibf ft)
'15-20 (11.0-14.8)
Nm (Ibf ft)
25-30 (18.5-22.0)
Type
bar (psi)
0.33-0.40 (4.8-5.8)
bar (psi)
2.4-2.8 (3.5-4.0)
%CO
approx.4-6
litres (qts)
63 (66)
Iitres (qts)
68 (71)
litres (qts)
approx. 7 (7.4)
litres (qts)
1990-
."
Capacity - measured in return pipe
022-4
Technical data
tFue~ sY$tem~
lPreSSllJllre
202 engone
lregu~a~oD'
'"
checki~g
vah.nes
o
VJ
Designation
Resistance at
ooe (32F
20 e (68F)
80 e (176F)
ohms
5800
ohms
2600
ohms
320
Designation
ohms
7000-11600
ohms
2100-2900
ohms
270-390
Resistance at 20 0
e (68F)
ohms
.. l'1
Saab 900
40-60
Technical data
022-5
... S 1/138
ohms
20 5
LH2.4
ohms
75
LH2.4.2 (M91-)
ohms
12 3
approx.72
1-2
Idling
0.25
Full load
4.0
lambda
sellilSOIi'
~njectors
Flow capacity
Fuel pressure regulator opening pressure (bar)
min
(ml/30 s)
104
1'10
3.0 (i)
90
3.0 (Lucas)
145
',I
Capacity
litl'es (qts)
63 (66)
Iitres (qts)
68 (71)
litres (qts)
approx. 7 (7.4)
'1990-
litres (qts)
approx. 10 (10.6)
llJJmmaU1f of
l~
cmp nlSlf'\)
Tab~e
Version
900iM, iA
Model Engine
year
LH
. 86
B202
2.2
3.0
"
"
"
"
11
88
11
2.4
11
11
11
e8B
11
2.4
11
11
11
11
11
11
"
"
-564 7487135
"
"
11
JI
-580 9119447 \
"
11
11
"
"
11
"
"
"
"
"
"
Ii
89
"
"
"
"
90
11
11
11
91
11
92-
"
91
- - "-
"
B212 2.4.2
"
11
"
"
11
11
11
11
2.2
2.5
86
11
11
11
11
11
"
"
u
87
"
11
"
88
"
11
"
"
88B
11
2.4
11
11
"
89
11
11
11
"
"
90
"
11
11
11
"
_u_A)
"
11
11
. ..:.
~
"
11
11
"
11
11
11
~-~
11
~ r'';''
92":'
11.
--
'Jj~.
-944 9128117
1l_005
-214 7501646
9375643 -706 7509862 -515 7525595
11
_"_A}l,~'
-536 75~8689
11
11
,~
11
11
B202
11
85
11
11
11
900 LM, LA
11
"
-706
92-
11
"
..
11
11
"
11
"
2>-013 7538655
"
"
"
I".:,:",
5MB
"
"
.
..-
LH module
87
"
Bar Bosch
Injectors
HLM
"
"
Pressure regulator
"
11
-537 7532146
--11
"
11
"
11
11
11
"
11
JI
"
11
"
"
11
"
11
11
11
-5$5 9119454
11
11
11
-11
... 11-
-582 9119462
11
"
11
11
11
11
':,S'
;<~i.~,
~-
.'
~-
.)
--
-585 911945~.
'Il
Saab 900
"l"
~~
Technical data
022-7
.... ~.-<. ""\'
CalJ"s
WOUll(o)lUl~
Yer~ion
Model Engine
year
900iM
-89
900 IA
900 iA
900 iM
"
"
90
_'~
,~":II~
'"
"
.:,"-
"
fI
..
..
"
"
"
"
"
"
..568 8975443
-573 9114703
-"'.68 89754.43 1
~'
":J~J, 9'1';470~1
"
"
"
"
"
"
fI
"
"
"
.. fI,-
"
"
"
"
"
"
92-~
"
"
"
"
"
"
"
"
"
-573 9'1'14703
"
__ u_
"
"
"
"
fI
-568 8975443
u \.
"
2.5
"
"
"
"
92-
900 LM
84.5
900 LM, LA
85
"
90g LM
86
,i
"
87
"
"
2.8
"
88
"
"
"
"
"
"
89
"
"
"
"
"
"
"
"
"
"
-255 7564131
"
"
-264 7568041
-",..
"
"
"
2.2
2.4
:2.4.2
Temperature sensor
Lambda sensor
Lambda sensor
x
x
Knock sensor1)
Knock sensor1),
-521 75,26114
-53S' 7529092
-""
"
"
"
"
11-017 8978280 -761 7487010 -569 7487119
Car versions
Bosch
Saab
All
-026
9357021
-009
7925603
-028
~392762
9358037
Gt~23'19,
-006
7568801
,
-300
7501612
2.4.2 M91-
-001
8857195
Cat. cars
-502
7516792
-516
7586019
.,',
, I
. t
Idle air control valve,
;;'0.'
lif~ ZWD3
i~~
'900 It\ 85 EU 1
8857179
,)f
-153 :;' 7518673
Auxiliary air'valve
)(
,
~
-107
8357832
~t
gOOJ~.EU 1
-122
' 9313909
)(
Evaporative emis,sion
canister, complete
Evaporative emissioJ1'..~j.
canister, excl. TEV
Tank breather valve, TEV
)(
"
-432 .
7486129
7532054
All
75392~6
x
x
All
-157
7539257
All turbo
-103
9390022
"
, ,
.....;..
L.._,._\..~,
-505
)(
By-pass valve
"
" *
3}Lucas
*) also 7560'170
LH system
"
"
_u_
fI
"
"
"
'Component
LH module
_~J_
." t."
Injectors
HLM
"
1),
Pressure r~gulator
91
900 iA'
900 IA
2,2
_u_
(C(l)Il'\1VPIl"!1kV
LH
B202
_"_ '\Ii
900 1M
900 iM
a (Cata~yt~(C
!'
022-8
Technical data
Version
Mode Engine CU
year
oprBssure regulator
Bar Lucas
900 SM, SA
90
"
II
"
8202
14.0
"
II
"
91
5MB
Mass air
flow sensor
Lucas
Injectors
"
"
14.1
II
"
-. II
II
"
II
II
"
II
II
84905 89776.'39
900 LM, LA
"
"
"
"
II
14.0
II
II
II
II
"
"
14.'1
"
II
II
"
"
II
"
II
II
II
II
II
90
91
II
92-
.l.
"
"
II
"
92-
900 LM, LA
SAAB
E,L\
"
Control module
II
"
"
"
"
II
II
1) Of Plerburg manufacture
cata~ytic converter
Mode Engine CU
year
Pressure regulator
Mass air
flow sensor
Injectors
Control module
Bar Lucas
900 LM
90
B202
14.0
II
91
II
14.1
"
II
"
II
92-
"
"
II
II
II
II
-- II
"
II
"
"
"
1) Of Plerburg manufacture
Lucas
Saab
73360
7485642
73367
7485600
)(
73357
7485634
73355
7485006
x
x
78161
7486723
x-
Bosch
-006
7568801
Component
CU
14.0
14.1
Compensating resistor
Lambda. sensor
Idle air control valve
x
x
x
x
Temperature sensor
Throttle potentiometer
Knocl< sensor
Cat. cars
900 LM, LA
-,
,
Saab900
II
Technical data
022-9
Model year
Normally
aspirated
Turbo (B201)
Test rpm
Swedeh
Others
;1.0-2.0
0.5-2.5
2000
850
1982,
Sweden
Others
0.5-1.5
0.5-'1.5
850
850
850
850'
1981
Sweden
Europe
'1.0-2.0
0.5-2.5
850
850
max. 4.5%
-
850
850
Sweden
Others
0.2-1.0
0.2-1.0
850
850
max. 4.5%
850
850
Sweden
Others
0.9-1.6
0.9-1.6
850
850
1982-
Turbo (B202)
Pulse
1985-
r~tio/rpm
(cat)
Model year
Pulse ratio")
Rpm
1981
55-65
875
1982-
45-55
875
198"
'1982-83
1984
Idlhlg speed
:lt50 ~pm
CO%
<, . test rpm
198'1
Market
45-45
Remarks
850
850
CA
875
CA
Saab 900
CO value
at idling .
speed
max. 4.5%
max. 4.5%
max. 4.5%
875
. 875
850
850
.~
.....
"
Special tools
83 92 482
CO
~djusting
key
83 93 852
83 93 860
83 93 878
102-1
83 92 5-16
83 93 886
Saab 900
83 93 183
SAAS
"'... s .......l'rttono
I'V't<)tap:-
83 93 597
83 93 514
8393597
83 94 i 32
83 94 322
Saab 900
Special tools
;J
83 94 314
102-3
83 94 223
Saab 900
r:\ --
"-:r
It
------Jf~--:.
_ ....... - - _ .. q: -==-,-.
~
83 94 397
83 94 462
83 94 330
,
I
86 10 834
Saab 900
Technical description
lFllJIe~
General..
.
Fuel tanl< and fue: lJ.. !t7;J
Fuel tank with pre~.sur}zad ! acc,>'el
Fuel accumulator
Fuel filter
Fuel distributor
Fuel line pressure regulator
Warm-up regulator
Regulation of control pressure
Cold-start valve
Thermostatic time switch
Injectors
200- 3
200- 5
200- S
200- 6
200- 7
200- 7
200- 9
200-10
200-11
200-11
200- '11
200-12
200-1
boostung system
200-31
200-32
290-32
200-33
200-33
slJ1lgu01les
200-34
200-13
200-13
200-13
200-14
200-14
200-14
lH mlUl~tll ~rrt
sys em,
18202 elrllguUile
fFl!le~
sBllruchmeU1lt
200-23
200-23
200-24
200-24
200-25
200-25
Starting system
Acceleration system
Connecting pins, P11 relay
B~B'il
200-35
200-36
200-37
200-38
200-40
200-40
Components
Cold-start function
Hot-start function
Fuel enrichment on acceleration
Fuel enrichment pressure switch
Electrical function, cold engine
Electrical function, hot engine
lFUJJe~
200-17
200-18
200-19
200-20
200-21
200-21
DIftl]eC
General
Injection system, EU (1984-)
Injection system, cars with
catalytic converter
Principle of operation
LH system 2.4
LH system 2.4.2
hne~
200-27
200-29
200-30
Saab 900
Fuel tank
Fuel tank ventilation and
overfill protection
Fuel pump, 1984Fuel pump, cars with catalytic
converter (-1988)
Fuel filter
Fuel pump 900i/S16, 1989Fuel tank and fuel pump,
900 Turbo (1990-)
Fuel pump (introduced in 1990)
Pressure regulator
Injectors
Fuel injection manifold
Throttle position switch
Throttle position sensor (1991-)
Auxiliary air valve
200-4'1
200-41
200-42
200-43
200-43
200-44
200-46
200-47
200-48
200-48
200-49
200-49
200-50
200-50
200-2
Technical description
Saab 900
Technical description
Fue~
Injection engine
1
2
3
4
5
6
7
Fuel filter
Fuel distributor
Mass air flow sensor
Air cleaner
Rubber duct connector
Warm-up regulator
Throttle body
8
9
10
11
12
13
Saab 900
Cold-start valve
Thermostatic switch
Injectors
Auxiliary air valve
Main fuse box
Thermostatic time switch
200-3
'.~
:['
Line pressure
pressure -0.1 bar (-1.5 psi)
1''''fi':MffiM Injection pressure
~\\\\\,'t'Control pressure
'[[fll1.LlIIIlJ Return, no pressure
~Line
1
2
3
4
5
Fuel
Fuel
Fuel
Fuel
Fuel
tanl(
pump
accumulator
filter
distributor
Saab 900
6
7
8
9
Warm-up regulator
Cold-start valve
Injectors
Line pressure regulator
Technical description
~QJel
200-5
!pump
'
converter)
"t,
1
2
3
4
Pressurized receiver
Main pump
Return fuel
To fuel accumulator,
5 Safety valve
6 Feed pump
7 Filter
,I
200-6
Technical description
IFlUIs~ aC<ClUlmUl~ait(Jl11'
The fuel accumulator is connected to the fuel line
from the fuel pump and is situated underneath the
floor in front of the 'fuel tank.
".....
Line pressure
3 After the engine has been switched off. the pressure in the fuel system drops to about 2 bar (29
psi) and is held at this pressure by the quantity
of fuel contained in the accumulator. As a result,
the fuel system remains pressurized while the
engine cools down, preventing the formation of
air locks due to vaporization of the fuel and possible starting difficulties when the engine is hot.
Saab 900
Shut-off pressure
Technical description
Fuel filter
THe fuel filter is fitted in the circuit between the fuel
accumulator and the fuel distributor. The filter contains a paper filter cartridge and. a nylon strainer
Fuel filter
1
2
3
4
5
F8Jle~ d1Ds~lribu
Outlet
Nylon strainer
Paper filter cartridge
Arrow indicating flow direction
Inlet
or
The fuel distributor distributes the fuel to the injectors and consists of a fuel control unit and four pressure regulating valves (two of which are shown), one
for each cylinder.
rz<i7~
Line pressure
Line pressure -0.1 bar (-1.5 psi)
I':':':':':{~ Injection pressure
~ Control pressure
111"""11 11 "11 Return, no pressure
Fuel distributor
'::.::"""'!<O{<!
Saab 900
200-7
200-8
Technical description
The skirt of the control plunger is in continuous communication with the line pressure which also acts on
the bottom of the pressure regulating valve. When
the control plunger is raised by the mass air flow
sensor's lever, four metering slots (one for each cylinder) which feed the fuel to the top of the pressure
regulating valves, will open ..
The pressure above the spring-loaded diaphragm
actr 'n the latter, deflecting it downwards and opening tl 3 r . 'let tn the injectors. A pressure differential
of 0 '. Lar ('I.:', psi) then arises between the line
pressure and the ~)ressure above the diaphragm.
This constant pressure differential is required to ensure that the injected quantity of fuel always remains
proportional to the open area of the metering slots
and is the same for all four cylinders.
~ Line pressure
Saab 900
Technical. description
line pll"essulre
200-9
!l'egtll~at08'
The line pressure regulator ensures that the presre in the circuit remains constant when the fuel
pump is in operation and also controls the recircu- (ation of fuel to the tank. When the fuel pump is
switched off, the regulator closes the return line at a
pressure of about 2.5 bar (36 psi) - the rest pressure
- which is maintained by means of an O-ring and the
.quantity of fuel in the fuel accumulator. The purpose
of the rest pressure is to prevent the fuel from vaporizing in the circuit when the engine is warm,
.i which~,would
make restarting di'fficult.
.
...
<
-
":J"'\.....,......."'"'"""'"P'C""""~~
.I
'''''
,~
.... ""
"
....
.1 ... .11"
-~
I
r'
t', " ,'\ " ",\,J
~~_w.~_,,-,.:.'~
I
I
"
~ Line pressure
~ Return, no pressure
f@Wia>olill Rest pressure
"0"
Saab 900
A Line presslIre
B Return line
C Control pressure return
,
Wallrm"'llJp Il'sgulatolr
When the engine is warm, the warm-up regulator (a
spring- loaded diaphragm valve) maintains a constant control pressure above the control plunger.
When the engine is cold and requires a richer fuelair mixture, the control pressure is reduced. This allows the control plunger in the fuel distributor to rise
so that more fuel can be supplied to the injectors.
The warm-up regulator consists of a diaphragm
valve which is actuated by a compression spring.
2
3
4
arm-up regu a or, co
engme
~Control
pressure
IIlIlllIlIIDl Return , no pressure
1
2
3
4
5
Diaphragm
Plunger
Compression spring
Bi-metal strip
Heating coil
==
==
Warm-up regulator, warm engine
~
Line pressure
Saab900
Technical description
200-11
lb
pressure
pressure -0.-1 bar (--1.5 psi)
~Injection pressure
~Control pressure
SaSUi't) va~"e
Saab 900
.\
Injector
1 Fuel strainer
2 Valve disc
3 Needle valve
1 Air cleaner
2 Mass air flow sensor
3 Rubber duct connector
4 Throttle body
5 Inlet manifold
6 Auxiliary air valve
Saab 900
Technical description
Air
200-13
C~ea81ISII"
The air cleaner, which contains a folded paper element, is fitted to a bracket on the front of the LH
wheel arch. The air flows through the inlet pipe into
tile air cleaner, through the air filter and upwards to
the mass air flow sensor, which is bolted to the top
of tile air cleaner.
54483
54484
Saab 900
[bO)dy
Ij
1,
1
ij
,
I
,j
'I
j
I
Saab 900
Technical description
200-15
S44liS
'."
o,i
".
Saab 900
200-16
Technical description
la
ThE
Via
ser
an<
ule
trib
Lal
Lal
pie
n01
l t t
J
!
l
!
5
S 5709
Saab 900
Technical description
g/km
Ideal mixture
13
14,5
16
kg air/ltg fuel
S 5700
Saab 900
200-17
200-18
Technical description
IN
TI
or
a~
5) f) "
2
H
te
55716
'j Electrolyte
2 Exhaw;t gas. s
3 Ambieni air
A
in
31
A
IT
C,
s
U
IT
Catalytnc convertsr
The final phase of exhaust emission control consists
of a catalytic converter located in the front section of
the exhaust pipe.
Catalytic converter
1 Ceramic insert
2 Passages
3 Catalytic coating
Technical description
MiOdlUl~a1tUrJlg va~ve
The modulating valve is a solenoid valve which
opens and closes at a constant frequency (70 Hz)
as soon as the engine has started.
How long the valve remains open and closed is determined by the pulse ratio.
716
70t30
50/50
30170
Frequency of 70 Hz
A Open
8 Closed
Saab 900
200-19
200-20
!FlUj(e~
Technical description
distributor
1
~
C
r
t
c
'-
tl
~ Line pressure
t;;l
Fuel distributor
1
2
3
4
5
Saab 900
Injector
Control pressure regulator
Inlet
Return line
Modulating valve
Technical description
SllImmallr'Y
The'pressure difference across the diaphragm in the
prElssure- regulating valves is controlled by variation
of the pulse ratio. Variations in the pressure difference give rise to a richer or weaker mixture. The
magnitude of the rise or fall in pressure is governed
b~ the signal voltage from the Lambda sensor.
Since the Lambda sensor does not become opera-
1F1!J.j(e~
sll1IlrolCfrumerr[
I)
Saab 900
200-21
Oxygen-sensor blocking
I
I
Cold-start
valve + P l l !
I c~
I CoIG-5~art
valve
I
L
J.
I\.)
f'-.)
-f
CD
(')
e:::-
::::r
(')
::J
0)
+ P11
I
I
Cold-start valve
o
o
Cold-start valve
i'J
c..
CD
(J)
(')
"""t
I
en
Ell
III
co
0
0
I
I
I
I
!
I
Closing temp
19t2
~
I
I
I
I
,
Cold-start valve
.:
Cold-start
valve + P11
S3
I
to
P11
r-+
P=-
:::::::l
C:=-
I Pll
J8i3
p-
Opening temp
Coolant temperature, DC
CJ)u:=;:;=~<OQ~::::;;tm
..Q
<8
.=r 3
--1 ~
"d"
"Til
Technical description
200-23
1981 83
0
C@~oj~stcalll't ffQJIHlCiiUOtrll
,2
1
2
3
4
:>
n
o
;)
I-
:>
:>
, ......o
-t;::'
,
-~ ......
:::J
J .c
?
)
C/)
-Q)
:::J
......
l.1lO
, c
) '':
::::J
:-0
B H@t=start function
If the engine is slow to start when hot because of
vapour in the fuel lines, the cold-start valve will be
controlled by pulses from a hot-start relay. The engine will then start on fuel provided by the cold-start
valve and faster purging of the vapour in the fuel
lines is obtained.
If the engine fails to start after 1.4 seconds, injection
pulses lasting 0.4 seconds will be obtained at 0.3second intervals.
>-
'0
:0
~E
)>-
,Q.l
,t
.~
1C/)
1>-
'Q)
i;!=
SOI311
ro
1C/)
l. >-
)~
)0
)0
IQ)
,i2:
ro
.>
!t
b~
i<f>
1-0
'0
!o
1
0
.......
200-24
Technical description
C Accelell"atioll1
lEI
elnl1'ftchmell1~
Th
bo
grc
ho
Engine cold
Enrichment remains effective until the engine temperature rises above 45C (-j '1 3F).
Engine hot
Enrichment for about 100 seconds if the engine has
been switched off for more than 30 minutes.
QJle~
b())(Q)s e p
eSSlIJD'S
/7;
swotclhl
IE
EI
er
m
6
2
3
4
5
6
lap ragm
Spring
Constriction
Spring contact arm
Vacuum connection
Electrical terminals
th
al
\'.]]!.
re
c(
m
C(
If
n;
:~I
.:.'
,..,.
51
Saab 900
Technical description
e~~C~li'oca~ iflUJll1l(CtD(Q)II'ilS~
SlI'1lgillilE!
200-25
C(j)~~
.~8A
:2
58134
1
2
3
4
lE~ec Il'DCtal~
~I'lJI7l-.-11
L--~34--Jo+
+10
1
2
3
4
5
6
7
8
Saab 900
SIlJS
Technical description
Fue~ @!1'i1WOhniHBU1lt
sys
200-27
em~
1.984",
A new fuel enrichment system was introduced was
introduced on model year 1984 cars.
The system is controlled by a P11 relay. This relay
replaces the time relay, the cold-s~artlhot-start relay
and the pulse relay incorporated hi the. earlier system.
The system consists of two main functioi~;';;:
14
TKK
TIP
(
A Starting system
B Acceleration syst~m
16
='-==
87
l10
11
112
hs
'00'.....
11 8
17
P11 relay
...
CD
.::t
N
en
1 Thermostatic switch
2 Thermostatic time switch
3 Cold-start valve
Saab 900
B
TJ-
at
tUi
ch
01
Fl
W
p'
is
m
15
er
pi
If
N
TI
tit
jE
11
D
E
s
1
2
3
4
tt
b
tt
tf
e
e
- ti
a
2 Hot starting, engine temperature above 25C
(77F)
Saab 900
Technical description
200-29
B Ac(Ce~elra~n:1nl system
This system of fuel enrichment improves the driv-ability of the car after starting. It is controlled by a
fuel booster pressure switch which senses pressure
.changes in the intake pipe.
2
15
6
~
'11
N
N
%
Ul
1
2
3
4
5
6
200-30
Technical description
IF
11
50
TKK
11
(<0
TI<K
Connecting pin for control of Lambda control module. Each time pin "Ii is grounded,
the modulating valve opens fully and provides full-load enrichment.
TIP
aE
is
pr
Signal from starter motor. This signal initiates the time function of 140 20 seconds, during which time full-load enrichment takes place..
(V')
%
(f)
Thermostatic switch
Through this pin the relay senses whether
the switch is open or closed.
Fuel booster pressure switch
Through this pin the relay receives a signal
from the starter motor (pin 16), which initiates fuel enrichment each time the starter
motor is engaged. Enrichment continues
for three seconds after the engine has
started.
Through this pin the relay also receives a
signal when the fuel booster pressure
switch closes (acceleration boost).
X2
Saab 900
tic
Fl
W,
pI
Technical description
200-31
(~1982)
Fuelboosting system
1 Pressure vessel
2 Electric control valve
3 Delay valve (6 s) (manual gearbox cars only)
4 Non-return valve
-----------------
57949
Saab 900
200-32
Technical description
lUI
~"""
ani
Turt
recti
0
0
The
coq
of tl
bi-n
whi
'::on
bar
phr
in t
fR
~~ full throttle
Via the non-return valve, the pressure vessel is in
communication with the pressure generated by the
compressor, thereby increasing the residual pressure enough to maintain the same level over a long
period.
When the throttle is fully open, the electric control
valve is activated via the throttle position sensor, resulting in immediate regulation of the control pressure and corresponding fuel enrichment due to the
"residual pressure" in the pressure vessel.
(C
wi
- - - - - - --I
I
I
Tu
Pn
mE
fur
by
S\i\
A
Sa
51296
su
tft
fuJ
ae
Tt
at
hE
7
At
or
A'
1"
Pi
Saab900
Technical description
Turb>Ol
~mgDrues
200-33
S 2 034
The special warm-up regulator on Turbo engines incorporates a steel diaphragm valve. The pressure
of the spring in the valve is'influenced not only by a
bi-metal regulator but also by a rubber diaphragm
which responds to the pressure generated by the
compressor. I-\t a charging pressure of approx. 0.4
bar (5.8 psi), the spring pressure on the steel diaphragm Is reduced and there is a consequent drop
in the control pressure.
(CI
Turbo
Pressure-controlled full-load enrichment supplements the speed-controlled full-load enrichment
function and also the enrichment that is controlled
by the throttle butterfly via ~he throttle position
switch.
Saab900
Oil"
Gra
The
itzdl
flow
sor)
jecli
,i.e
cou
in it
by t
anc
atUi
air I
witt
stre
fhi:
qUe
rna:
for
In i
voll
sur
ThE
ear
I)
)
o
o
o
Saab900
I
I
I
Technical description
L,H f
8202
Generra.~
The Bosch LH-Jetronic IL uftmassenmesser Ii
itzdraht) fuel injection system, comprising a mass air
fh:/w sensor incorporating a filament (hot-wire sensor), combines the best features of different fuel injection systems with measurement of the air mass
, Le. the density of the induction air is taken into account - unlike earlier fuel injection systems.
in the LH-Jetronic system, the air mass consumed
by the engine is measured, which means that allowance is made for the composition of the air (temperature, pressure and humidjty). Measurement of the
~ir mass is performed by the mass air flow sensor
with the hot- wire sensor, which measure the air upstream of the inlet manifold.
This method provides a more exact measure of the
quantity of oxygen supplied to the engine by the air
mass, which determines the quantity of fuel required
for efficient combustion.
In all previous fuel injection systems, only the air
volume (quantity of air) and/or the atmospheric pressure has been taken into account.
The LH system has the following advantages over
earlier types of fuel injection:
o
e,
Fewer components.
, Lighter.
~
Saab 900
200-35
200-36
Technical description
21
Fuel injection system, EU (1984-)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Fuel tank
Fuel pump
Feed pump
Fuel filter
Fuel Injection manifold
Fuel pressure regulator
Control module
Distributor
Ignition coil
Coolant temperature sensor
Injector
Vacuum line
Intake pipe
Throttle position sensor
Auxiliary air valve
Mass air flow sensor
Pressure switch
Main relay
Fuel pump relay
Battery
Ignition switch
Saab 900
200-37
Technical description
<,..
-<l-
W
L(i119
n
-l>
0(>-
Ir--l
12
"
~20
12
CX)
(T)
1Cf)
1 Fuel tank
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Fuel pump
Feed pump
Fuel filter
Fuel injection manifold
Fuel pressure regulator
Control module
Distributor
Ignition coil
Coolant temperature sensor
Injector
Vacuum line
Intake pipe
Throttle position sensor
Auxiliary air valve
Mass air flow sensor
Oxygen sensor
Pressure switch (Turbo only)
Main relay
Fuel pump relay
Battery
Ignition switch
Saab 900
200-38
Technical description
Prnncipie of operation
In tl
air f
wirE
the
moe
with
moc
the
ThE
ane
niti(
fror
cor
ce~
the
fun
mic
on
full
tra
am
Thl
per
The mass air flow sensor consists of an aluminium housing enclosing an air duct. On M1989 and
later Saab 900 Turbo models with catalytic converter (LH2.4), the mass air flow sensor housing is
made of plastic: Located in the centre of the duct is
a tube which houses the platinum filament (hot wire).
The temperature of the hot wire is maintained at approx. 100C (212F) above the temperature of the
inlet air, regardless of the coniposition of the air or
the air flow.
The device for controlling the current required to
maintain the hot wire at a constant temperature consists of a bridge circuit and a detector resistor, the
voltage variation across which is directly proportional to the magnitude of the inlet air mass.
The electrical components are located in a module
on the mass air flow sensor housing. Since the hot
wire is sited inside the inlet duct it can become
coated with dirt which reduces its sensitivity and affects the results of measurement. To keep the hot
wire free from dirt, it is heated to a temperature of
about 100DoC (183D O F) for one second. This takes
place four secollds after the engine has been
switched off.
Saab 900
en!
ule
per
rno
tiar
Th
ule
Jr
011
thr
tin
ste
thr
Th
. to
alii
Or
au
idl
sa
en
B~
lie
Technical description
In the event of a break in the signal from the mass
air flow sensor (MAF sensor)caused by a brol<en hot
w.ire, for instance, an emergency system built into
the control module and known as the "Limp- Home"
mode will take over, enabling the car to be driven
with impaired performance. When the Limp-Home
mode is in operation, the CHECI< ENGINE lamp on
the instrument panel will light up.
rl
en
L()
rl
'N
[J)
Saab 900
200-39
200-40
Technical description
Co
The LH 2.4 fuel injection system has been introduced on all M1988 and later cars with a 8202i engine and on all M19988 and later Turbo cars. This
system is a further development of the earlier LH 2.2
fuel injection system. The improvement consists primarily of an expanded memory capacity for the control module, as a result of which the module is fitted
with a 35-pin connector.
The
and I
line,
IFl\JJE
The
oven
fuel I
pi. (
Whe
tially
New CP valve
An a
the I
bree
"on
LIppI
raph
fuell
umE
On M1-991 and later cars a number of new diagnostic trouble codes, which can be read on an ISAT,
have been included in the fault diagnosis system.
llHl 2.4.2
fllJe~
HlI1jectooll1 system
Saab 900
mOIi
Technical description
200-41
COmp@Oilerilt$
Fuel tank
The fuel tanl~ is made of injection-moulded plastic
and houses theiuellevel transmitter, the pump inlet
line and a connection for the fyel return line.
The tank is equipped with a breather system and
overfill protection, which ~'Iows for expansion of the
fuel inside the tank.
O>~~il"fm
r=---.~7
: a
11 n
L
~~_.~
.-- -
----
001111
--------
1
2
3
4
5
Fuel tank
Filler pipe
Breather pipe
Breather hose
Constriction
6
7
8
9
10
Saab 900
Vent hose
Filler cap
Vacuum valve
Expansion space
Return fuel line
I
.J
200-42
Technical description
lFue
con
The fl
the fu
and r<
tied fc
relief
pres e
the pi
medic
An ell
fuel 11
veSSE
plied
matic
fUE
ann
Fuel pump
1 Inlet
5 Non-return valve
6 Outlet
Saab 900
mou
sure
tion
anI
mou
'"'rw
lhe
any
- -
200-43
Technical description
..\
n
I
C>
fjl.\Or-=~
Fuel pump
1 Fuel pump
2 Container (pressure vessel)
3 Feed pump
Fuel filter
On model year 1985 and earlier cars the fuel filter is
mounted on the left-hand wheel arch, in the pressure line between the fuel pump and the fuel injection manifold.
P~per
Fitt~r
slement
3 Nylon strainer
Saab 900
'"
~
VI
200-44
fue~
Technical description
pump, 9000/516
(~989 ..)
Thl
thE
ani
thE
pu'
Th
me
tio
fUE
ac
ret
n
is
en
wI
ar
V\
ta
pi
rE
'T
Ie
Fuel pump, Saab 900il8 (1989-)
1 Main pump
2 Ejector pump
3 Filter
4
5
6
7
Reservoir
Pump delivery line
Return line
Screw top
8.6al
.. ,9 'Spring
"fa Breather pipe, filter
Th,e design of the tank has been modified to accommodate the new pump.
The pump cannot be fitted in fuel tanl~s of earlier
pattern.
\
Saab 900
Technical description
......
200-45
'Jel
Saab900
200-46
Technical description
fu
SOO
1'1lI11'b
(1990..)
Ear
pun
witt
f-
Thi
car
wi'll
The fuel pump filter is fitted \"ah a vent lJi e to evacuate any vapour !Jvhich migU form.
I'll
pre
in 1
sirr
the
5
~~ !===~-4
~~~6
P
f-
Reinforcement ring
Sealing ring
Fuel pump
pump cover
Screw top
Alignment marl<s
Fuel tank
Saab 900
Technical description
200-47
,AL 3007857
" AL 50030'12
AL 7021651
1
'2
3
4
Saab 900
To fuel filter
Non-return valve
Feed line
Return line
fue
The f
tion '"
jectio
regul
The purpose of the regulator is to maintain a constant ratio between the fuel pressure immediately
upstream of the injectors and the pressure in the inlet manifold.
The regulator comprises two chambers, separated
by a diaphragm which is held against a valve by a
spring and tile negative pressure in the inlet manifold.
Tile regulator has three connections: one for the fuel
line from the fuel injectio(l manifold, one for the return fuel line to the tank, and one to the inlet manifold.
T~llB
1 To inlet manifold
2 Spring
3 Diaphragm
4 Valve
5 Return fuel
6 Fuel injection manifold
The
"l.CCC
rJas~
for tl
vaCL
The
bod~
'~01jectors
mine
whic
buttl
Insil
thra
On
idlin
tuat
At f
sitic
tact
rich
3
i
2
3
4
5
6
7
Saab 900
Body
Nozzle
Insulation
Spring
Coil
Electrical terminal
Filter
Technical description
200-49
Tn
oU~e
pOSiotoOlfl1 s'Woictn
1--~~-+-
At full throttle, the butterfly is in the full throttle posi~ion and the cam plate closes the full throttle con-
1
2
3
4
5
Saab900
Actuator
Cam plate
Full throttle contacts
Microswitch (butterfly closed)
Butterfly spindle
-.J-.a..u..--4
200-50
Technical description
Idle
The earlier throttle'position switch has been superseded by a throttle position sensor which provides
the control module with continuous and stepless information on the angle of the throttle butterfly. This
information is used for various purposes, including
fuel shut-off.
{lH
The throttle function is adaptive, i.e. the control module "learns" which signal corresponds to idling and
which signal corresponds to full throttle. This means
that manual adjustment is unnecessary.
TIle il
a bui
Theil
of air
air is
idle a
from
ous r
maxil
Toge
toma
stE
be
inc
co
co
he
tel
hi!
For
254
1
2
3
4
Saah 900
Bi-metallic strip
Coil
Electric terminals
Valve disc
200-51
Technical description
(LH 2.2)
The idle air control valve allows a controlled volume
Qf .air to by-pass the throttle butterfly. The volume of
air is determined by the degree of opening of the
idle air control valve, which is controlled by signals
from-the LH control module.
"1"
Together with the mass air flow sensor system, automatic idle control has been introduced to give:
~-/'+I-+--5
L----6
Idle air control valve
1
2
3
4
5
6
Valve body
Valve
Casing
Solenoid
Electric motor casing
Three-pin connector
"
Saab 900
200-52
Technical description
"fa"
resn
The Limp-Home function, which comes into operation when a fault occurs in the lAC system, such as
a loose connection, causes the valve to give a fast
idling speed of 1200 rpm.
The t
manif
modu
the e
quani
ture.
Wher
the v
riche
to co
intal,
tr
As
of fUI
~AC
The
whic
Tem
mCi
lowl
cont
If th
ruptl
ule'
engi
~
6
J69
<~
~>-
~"
15
J.}
200
LH 2.4.2
r
Adaptive
Un
ThE
on i
All
rpIT
StOI
idl~ull1g c(l)rntro~
Ar
ma
the
ing
Thl
tiar
inl
pel
Saab 900
Technicaldescription
-Temperrail:lUIre sensor (
resistor)
Te
1 Resistor
2 Body
3 Connector
lH
2.2)
200-53
Saab 900
-----------------------'-------------:~l\!
Mas
The expanded memory of the control module enables new monitoring and control functions to be incorporated in it.
To accommodate the new functions, a 35-pin connector replaces the earlier 25-pin connector.
The IT
filter a
It conE
from
the air
filarne
outlet
filter.
The t
const
abov,
the c
SinCE
beco
ityar
the ~
aturE
take~
switc
The
The
mail'
sists
vOltE
:mc
The
mas
POtE
Justi
ing
with
rate
pre'
scr~
In tl
air 1
stal
mOl
takf
pail
Saab 900
---..
Technical description
200-55
.....
-"'"'"'.- -----------------------------------
Mass ,air
f~ow
sellilsou-
filter.
Saab 900
Fine-mesh filter
Detector resistor
Hot wire (filament)
Inner tube
CO adjusting screw
200-56
Technical description
Aui" cleaner
Eval
(lH
The air cleaner, mounted on a bracket on the lefthand wheel arch, consists of a cylindrical container
to which an air intake is connected. Inside the container is a folded paper element and the removable
cover is secured by means of four toggle fasteners.
Gase(
trappE
pass'
gine v
Adlap~nve
Thep
by si!
functi
engin
The adaptive (intelligent) Lambda system compensates for variations in the fuel-air mixture.
This compensation is carried out by raising or lowering the basic setting according to the variations
occurring in the system, which can be caused by air
leaks, fluctuations in the quality of the fuel or normal
wear and tear.
No basic setting or adjustment of the Lambda system is necessary.
Int.
Shnft=up DlI1dicaftion
Now that shift-up indication is built into the new control module, the relay and all sensors and switches
that were previously incorporated in earlier shift-up
indication systems have been discontinued.
Saab 900
The
impr
fault
laml
, dun:
cati
poir
Int
She
sys'
nak
- -
Technical description
E",aPO>Il'Bl~hi'ea~(Q)S$ c(Q)lnl~rro~
device
{LH 2.4)
Gaseous hydrocarbons from the fuel tank are
tr.aRlDed in the charcoal canister. They subsequently
pass through the canister purge valve into the en~ine where they are burnt.
'ifil;Je purge valve on the charcoal canister is activated
D~)f'\nals from the control module. The purging
'f!~f1C n Is dependent on engine load conditions and
f' l"f.+. ~i'
! '" ~~~erj.
,I,
'\
Integlraltedl
ffallUl~tc(Onaglnlosns
syslteD'i1i1
Integrated!
rPll'eSSQ.lHre
selrBsOJIl"
Saab 900
200-57
prel
urr
The
two
air i'
Iira\
VilW
The
air I
ThE
fue
821
am
ma
Ins
wh
Thl
ani
thr,
exl
N(
Th
We
tht
preheating . . . . . . . . . . .
232-1
'e.'
. 232-1
Air clea.ner
The air cleaner, mounted on the LH wheel arch, has
;fWo functions: in addition to cleaning the induction
air it also dampens the noise made by the air being
(lrawn in. The filter element, made of special paper,
lll1ust not be washed or moistened.
l1/fte mass air flow sensor is mounted on top of the
air cleaner.
;\{'Ii f)'
<l~I'"
Prehle~to Iillg
The following applies to all cars equipped with CI
fuel injection and a catalytic converter (US, EU), to
6201 engines with Clan 1984 and earlier models
and to Turbo 8201 engines on 1985 and earlier
mm:lels.
Inside the air cleaner intake is a thermostatic valve
which regulates the temperature of the induction air.
111e valve housing has two inlets, one for cold air
and one for preheated air. The preheated air flows
through an insulated .hose from a hot spot on the
exhaust manifold.
Note:
The preheater hose must be tied or clipped to the
wastegate valve on Turbo engines to keep it clear of
t~e battery.
Saab 900
232-2
On normally aspirated engines the valve is actuated by means of a cable attached to the body of a
thermostat fitted upstream of t~e. throttle housing.
The thermostat senses the temperature of the
blended induction air, which is maintained at a temperature of between 23C and 37C (73-98F) by
the valve butterfly, which oscillates continually between the cold air and preheated air inlets.
ArOl
by nl
mOV I
Fore
~
":>-. ?
6'/
~'~_/
~\
~
57&1J
pletE
stat.
priat
posi'
Notl
On Turbo engines the thermostat body is fitted inside the preheater valve and senses the temperature of the ambient air. The valve maintains an air
temperature of between -SoC (23F) and +SoC
(41F).
WhE
cabl
the
For
_5C
+5
Nor
23
37
\.
Saab 900
Prehelter v21~Ve
~heck (c 1985)
232-3
fl\JBl1c~n(i)n1
s1at. Immerse the thermostat in water at the appropriq,te temperature (see below) and check the
'fDosition of the butterfly.
'oo'
Note:
WHen pefiorming this check, make sure that the
carole adopts roughly the same position as it has in
the car.
)
'''3
.
Checking the preheater valve (normally aspirated engine).
,--- -_....",-_.
"
~Qlln
________-'--
-=---=-==:-Saab 900
~I'
"0:(0";;
Fe
ct
pl
ct
. pl
Fuel system
988)
CAUTION
There is an acute danger of fire due to fuel
atomization when carrying out this test. Do not
smoke. Mal<e sure that the area is well ventilated.
Note:
Make sure that the tank is at least 3/4 full before
starting this test.
pu mp.
':;J~
-'~~~,
Note:
Take care to prevent the leads from touching each
other or any metalworlc
3 Slacken the clip on the pump using a flexible
socket driver.
Saab 900
233-1
. 233-10
. 233-30
233-2
Fuel system
4 Cars with LH injection system (cars with CI injection system, see point 5):
No
Alv
the
me
9
N e:
No
Me
OVI
sel
c
(V
Note:
fa
1
6 Start the feed pump by setting the switch to ON.
CAUTION
Since a large volume of fuel may be dischargE!d, take precautions to prevent it from
getting into the luggage compartment. If fuel
does get into the luggage compartment, make
sure that all petrol fumes are expelled.
8 If no fuel is discharged through the safety valve
when the feed pump is running, fit a new feed
pump. If the feed pump does not wort" check the
electric leads connected to it.
"
4
.....
Saab 900
Fuel system
.J\Jote:
Always turn off the pump's power supply by setting
the switch to OFF before connecting any test instrument.
9 Fit in reverse order.
No.te:
Make sure that the area round the hole for the c! ler
over the fuel tank is clean and perfectly dry 1:J'fi','iim3
seduring the clip on the fuel pump collar.
ChBlDilgi 9 !he
(with feed
fu~~ lUImp
)~ c~ 988
To rsmove
1 Disconnect the battery cables.
2 Remove the luggage compartment floor and
floor panel and also the circular cover over the
fuel pump.
-5
~'.,
.'
~:-f'-'.~
6-if "'--.2} _ .
I.
..,
Q~J.~7"
J.
!U/L30l'
1 Rubber collar
2 Main pump
3 Filter
4 O-ring
5 Re,ceiver
6 Feed pump
7 Filter
Saab 900
','
233-3
233-4
Fuel system
To fi
1 Co
wh
lea
2 Fit
thE
1[
2,
Note:
On earlier pump variants, the existing feed pump
filter must be replaced with the latest version. Accordingly, plug (1), washer (2), filter (3), clip (4) and
a-ring (5) will become redundant.
+
3
e
11
C
n
4:
1
2
3
4
5
Saab 900
Plug
Washer
Filter
Clip
O-ring
--
Fuel system
To fit
1 oonnect the electric leads to the feed pump:
white lead to the positive (+) terminal and black
lead to the negative (-) terminal.
= 42
Saab 900
233-5
233-6
Fuel system
To
-j [
2 F
fl
fl
3 [
~
4 L
Saab 900
Fuel system
- -
233-7
e.,ars)
Tp remove
'j
fll
-<::
,N
lJl
Saab 9QO
233-8
Fuel system
~it
1 Fit the pump to the mounting so that the distance
To
To cl1
The non
can be
screwdr
Avoid 9
damage
Tighten
E
E
l.D
..!,
n
<t
l!:
1---- 6
1 Non-return valve
2 Fuel pipe
3 Pump bracket
4 Clip
5 Pump
6 Cap nut
Hol,d the pump with the positive (+) terminal facing the left- hand side of the car
Align the suction strainer inlet diagonally rearwards at an angle of 45 towards the right-hand
side of the car.
On ml
valve
A Front of car
Saab 900
---2
Fuel system
To change the l11lorn=trsturrn
va~ve
233-9
9mm
4mm
+-----+A1
~ +---I-Ho-....I
CJ
'.
Saab 900
233-10
Fuel system
th~
Cha
To r
-I Oi
CAUTION
2 01
3 El
4 Ai
tri
5 Ti
6 A
7 R
Note:
BU
_r~
Saab 900
--
Fuel system
OlUUl.giD1g the
~W~~
pump
10 remove
1 Disconnect the negative battery cable.
Apply tool
f.,J 94397.
'.,.
Saab900
233-11
Fuel system
233-"12
-------~----------------------------......:.;.~
CAli'
WilE
suet
tran
ven
If al
fum l
We,
with
ing clamp.
2 I
I
Saab 900
Fuel system
---,
233-13
'l:"""'
......- - - - - - - - - - - - - - - - - - - - - . , , . . . . . . - - - - - - - - - - - - -
....G,.AUTION
.
When carrying out any work on the fuel tank,
.such as replacing the fuel pump or fuel level
transmitter, make sure that the area is well
v.entilated.
If approved extraction equipment for petrol
fumes is provided, make use of it.
Wear suitable gloves, as prolonged contact
with fuel can cause dermatitis.
To Il'em@ve
1 Disconnect the negative battery cable.
Saab 900
233-14
Fuel system
6 Al
F
E
t
Note:
Although the fuel system has been depressurized, a.
small amount of fuel will still escape from the connections,
Saab 900
Fuel system
Iii Apply tool 83 94 397 as shown in the Fig.
Pass the chain through the load-securing brackets on the luggage compartment floor. Secure
the chain by means of a screwdriver as shown
in the Fig.
-"
Saab 900
233-15
233-16
--
Fuel system
To fi
1 Po
so
mE
pu
du
Pc
the
of
UI
2 :
I,
Saab 900
Fuel system
~--
ft)
fit
Saab 900
233-17
233-18
Fuel system
Not
To
the
10'/11
Tig
Tht
tha
Saab900
Fuel system
Note:
1'0 prevent the ejector pump from being damaged,
the pump must be correctly positioned and not aiD
rowed io tum when the screw top is tightened.
I
iT'ighten it as far as it will go.
than 30 from
Saab 900
233-19
233-20
Fuel system
TOll
1 R
2 R
3 S
s'
4 F
5 F
6 F
9 Refit the circular cover and the luggage compartment floor panel.
Saab 900
Fuel system
.,
Saab 900
233-21
233-22
FOJle~
1'0
--
Fuel system
lUmp
fn~tef1'
Se~
sec
lrelP~aCe
The filter and reservoir are an integral unit and cannot be replaced individually.
1 Remove the pump, see "Fuel pump, removal
and fitting" on page 13.
4 Fit
0-
5 F
P
.t,
tl
Saab 900
Fuel system
6 Fit the pump, see "Fuel pump, removal and fitting" on page 17.
Saab 900
233-23
233-24
Fuel system
------.:........--------------------------441 ___
To rl
1 RE
2 RE
3m
4 Cc
5 Fi1
6 Fij
Saab 900
Fuel system
1~ relP iace ttlhe ejectolJ'
IrnllMIPl
Saab 900
233-25
233-26
Fuel system
5 Fi
Ejector pump
To
pI
Irep~ace
1 Remove the fuel pump, see "Fuel pump, removal and fitting" on page 13.
6 I
1
2 Remove the ejector pump, see ''To replace the
fuel pump filter", page 22.
Saab 900
Fuel system
233-27
233-28
Fuel system
Rc
dr:
3 B
a\
Ir
NotE
Alwc
4
I
(
Saab 900
Fuel system
Nate:
Always fit new O-rings.
4 ,Assemble and refit the pump, see page 17.
Check that it is in proper working order.
Saab 900
233-29
233-30
Fuel system
~
T r
0 (
99 on)
CAUTION
Do not smoke.
Be mindful of the danger of sparks being
caused by short circuits, when connecting and
disconnecting live circuits, etc.
Make sure that a suitable fire extinguisher is
alwavs near at hand and work only in a wellventHated area.
To remove
1 Disconnect the negative battely cable.
8
3 Remove the luggage compartment floor panet:
4 Undo and bend aside the cover over the pump.
5 Remove the locl<ing clamp and unplug the connector.
Saab 900
--
Fuel system
6 Disconnect the fuel lines from the pump. Move
them out of the way and secure them by means
of a cable tie.
462.
Saab900
233-31
233-32
Fuel system
T@ fit
Saab 900
Fuel system
4 Fit new O-rings on the fuel line fittings and connect them to the pump.
i,
Saab 900
233-33
Ren
Fitti
F'ue
ReF
c'
[
c'
Thl
fue
be
ing
234-1
-------------------------------es
IIIl
Removal of tan!{ . .
fitting of tank . .
Fuel lines. . . . "
Replacing f1uel lines
. . .
. . .
. . .
inside cal' .
234-1
234-3
234-4
. 234-5
234-7
. 234-8
CAUTION
Do not smol". [-'3 mindful of t:1e danger of
sparks beintl t. lused by shOT:: circuits, when
connecting and disconnecting live circuits, etc,
t." Make sure that a suitable 'fire extinguisher is
always near at hand.
Work only in a well-ventilated area.
, ,
Disconnect the fuel line from the fuel pump, connect a special line to the pump and fit the other
end to a suitable receptacle, The receptacle
should be. closed and equipped with a vent hose,
which should be run back into the fuel filler pipe.
Note:
Do not run the fuel pump without any fuel in the tank.
S79B7
Saab900
234-2
To f
1 Me
the
2 Ch
ble
tut
3 Lifi
.'Vt
27
30
tilE
iiih
5 RE
tul
6 RE
Connec t the fuel pump's switche djumpe r lead 83 93 886
across fuses 27 and 30.
tel
fUi
7 Lc
RI
Saab 900
- -
To fit
1 Make sure that all seals are correctly fitted on
the tank.
e Reconnect the leads for the fuel level transmitter and fuel pump and refit the cover over the
fuel pump.
7 Lower the car.
Saab 900
234-3
234-4
IFUJle~ ~nD1le
the
II'UJlns
(c,
The
r---------:e~;;:---------l alongfuel
thE
To rei
1 Rem
pet f
2 Ren
3 Ren4 Disc
pres
the I
Disc
metl
5 Und
~irBes
'le
Checking
fllle~
line
the'
fuel
To fi1
1 Cle
thrc
rna!
2 Insl
bull
nee
3 Fit
he.
COlluuectiOIl1S
br2
4 Fel
the
ani
thE
v
Saab 900
Fit
thE
the Calr
r
'fhe. fuel lines from the tank to the engine bay run
alelilg the left-hand sill inside the car.
fa rem))ve
1 Remove the scuff plates and turn bad, the carpet from t! 'Fa sill.
2 Remove th3 ~ELe 'oJ' inq 6e :uelline.
:3 RemO\le the
bUIl\hc-ad,
To
'j
fot
Clean the fuel lines by blowing compressed air
through them. Sianl, off the ends of the lines with
masldng tape.
3 Fit the rubber grommets in the holes in the bulkhead and in the front holes in the spring link
bracket.
4 Feed the fuel lines through the cabin, connect
them to the lead-through adapters at the rear
and secure them with tape at two points along
the sill.
5 Fit the insulating felt to the bull<head and replace
the carpeting and sill scuff plates.
Saab 900
234-5
234-6
Mal
Tc remove
Mate
soldering
GO
Or
Or
1 (
it
t
3 (
41
i
S 5192
'
Diffl
use
mOl
tere
ad
cal
, Tc
trc
1
2
To fit
1 Use a knife to cut off a short section of the fuel
line. Cut off as short a length as possible.
Nt
Tr
'I!
la
Saab 900
234-7
S 5196
Fue~ ~eve~
trans i tell"
tra.nsmitter
1 Disconnect the negative battery cable.
2 Remove the rubber plug from the transmitter
and disconnect the electric leads.
,
~'r
Note: '
Transmitters intended for model year 1981 and
1982 cars cannot be fitted in model year 1983 and
later cars, and vice versa.
Saab 900
234-8
5 Remove the transit safety from the new transmitter (as from 1983 models).
Fuel
Fu
cable.
Ch
Gcn
l\ 3
Air 1
lv1a~
Ma~
MaE
Aux
Wal
The
FUE
Vol'
Inje
Col
To remove
-I Remove the trim on the right-hand side of the
luggage compartment.
ct
Ge
COl
Co
Lin
Id
Se
CC
CI
e)
1'0 fot
51
Cl
Gl
s{
C
T
P
C
5 2/382
,
11
- -
Saab 900
--
240-1
--..,..-----------------------=----------
falUn
. ;1 '(~,f;i1eral
, .' ,'. . I ' "
' ,1'.'" ',\.' ,;:l. :.~ Ieakage
('.
240-3
240 -3
.; .. "":f'
.."j~ .,', '.
I
240 4
.~I\:,:'lea'(age...................................................... "
'~'i
~
Mass air flow sensor lever mounting
240-4
Mass air flow sensor plate clearance
240-5
~ass air flow sensor plate rest position
240-5
Auxiliary air valve
240-6
Warm-up regulator
240-6
Tbermostatic time switch
240-7
Fuel pump capacity
240-7
V<:>ltage across fuel pump
240-8
lriljectors - performance and sealing
240-8
C9ld-start valve - function and sealing
240-9
Mixture
General .. ,
@0titrol pressure: engine cold
Centrol pressure: engine hot
kine pressure
240- '10
240-11
240-11
240-12
IdUnQl adjll.lls1tmell1t
Setting idling speed
eo adjustment
240-14
240-14
240-15
resBdI
240-16
240-16
240-23
240-24
240-25
240-27
240'-28
240-29
lUlrDnt
To remove
To fit
Fuel distributor
Line pressure regulator
240-29
240-30
240-30
240-30
240-31
240-32
~ril~ectotrs t~ Il"ep~ace
240-34
240-35
Warm"'llIfP Irl!gllJl~at(Q)1l' ~
~@ U'eplace
~
240-36
240-H
t@ rrep~ace
240-36
lFl\,He~ aCClUlRnl!JJ~atOIl'
240-18
Removal/fitting
240-37
240-37
240-18
Thfi'@U~<e
240-20
240-21
a~
pll'eSSlIJIll'te
rcO)[llltrr~
sys em
CheckUliilQ pll"essull'ss
Checkoli1g
J1nagl/1osis~ C~
240-20
Saab900
240-2
Gen
240-38
240-40
240-40
Befon
starte
mech
syste
clean
out 01
thoro
nectE
240-41
240-41
240-42
240-43
240-44
240-45
240-46
240-47
240-49
240-50
240-51
Fu
ChE
.. con
fuel
Fit
Dar
ChI
jec1
Co
oth
dar
Saab 900
Generral
Before testing and fault tracing of the CI system is
started, it must first be established that there are no
mechanical faults in the engine and that the ignition
system is in proper worl<ing order. Scrupulous
ct3''Inliness must be observed while work is carried
0U1 f1 the system. The surrounding area should be
tho r uGh"! cleaned \: "fore any lines are discon-
net d.
CAUTION
Fuel ieakage
Check that there is no leakage at
connections and in the fuel lines. Check around the
ft!Jel tank, inside the cabin and in the engine bay.
F.it new seals to any leaky connections.
Damaged fuel lines should be replaced.
Check that fuel lines do not chafe against other objects (particularly those made of plastic).
Oontinuous chafing (e.g. against the dipsticl< tube,
other fuel lines or the throttle cable) can result in
damage to the fuel line.
Saab 900
240-4
ilr
Mal
~ealkage
Chec
mas!
form
\t ',e rubber du':t between the mass air flow sel1,01 .If j tl18 ~hr ... l"tIe body
'ViE
pO
Unwanted air can also be inducted via the crankcase ventilation hose, the oil filler cap, dipstick tube
or camshaft cover gasl<et.
ass aDD"
f~o>w
samsoll'
Che
plat
wor
the
~evell'
mtOlunio81lQ
Remove the rubber ducts and check the movement
of the lever in the mass air flow sensor. As the lever
is lifted, steady resistance should be felt as a result
of the damping action of the control plunger. No resistance should be felt when the lever is suddenly
pushed down away from the plunger. If the mass air
flow sensor has not been removed, use a pair of pliers or a magnet to lift the lever. If any binding is felt,
the mass air flow sensor must be repaired.
res'
she
turi
ser
ed~
mi~
the
Th
(A
m,
fin
Saab 900
_.
240-5
A
Mass air flow sensor plate clearance
A Correct
B Incorrect
Mass auif'
posUtOOIJ'1l
ff~OlW
sell'ilsoU'
fP~ate
reslt
~
[I).
Saab 900
St.:4R9
240-6
V'
4
tt
s
L
tl
II
C
tl
ti
Walrm~l!Ip lregLll~ator
Check the electrical leads running to the warm-up
regulator as follows:
Unplug the connector on the warm-up regulator and
connect a multimeter across the connector pins.
Remove the fuel pump relay and connect a jumper
lead between terminals 30 and 87 on the relay board
to supply the fl lei pump (and the rest of the CI system) with power. Read off the voltage at the connector, which should not be below 11.5 V.
o
Saab 900
fhermosftatoc
~om SWH
elm
Fue~
pump C8Ipacoty
If the amo',mt OJ hiel c,)!lo ,ted is be:ow that specified, the following possible causes should be investigated:
17
Saab 900
240-7
240-8
Ur
lei
81
frc
sensor.
PI
ric
er
of
R
-Ie
to
te
P
a:
8\
sl
Vi
e
3 Remove the fuel pump relay and connect a
jumper lead between terminals 30 and 87 on the
relay board to supply the fuel pump (and the rest
of the CI system) with power.
4' Fuel atomization: Raise the mass air flow sensor lever and observe the spray patterns of the
injectors. If atomization is poor, refer to the "In_
jectof8 - ~o clean" section.
Saab900
- -
I"'" ,-
CAUTiON
'There is an acute danger of fire due to fuel
atomization in this test. Make sure that the
area is well ventilated and that nobody is
smoking.
~ Valve sealing: Switch off the ignition. Th\:1 "'Jel
,f,
, I,
I ,(, ;
'J.
; 70S>.
Saab 900
240-9
240-10
COl
Geli1lerraJ
Connect pressure gauge 83 92 516 as follows:
Disconnect the control pressure line from the fuel
distributor and connect the pressure gauge between
the fuel distributor and the line running to the
warm-up regulator.
This
plain
poor
rlod.
cold.
test
seVE
that
start
com
the 1
Can
omr
surE
If th
Note:
The safety device for running the fuel pump is controlled by a pulse sensor in the pump relay which is
actuated by the ignition pulses.
Cc
Car
per
nor
OPI
Plu
Lee
sta
Co
If tl
- - - - - - - - - - - - - - -Saab
- -900- - - - - - - - - - - - - - -
240-11
Saab 900
240-12
-.--
Une pressure
If tl
the
tiVE
If tl
cal
II
Le,
re{
"FI
tic
I)
El
Al
Af
re
This test should be performed in the event of complaints about starting trouble when the engine is hot.
ac
Tt
st
a\
b,
\A
is
Ti
1:
Saab 900
240-13
1
2
3
4
Saab900
240-14
luI'
lUi
CO
SettRB1lg
8cdl~ifi1g
speed
Note:
If rough idling or difficulty in reducing the idling
speed is experienced, check the setting of the deceleration valve.
Afl
pll
(
E
VI
'h
C
o
II
e
e
CAUTION
Saab 900
240-15
CQ,')U1lll1lectu~cri1
f exhaust
e){tlractoOlIli1 <eq] lUJ~ pmsnt
'1i:......._-
A Right
BRight
C Wrong
Saab900
240-16
--
ctu
TUI
AH
Genera~
1 R
IT
t~
2 [
[1
c
3 F
i
i
I
4(
f~ow
Saab 900
b .
\.
'
Turbo,
982
(waot
.
:.~ C)
.1
J -
A ties,,)!
~oadl
(lnot
h.HI:~
throttle)
Pwmp up the pressure to 0.8 bar (11.6 psi) (owing to the' action of the delay valve, keep checking the reading on the gauge until the pressure
has stabilized).
B Full
thrott~e
1M
Saab 900
240-17
240-18
Checki 91 he
pressure
rres8dUJla~
"I-t
..
1 Connect pressure gauge 83 93 514 (for checking charging pressure) between the non-return
valve and the pressure vessel.
S 7299
Checking f el
Tur
"
0)
enric!hment~
PC (1982)
A
S21056
A Plug
Saab 900
240-19
-',
'
S 7156
tl
5
4
3,6
3
2,6
2
1'1
11 0,16
0,32
!-~I.r--..LI-4""i_--;-_--y
0,2
A Control pressure
B Boost pressure
Saab 900
0,4
0,6
0,8
B
_
(bar)
240-20
dJlIS Ulil1gl he
lblUlUe8"f~y sftp
~hlw(Q)t ~
3 C
t~
4a
5 (
Saab900
S~~
'f th
whil
the
cau
Saab900
240-21
240-22
poe
perri
1 C
E
pi
Ie
N
CI
2 a
b
--
v
(
p
S 2/126
3C
i1
4 (
3 a Check the CO content (engine hot).
b Check the pulse ratio, see section 254, Service Manual 2:4 (US specification)
Ched< the hot-start reiay, see "Cold-start valve performance and sealing" on page 240-9.
4 Check the rest position of the mass air flow sensor plate in the mass air flow sensor. (The top of
the sensor plate should be level with the lower
edge of the air venturi or slightly below it, max.
0.5 mm.) Adjust by means of the spring slip (A).
Saab 900
5 Check the fuel enrichment system, see "Coldstart valve - performance and sealing" on page
240-9
Saab900
240-23
240-24
POI
1 (
3
o
o
Saab 900
fle'or
240-25
spsedl
S 5206
2 Check that the fuel flow rate is sufficient by measuring the quantity of return fuel obtained during
a 3D-second period. See "Fuel pump capacity",
page 240-7.
Il
Saab 900
240-26
o
E~
1
2
3
55209
Saab900
240-27
g Check the
55209
S 5212
"
Saab 900
240-28
3 (
2
2 Check whether any parts of the mass air flow
sensor are sticking, as follows:
Run the engine to normal operating temperature
and then connect a CO meter.
Dt..
o Switch off the engine and start it again witliJt
I.'t5l.l},ching the accelerator. Read off the CO con171eR'~ 1- ~ "","('-k cMo
o ReJ~1f1e engine to about 3000 rpm and then
allow it to return to idling speed. If the CO content
is now different to the earlier reading, then either
the control plunger or the lever is sticking.
f~~,.,
3
4
5
6
7
M
If the control plunger is sticking, separate the fuel
distributor from the mass air flow sensor, taking care
to prevent the control plunger from falling out. Remove and inspect the control plunger (avoid touching the sealing surfaces). Wash the plunger in clean
petrol, refit it and also refit the fuel distributor. Do
not dismantle the fuel distributor more than this.
Saab 900
11
1
,.
f.
Rep~
cong he air
f,Utelr
e~melin~
c~eall1le
To remove
1 Thoroughly clean the area round the fuel connections on the fuel distributor.
2 Disconnect the fuel lines from the fuel distributor. Disconnect the lines to the injectors before
disconnecting the control pressure line to avoid
damaging adjacent lines when the control pressure line is removed.
3 Remove the rubber duct between the mass air
flow sensor and the throttle body.
4 Undo the retaining bolts and remo,'e the Ttlef
distributor from the air cleaner.
Saab 900
240-29
240-30
1'0 fit
La
se
1 Make sure that the air cleaner element is correctly positioned and then bolt the fuel distributor to the air cleaner.
l'(
5
Fue~
distri IUItor
The fuel distributor must not be dismantled for repair but should be replaced if it is faulty.
~..--.._----
-,-.-_.
'.'
Saab 900
240-31
Lever~
1t
Saab 900
!.':
240-32
fo fit
1 Place the counterweight on the lever but do not
tighten the screw fully.
piE
Til
1 2 3 4 5
.666~~l
8 A
bl
d
9 P
a
tt
s
d
Note:
p
n
1 Clrclip
2 Shim
3 Seal
4 Spring
5 Ball
10 I
I
j
Flnl
the
Sel
Saab 900
it. Checl< that the lever can move freely, completely without resistance.
Tightening iorque:
5.0~5.5
Sash 900
240-33
240-34
~R1]ec
ors
(Q)
Il"SP
ace
Inj
If a
leal
2 Disconnect the fuel line from the injector. Prevent the injector from turning by holding it with a
spanner.
ten l
refT
jeci
Of t
3
3 Remove the retaining plate.
4 Withdraw' the injector and pull off the rubber
seal.'~.
4-
Injl
ca
su
in~
fat
Saab 900
IMjec~Il'S
ft(Q) c~eaUl1
Perfect atomization
Acceptable atomization
saSH:
Saab 900
240-36
Warm",Ulp
regu~at()r..
replace
To
'1
t".
P<
c~
uxn~Oalfi1f
(Q)
Ire~~ace
N
p,
v
s
Fit in reverse order.
Saab900
To remove
1 Clean the ~rea round the fuel connections.
2 Undo the connections and remove the fuel accumulator.
To fit
1 Mount the fuel accumulator on the bracket.
2 Connect the fuel lines. The line from. the fuel
pump should be fitted to the connection nearest
the edge of the fuel accumulator.
Position the fuel line from the pump so that it cannot
chafe against the car body.
~ fo~t@R'
co
~tQ) lrelP~a<ce
Note:
Avoid loosening the fitting on the outlet side to pre-
Saab 900
240-37
240-38
C~ ~8.!le
jeC
BO sys
~mA~
--
lEU
(US s ecnfnccal O@ )
The v:
cel era
tlvate(
tio of
8irf;:
~~2
The d
'i'
the
atul
When reading the component descriptions and faultdiagnosis chart included in this section, refer at the
same time to the corresponding wiring diagram in
Service Manual 3:2.
Fuel
shv)Jtc(J~f
on
the
pOE
f~eceleratiolil
(1981)
en~
tlie
The (
as
SC
off ac
The!
has c
52075
1
2
3
4
5
6
7
8
Principle of operation
The deceleration system causes the induction air
that normally passes the mass air flow sensor plate
to by-pass the plate via a hose and vacuum valve.
As a result, the sensor plate remains in its rest position and so shuts off the supply of fuel to the cylinders.
Vac
Whl
lene
tion
mal
ope
Saab 900
240-39
--._---------------------_......:..-----------The vacuum valve acts as a by-pass when the deceleratjon system is engaged. When the relay is acfivated. the control module selects a fixed pulse ratio of 60%.
The deceleration relay is activated when:
the thermostatic switch is closed (coolant temperature above 45C)
the timo ie.lay (P 11) is not activated (relay in rest
position,
engine Sf ;ed '5 '1! hsr tl1ail 1575 "175 rpm
the throthB position switch is closed.
lihe deceleration system shuts off the supply of fuel
as soon as the throttle position switch closes (foot
Qff accelerator).
lhe supply of fuel is resumed once engine speed
has dropped below 1375 75 rpm.
S207G
When current flows through the vacuum valve solenoid (4) from the fuse board (2) via the deceleration relay (3) to ground, the pressure in the inlet
manifold acts on the diaphragm in the valve, thus
opening a by-pass port.
31
3
87
{)
Vacuum valve
Saab 900
240-40
--
The
the~
The tl
Closing function
The throttle position switch is closed across terminals i and 2 only in the idling position.
As a result, terminal 30 of the deceleration relay and
the TRK terminal of the time relay receive a ground
<::r nal (see the description of the relevant relay funcr, 1 fIJf fUri:her details).
C :e 'hc"! \mttle t"Jitelily has opened beyond 72,
th .. s\l1/itch closes acro~s terminals 2 pnd 3 and a
ground signal is receivea ;r{\m the T <. Kr minal of the
AC relay (156). This causes disengag;:;ment of the
electromagnetic clutch on the AC compressor (cars
with AC).
low
111ghe
tempi
[T1ost l
most.
Cons
cold(106:
Thl
The
low
thaI'
atur
Dual function
The throttle position switch is closed across terminals 1 and 2 from the idling position until the butterfly opening angle is greater than 72.
During this time, terminal 31 A of the speed relay receives a ground signal (see the description of the
TIP relay function for further details).
When the butterfly opening angle passes 72, the
throttle position switch changes over and a connection is made across terminals 2 and 3. As a result, a
ground signal is received on terminal TK of the AC
relay (156) (disengaging the electromagnetic clutch
of the AC compressor), terminal 11 of the deceleration relay (106) and terminal 1i of the Lambda
control module, which produces a pulse ratio of
more than 92%.
Not
The
of tl
dec
At '
sig~
tra\
sar
Atl
sw
lec
Tu
Th
st,
thl
6C
Saab 900
240-41
--~---------------------~-----------
swu~clhJ
45/38(; aB101
therMostaitnc Urns switch
hermostaiic
TM thermostatic switch closes at temperatures below 45C (112F). If the temperature has been
higher than this, the switch will not close until the
.emperature has dropped to 38C (1 GOF). The thermostatic switch is connected in series with the thermostatic time switch (92).
Consequently, no grounding is available for the
cold-start valve or terminal TKK o'f the time relay
(106) at temperatures above 45C (112F).
'.
Thsll'MostaUc
SWD
clh 25/18
The thermostatic switch closes at temperature below 25C (7JOF). If the temperature has been higher
than this, the switch will not close until the temperature has dropped to 19C (66F).
i'l
l/J
Turbo
~ngines
The function is the same except that the thermostatic switch is connected directly to terminal 12 of
the Lambda control module. A fixed pulse ratio of
60%is obtained.
3 Therm0static switch 97
Saab 900
240-42
----
lambda
COIntIl'O~ mo:h.!l~e
Term
Pin 2
Pin 4
Pin 'I
necti
Pin '\
integrator
Brcl/I
output stage
Pin !
Yelle
Pin ~
Pin
Red.
Pin
Yell(
Pin'
Red
Pin
?in
'"...
:(l
i'I
III
----,
I
I
I
I
5
I
I
I
I
I
-~
Fu
Wh
ne
dial
dirr
"
bell
ThE
inci
ant
sw'
1 Lambda sensor
2 Lambda sensor monitoring
3 Comparator
4 Integrator
5 Output stage
6 Modulating valve
240-43
tor
to
~st
at-
lin
si-
6
1
2
3
4
5
6
Saab 900
Diaphragm
Spring
Constriction
Spring contact arm
Vacuum connection
Electrical terminals
240-44
Tome
rre~alY
DE
1P11
as
Thl
aftt
Wll'
abc
45'
wt
pie
po
lay
thE
ter
se
co
La
pi
pi
E
p
X2
~
17
113
14
1112
11
31
19
Its
14
TIP
TKK
liO -11
Its
X2
16
PIal
31 12
12
30 4
TD~
S
118
87\
UL
Ii
17
87\6
19
I I
I I
Relav fit 1 t.
Xl
rruni~lfoll
pins
pin 87
pin 50
pin TIP
pin 31
Ground
pin 11
pin TKK
Ground via cold-start valve 94, thermostatic switch 97 and thermostatic time
switch 92
pin)(2
1i1l00B'ma~~y
Terminal pins
pin 15
pin TO
pin 30
X2
PIa!
pin 31
Ground.
pin Xi
pin 87
, '.,' pin X2
Saab 900
12
30 4
TD~
5
Deceleration relay
(non- Turbo engine)
31
Xl
87
b
16
19
240-45
C~
WI'
tior
swi
If tt
the
call
frol
gro
en!
nin
Wt
tior
ply
pUi
sta
coi
re~
12
X2
31Cl
TD.1l1!
16
-1..k.
19
30 4
31
Xl
87
pin 15
pin 31A
pin 87
Th
igr
(1 t
err
of
Li
Th
se
Speed relay 3600 rpm (model year 1987 and earlier) or
above 4600 rpm..{modeJ year 1988 and later). Turbo engines only.
tro
thE
si~
se
an
(1 :
mi
135
Tt
su
TI
cu
in
pI
cc
TI
pI
+:
Ve
TI
c(
til
v,
in
51
(0
81
Saab 900 .
240-47
-----------------------_~-=------------
Ele~trr8ca~ system
of pelra RlDil
..
!PB"oflilcnp~e
CI system
When the ignition switch is turned to the Start position, the starter motor (4) and the thermostatic time
switch (92) are supplied with current (+50 supply).
If the engine is cold (temperature below 45C), the
thermostatic time switch (92) will be closed. The
cold-start valve (94), which is supplied with current
from, terminal 16 of the starter motor (4), is then
grounded. This causes the valve to open and the
engine receives extra fuel (for up to a maximum of
nine seconds) while the starter motor is engaged.
When the ignition switch is in the Start/Drive position, the fuel pump relay receives current (+15 supply) via fuse 22. Relay 102 operates and the fuel
"pump (103), which receives current via fuse 30,
starts to run. Current is also supplied to the heating
coils in the auxiliary air valve (95) and the warm-up
regulator (96).
The fuel pump relay and the Lambda system receive
ignition pulses from the ignition pulse amplifier
(147). If the engine stops, the pulses cease to be
emitted, causing the relay to release and the supply
of current for the fuel system components is cut off.
Lambda
or
n-
Saab 900
240-48
Cc
Thl
en!
ter
Fa
vic
7
9
2C
2~
5~
Saab900
240-49
-_.-------------------------=-----------component locatiorns
The component locations are the same for 8-valve
engines with CI fuel injection and the Lambda system (EU), fuel injection engines and Turbo engines.
For further details of component locations, see Service Manual 3:2.
4
7
9
20
22A
59
60
77
79
82
-94
95
96
97
99
100
102
\'08
105.
106
'135
136
138
t.
139
1L:4
147
152A
'152C
156
158
159
201
203
260
Saab 900
Checking
Fa
sy:
General
1 Connect pulse meter 8393 597.
Fal
.aJ
b)
b)
EI
W
is
di
tI
Saab 900
s'
sympttoms
, ne, 'Ot:: see checl<ing/fault diagnosis '\:l Em;d1ment during the warm-up period, bel'me<f 4S0C",
fi.,
Starting wnth
45C
be~ow
c~~dl ell1goll1le~
Note:
The thermostatic switch (97) must be closed (temperature below 38C).
Saab 900
240-51
240-52
Note:
The connector must be plugged in during this test.
If the engine temperature is below 45C (113F) the
lamp should be on. When the starter motor is engaged, the lamp should go out for a few seconds.
This indicates that the thE)lT\1os::'I(I~ t;Tne switch has
interrupted the ground circui~ c.md t2; thus working
properly.
4 To check the operation of the cold-stalt valve,
see Service Manual 2:3, section 240.
18
ti'8tDO)
4\
Mode of operation
Checking
1 Connect pulse meter 83 93 597 to the test
socket. Remove the ignition switch relays (E)
from the main fuse box and connect a jumper
lead between pins 3 and 4.
The
2 When the starter motor is engaged the pulse ratio should be 92 10%.
forI'
con
Mo
Nor
FU{
(94
(97
swi
fault diagnosis
(Electrical testing)
1 Remove time relay P11 (106) and connect one
lead of a test lamp to +12 V.
2 Normally aspirated engine:
a) Connect the other test lamp lead to pin 31.
The lamp should light up (connection to
ground).
b) Connect the other test lamp lead to the TRK
pin. The lamp should light up only when the
throttle butterfly is fully closed.
Saab 900
"," ,-
Mode of operation
Fuel enrichment is effected by the cold-start valve
(~4) 'and controlled by a 45C thermostatic switch
'97), a thermostatic time switch (92) and a pressure
switch (79).
Saab 900
240-53
240-54
Checking
Chi
F211
Me
A
S\f\
fix
Mode of operation
co
900 Turbo:
the 25 C thermostatic switch (99) grounds terminal
12 of the control module and fixes the pUlse ratio at
60%.
CI
CI
thi
900i:
the 25 C th(:JilTlostatlc switch (99) grounds terminal
i 2 of the control module (via terminal Xi of the
speed relay (105) on cars with a manual gearbox)
and fixes the pulse ratio at 60%.
Q
th
he
Saab 900
Checking
Check whether fuel enrichment continues for more
than -140 seconds.
Note:
The 45C thermostatic switch (97) and the 25C
thermostatic time switch (99) must be open and
three seconds must have elapsed after the engine
has been started.
Saab 900
240-55
240-56
Fau
1
2
3
V.
3 Connect the other lead to:
pin 31 - the test lamp lights up
the TRK pin - the test lamp lights up when the
throttle position switch closes
4
5
Mode of operation
Fuel shut-off cannot take place when the thermostatic switch (94) is closed or while fuel enrichment
is in progress (i 40 seconds).
When the vacuum valve (260) opens, the pressure
difference between each side of the mass air flow
sensor plate is equalized. The sensor plate assumes its rest position and fuel injection into the fuel
distributor via the control plunger ceases. A fixed
pulse ratio of 60%is selected.
Checking
1 Start the engine and nm it for 140 seconds.
2 Connect a test lamp to the red lead of the fuel
booster pressure switch (79) and ground, and
connect pulse meter 8393597.
3 Slowly increase engine speed to 1600 rpm.
4 Close the throttle rapidly.
The test lamp should light up until the engine
reaches a speed of about 1375 rpm. The pulse
meter should first indicate 60%and then 50%.
Note:
The fuel shut-off function will not operate during the
first 140 seconds after starting.
SBab900
31 :
the test lamp should light up
30:
the test lamp should Ii~ ht up when the throttle
position switch is closed
X2:
the test lamp should light up after 140 seconds.
4 Cbnnect'one of the test larrip leads to .grqund.
5' Connect the oth'er lead in turn to 'the following' ' ..
. pins of the deceleration relay (105):
31b:
the lamp should flash (ignition pulses)
15
the lamp should light up (+12 V)
Xi:
the pulse ratio should be 60%
87:
Fuel shut-uff should take place (on deceleration).
Component possibly defective
~
2!
ell
c:<D
Fault diagnosis
2!
c:
0
.l:
0
'I::
I::
<D'
c::
0
==
<Il
I::
0
,."
~
iii
>
'iii
0
c..
:t::
(I)
.c
2:J
ii
"iii
2i0
u.
Ib5
Ib5
Ib5
Ib5
.. Ib5
Ib5
Ib5
(l)
'3
:t:
~(I)
Cl
ell
.l:
0
ffi
Saab900
<Il
Qj
:J
'C
0
ell
>
'iii
>
Ol
c:
~
'3
~c::
8
ltl
'C
.c
E
j
Ib5
Ib5
'C
0
240-57
240-58
I~
(
Ge
Thl
Mode of operation
58;
The speed signal goes from terminal 1 of the ignition coil via the ignition pulse amplifier (147) to the
TD pin of the speed relay (138).
jl,ls
CO
Checking
se
Checking
When the throttle butterfly closes, the pulse ratio
should rise to 92%.
Saab 900
sh
rei
RE
ho
pa
Sf
RI
Ie'
l-
.comes necess3u'l, .
Readjustment 0)' . e rrlix1'.ll'l.3 may be necessary,
however, if the mas", ail' flow sensor has been repaired or if fault diagnosis shows that the mixture
setting is incorrect.
,setting a new mass air flow sensor
75 rpm.
Saab 900
240-59
240-61
e~uipment.
240-64
Cslour codes
240-64
Fuel syst/.;.!'n
Line p(e r " \1l!J
~
:
Fuel prest>"'l"e Fqgufator
HesidIJal pfessure
,
:.. 1
FU~I pump delivery
pressuJe :
:
:
Fuel pump delivery
flow
:~
,
2..4
240-67
240-68
240-69
240-75
240-87
240-89
240-156
240-65
LH 2.2
LH 2.4
2.2
2.4
24a~154
:.240-!54
240_155
240-155
.
240-156
..
Saab 900
Main relay
240-158
Fuel pump relay
240-159
Pressure switch
"
240-160
Temperature sensor
:
240-160
Throttle position switch
(checking/adjusting)
240-161
Injectors
240-163
Mass air flow sensor
240-164
Hot wire (filament) burn-off,
function
240-165
CO content (checking/adjusting)
240-166
Fuel injection system, basic setting
(cars with catalytic converter)
240-1.66
Signals to control module
; 240-168
Input signals to control module
240-1.6.8
Control module connections
240.-1069
Control module signals to
injectors
240-171
Fuel shut-off on starting
240-172
Full-load enrichment
240-173
Warm-up period
240-174
Idling compensation on start of
AC compressor (cars with auxiliary
air valve)
2.40-175
Idling speed compensation on start of
AC compressor (cars with idle air
control (lAC) valve)
240-175
Lambda (oxygen) sensor
240-176 ..,
Induction system
240-177
Auxiliary air valve
240-179
Idle air control valve (lAC)
240-179
Basic setting of throttle butterfly, LH 2.2.240-180
Basic setting of throttle butterfly
(LH 2.4)
240-180
Idling speed adjustment (not cars with
catalytic converter)
240-181
Idling speed adjustment
(cars with catalytic converter)
240-182
240-62
Component replacement
Control module
Main relay and pump relay
Temperature sensor
Throttle position switch
Fuel injection manifold with
injectors
Mass air flow sensor
Fliel filter
Fuel pressure regulator
Auxiliary air valve
Idle air control valve, lAC
Air cleaner
:
240-185
240-185
240-186
240-186
If
240-187
240-188
240-189
.240-189
240-190
240-190
240-191
240-192
v
V
\/I
~
i:
Sa
5)
Wiring diagrams
for main relay and pump relay ...240193
.:-r,
,-
1
2
3
4
5
6
7
Saab 900
CAUTION
When carrying out any work involving fuel, fuel
supply systems or fuel injection, make sure
that the area is well ventilated.
If approved extraction equipment for fuel
vapour is available, use it.
Wear suitable gloves, as prolonged contact
with fuel can cause dermatitis.
No smok.ing anywhere in the vicinity.
Alway1.3 mcM~; sure a suitable fire extinguisher
is nearby.
'j
't~.'
,
th~
connections
Saab900
240-63
240-64
Connection of exhaust
extraction equipment
.......
, Ri~ht
BRight ,.
C Wron.g
~=B
-#:
Colour codes
Whe
cert~
gran
see
Nott
Befe
testE
'on l
tent
"FaL
tem,
It is
_H t
ule'~
, infol
the I
be II
Thi~
-M1991
M1991-
BL
blue
Code
English
BR
brown
BK
Black
GL
yellow
BN
Brown
GN
green
BU
Blue
Be
Mar
sysl
elee
disc
For
it to
testl
GR
grey
GN
Green
OR
orange
GY
Grey
RD
red
OG
Orange
SV
black
RD
Red
VL
violet
VT
Violet
I(
VT
white
WH
White
YE
Yellow
E
IiE
PK
Pink
dia~
C
IE
F
It i~
rna
3
4
Saab 900
240-65
system tester,
LH 2.2 and LH 2.4
When c~rrying out fault diagnosis, make absolutely
eertain that you refer to the appropriate wiring diagram for the model year and LH system concerned,
see Service Manual 3:2.
Note:
:Before starting fault diagnosis with the lH systl1'lTI
,ester, it is advisable to use the integrated function
,(in I.H 2.4 cars for identifying data on any intermitteAt faults recorded in the control module. See under
l(Fault diagnosis with integrated fault diagnosis syslem, LH 2.4".
It is important to do this first, since connection of the
(H tester to the control module interrupts the module's power supply, with the result that any fault
information stored in its memory will be erased and
the opportunity to identify any intermittent faults will
be lost.
This will also occur if either of the battery cables is
~isconnected.
240-66
~
fau'
-co(lE
600'
E10'
FO O:
Be alert to the possibility of interference from components connected to the wiring concerned. Also
check that the wiring is in good condition and not
the cause of defective grounding.
I'
E10:
1;00
r'
E10
EOO
'EOC
EO(
,EH
Note:
Reference values for some of the parameters that
are to be checked are preprogrammed in the microprocessor incorporated in the LH system tester.
E21
EOI
E1
EO
EC
E'
LH 2.2
LH 2.4
E002
E013
E020
E207
E113
E020
E207
E118
Saab 900
E1
EO
E(
El
E
E
E
E
(
. I
I
240-67
1=001
E101
E002
102
"
'E003
.tilt;,' .
}" ,t103
1;005
S006
E007
E107
E207
~008
E108
E009
E109
E010
E911
EQt2
E112
E013
E113
E014
E017
E018
E020
E120
E220
E021
E023
AIC
E024
E025
Pin No.
Malfunction indicated
Action - see
page
69
69
69
69
69
70
1
2
2
3
3
5
6
7
7
7
8
8
9
9
10
1'1
12
12
13
13
14
17
1.8
20
20
20
21
23
23
24
25
No injection pulses
Injection pulses erratic
Mass air flow sensor, break in CO adjusting circuit
Pump relay control circuit faulty
No +15 supply
Lambda sensor, no signal
Lambda sensor, signal too low
Lambda sensor, signal too high
Main relay control circuit faulty
lAC valve, no signal from pin 23
lAC valve, pulse.'ratio faulty
No load signal "
Control module pin 25 not grounding
'''C 5"
"F PU"
"FUEL"
"OFF"
"F IN"
"MON"
70
70
70
70
70
70
71
71
71
71
71
71
72
72
72
72
72
72
73
73
73
73
74
74
74
74
240-68
Ff
Fal
Fault
code
Pin No.
Malfunction indicated
Action see
page
EOO-1
E101
E002
E102
E003
E103
E005
E006
E007
E107
E207
E008
E108
E009
E109
E018
E118
E020
E021
E024
E124
E224
E025
E033
E035
1
1
2
2
75
75
75
75
75
76
76
76
76
76
76
76
3
5
6
7
7
7
8
8-
Main relay, no
Main relay,
18
13
20
21
24
24
24
25
No injection pulses
33
35
No +15 supply
12 V supply
Saab 900
77
77
77
77
77
77
78
78
78
78
79
79
79
chi
trit
240-69
EOO1
Control
Malfunction indimodule pin cated
No.:
1
,
No ignition pulse.
I'
I'
:.
,j
Action
(E010)
(E017)
A Check battery voltage and capacity:
Starter motor revs
8 Check the wiring between the positive terminal of
too low.
the battery and pin 30 of the starter motor and beNote:
tween the negative terminal of the battery and
Engine temperature
grounding points 7 and 211.
above +10C
C Check the operation of the starter motor.
E101
,'I}
'~
;Ii
'.
E002
It
,.
',:
.,
'.
A Check the wiring between pin 2 of the control module (200) and pin 1 of the temperature sensor (202)
and between pin 2 of the temperature sensor (202)
and grounding point 201.
B Check for good ground at grounding point 201 .
C Check the temperature sensor (202).
o Fit a new ~H control module.
~
'00
. '
E003
Throttle po~ition
sensor (203) contacts constantly
open
"
Ii'
I,
I'
It
I'
E102
Saab 900
240-70
Fault code
E103
Action
Throttle position
A Check setting, and operation of throttle position sensensor (203) consor.
tacts constantly
8 Check th~ wiring between pin 3 of the control modclosed (when enule (200) and pin 1 of the throttle position switch
gine revs increased
I,
(203).
from idling to 2500 C 900i/900S
rpm).
Check the wiring between pin 3 of the control mod- .
ule (200) and pin 7 of the EZK control module (176) '. '
via connector 57.
~:'
D Check the EZK ignition system.
EI
'
E005
Control module
(200) pin 5 not
grounding.
A Check the wiring between pin 5 of the control module (200) and grounding point 201.
8 Check for good ground through the engine grounding point (201).
I'
d~
~
E006
E007
Mass air flow senA Model year 1988 and later: check the wiring besor (205), no signal.
tween pin 3 of the mass air flow sensor (205) and
pin 2 and grounding point 201 (not Turbo).
8 Check the wiring between pin 4 of the mass air flow
sensor (205) and the engine grounding point (201).
Check for good ground at the grounding point.
C Fit a new mass air flow sensor (205).
I'
E107
Mass air flow senA Check the wiring between pin 7 of the control modsor (2 5), no signal.
ule (200) and pin 5 of the mass air flow sensor
(205).
8 Check the wiring between engine grounding point
201 and pin 4 of the control module (200).
C Fit a new mass air flow sensor (205).
Mass air flow senA Check the wiring between pin 7 of the control modsor (205), signal too
ule (200) and pin 5 of the mass air flow sensor
high
(205).
8 Check by eye that mass air flow sensor hot wire
(filament) burn-off takes place.
C Fit a new mass air flow sensor (205).
E207
E008
Mass air flow senA Repeat t1?, \'c:::;t. Rev up the engine to 2500 rpm for
sor (205), no hot
at least 3 se\" 'I'lds ("SET 2500 RPM").
wire (filament) burn- 8 Check the wiring between pin 8 of the control modoff function
ule (200) and pin 1 of the mass air flow sensor
(205).
C Fit a new LH control module (200).
-I!i
~,
I~~
I'
1\
i\
Saab 900
Control
Malfunction Indimodl,lle pin cated
No.:
Action
240-71
E108
E009
A Check the wiring between pin 8 of the control module (200) and pin 1 (p>hn 4 on model year 1988 and
later cars) of the mass qir flow sensor (205).
B Fit a new LH control module (200)
E109
Main relay, 12 V
supply too low
E010
10
lAC' valve, no signal A Check the wiring between pin 1 of the lAC valve
from pin 10.
(272) and pin 10 of the control module (200).
B Check whether +12 V battery voltage is applied to
pin 2 of the lAC valve (272) (ignition switched on).
C Check the wiring between pin 2 of the lAC valve
(272) and pin 87 of the pump relay (102).
o Check the wiring between pin 30 of the pump relay
(102) and the +30 supply terminal (230).
E Fit a new pump relay.
F Fit a new lAC valve (272).
G Fit a new LH control module.
~,
'"
,
E011
11
LH control module
(299) not grounding.
E012
12
Throttle position
sensor (203), fullthrottle contacts
constantly open
A Check operation by flooring accelerator on command from LH system tester. Check display to see
whether throttle butterfly opens.
B Check operation and setting of throttle position sensor.
C Check the wiring between pin 12 of the control
module (200) and pin 3 of the throttle position sensor (203).
o Check the wiring between pin 2 of the throttle position sensor (203) and grounding point 201.
E Check for good ground at engine grounding point
(201 ).
Saab 900
240-72
Fault code
E112
Control
Malfunction indi.
module pin csted
No.:
12
Throttle position
sensor (203), fullthrottle contacts
constantly closed.
Action
..
E013
13
.
:
E113
13
Erratic injection
pulse's.
See E013
E014
14
E017
17
E018
18
No +15 supply.
Saab 900
Control
Malfunction indimodule pin cated
No.:
E020
If',
20
Lambda sensor
(136), no signal.
Action
240-73
E120
;J
20
Lambda sensor
(136), signal too
low,
t'
'i
-,'
. ,
Ii
E220
20
Lambda sensor
(136), signal too
high
,
!
E021
'I
\
,I;
21
Saab 900
240-74
Fault code
E023
AICa
23
E024
24
No load signal to
ElK (not Turbo)
E025
25
Saab900
El
240-75
E001
Malfunction indiControl
module pin cated
No.:
1
No ignition pulse
Action
,.
Note:
If the engine fails to start, the ignition switch must
be left in the Drive position for about 20 seconds. If
this is not done, the instrument will not be able to
detect the fault.
" r,
I:~
E101
('
E002
Throttle position
sensor (203) idling
contacts constantly
open.
o
I'i
E102
Throttle position
A Check the setting and operation of the throttle posisensor (203) contion sensor.
tacts constantly
B Check the wiring between pin 2 of the control modclosed (when enule (200) and pin 1 of the throttle position sensor.
gine revs increased C Check the wiring between pin 2 of the control modfrom idling to 2500
ule (200) and the EZK control module.
rpm).
D Check the operation of the EZK ignition system.
E003
Throttle position
sensor (203) fullthrottle contacts
constantly 9pen
I'
,
~
I_
,'r,
A Check operation by flooring accelerator on command from LH system tester. Check display to see
whether throttle butterfly opens.
B Cheek operation and setting of throttle position sensor.
C Check the wiring between pin 3 of the control module (200) and grounding point the throttle position
sensor (203).
D Check for good ground at engine groundin~J point
(201).
Saab 900
E103
Malfunction indi
Control
module pin cated
No.:
3
Throttle position
sensor (203), fullthrottle contacts
constantly closed.
Action
E005
LH control module
pin 5 not grounding
to grounding point
201.
A Check the wiring between pin 5 of the control module and gro\.mding point 201.
B Check for good. ground at grounding point 201.
E006
A Check the wiring between pin 6 of the control module (200) and pin 2 of the mass air flow sensor
(205).
S Check the wiring between pin 1 of the mass air flow
sensor (205) and the engine grounding point (201).
C Fit a new mass air flow sensor (205).
E007
No signal between A Check the wiring between pin 7 of the control modpin 7 of the control
ule (200) and pin 3 of the mass air flow sensor
module and pin 3 of
(205).
the mass air flow
B Fit a new mass air flow sensor (205).
sensor (205).
C Check whether a +12 V supply is present across
pins 1 and 5 of the mass air flow sensor (205)
Fit a new LH control module.
E107
E207
E008
Mass air flow senA Repeat the "SET 2500 RPM" test for at least 3 secsor (205), no hot
onds.
wire (filament) burn- S Check the wiring between pin 8 of the control modoff function.
ule (200) and pin 4 of the mass air flow sensor
(205).
C Check the wiring between pin 5 of the mass air flow
sensor (295) and pin 87 of the main relay (229).
Fit a new LH control module (200).
Saab 900
Control
Malfunction indimodule pin cated
No.:
Action
E108
E009
E109
E018
18
.
,
240-77
,
,
A Check the wiring between' pin 8 of the control module (200) and pin 4 of the mass air flow sensor
(205).
B Fit a new LH control modl,.lle
,
I~
"
E118
18
Pulses to injectors
See above.
(206) erratic in relation to ignition
pulses.
E020
20
"
Saab900
240-78
Fault code
Control
Malfunction indi
module pin cated
No.:
21
E021
24
E024
24
E124
I'
.,'
Lambda sensor,
signal too low.
,
,
Action
'\
A Check the voltage across the Lambda sensor between connector 60 and ground.
~
B Check whether a +12 V supply is present between
pins 1 and 2 of the connector (59).
C Check the wiring between pin 5 of the control modI:,'
ule and the braided screening round the signal
lead.
D Check the Lambda sensor preheating function.
E Check the wiring between pin 24 of the control
module (200) and the connector (60) and between
the connector (60) and the Lambda sensor (136).
~
F Check for leakage in the induction system.
G Check for air leaks in the exhaust system between .
the engine and the Lambda sensor.
H Check injector operation and delivery flow.
I Fit a new Lambda sensor (136).
if
24
E224
Lambda sensor,
signal too high.
A Check the voltage across the Lambda sensor between connector 60 and ground.
B Check whether a +12 V supply is present between
pins 1 and 2 of the connector (59).
C Check the Lambda sensor (136) preheating function.
D Check the fuel pressure (line pressure).
E Check the Lambda sensor (136) preheating function.
F Check injector operation and delivery flow.
G Fit a new Lambda sensor.
11
1'1'
'j
';
,I
I
"
~ll
:j
Saab 900
Control
Malfunction indimodule pin cated
No.:
Action
240-79
-.("1',
,',
E025
25
No load signal to
EZK (176).
I", 033
33
lAC valve, no signal A Check whether the throttle butterfly is correctly adfrom pin 33.
justed (as near to the closed position as possible
without binding).
B Check the operation and setting of the throttle position sensor (203).
C Check the wiring between pin 33 of the control
module (200) and pin 2 of the lAC valve (272).
D Check whether a +12 V supply is present across ,
pin 1 of the lAC valve (272) and ground.
E Check the wiring between pin 1 of the lAC valve
(272) and pin 87 of the main relay (229).
F Check the wiring between pin 30 of the main relay
(229) and the +30 distribution terminal (230).
G Fit a new main relay (229).
H Fit a new lAC valve.
I Fit a new LH control module.
~.
r
I,
,Ii
I,
.
E035
35
.'
Saab 900
240-80
Cc
T.hi
wit
Te:
cal
pal
In 1
Cal
eVI
ide.
'\".
Fa
COl
'liol
sh'
in~
in~
II
\
t,I
!
) -
I\
,
I.
I
I
Note:
If a serious fault occurs repeatedly, each occurrence
will be recordedih the memory and the "CHECK
ENGINE" lamp will light up. Once the fault has been
rectified, it may-be necessary to clear the memory by
erasing all its contents to delete any additional
codes for the same fault. In doubtful cases, take the
car out on a road test.
Saab900
Note:
All code indication and testing will.be abortedwhefl!
:the ignition is switched off.
"
.'
....
+.
.:..:;....
~...
Saab 900
..=~ .....
'. I
',.~
240-82
-.
control module).
,;~~tn ...
\14"'"
N(
Th
of
TIllS
en
@
iJIA lA,likUA. v- v- l~q,O 0.. 41.CicA1
. . ~'( ke/k b l'-/'<.,c.
Itdelt -2:. 1<;.A:7i
Ct-(
.~
\ \ I ;1/
(OL~el-
. Check
. Engine
@r~ftJ~-k
~~10<.l
I ,~
. ", \ULkt c;l {. u~\IA.v ).t, 'to l~(,I.1 'hI
(9.' /J1J\..!p. uk
F
1
d
5 Watch the "CHECK ENGINE" lamp carefully. 'After about 2.5 seconds itwill.flasl1 brief!y,t sig~i
fying that the first fault code is to be activateCl.
"
-,
/'
-t.f
1/"
I
Note:
Check
Engine
240-83
:;;:2,.5
;'
4--.Jr-----------Q
---0
;.
.};
"
'h
Fault code,
The, entire sequence takes place as shown in the
diagram.
.
Saab900
l.:"
'~
. ,
240-84
In the example, the fault code is "1 2 1 1 2". "Reference to the table shows that the fuel-air mixture on
idling is incorrect.
When the switch is set to "OFF", fault code "1 21 1
2" will be flas,hed repeatedly and the next fault code,
if any, in the control module memory will not be activated.
.
'l~~ ~i\-\V~
Note:
,I"'r
I~
(i
\W,
.J
V~~~
.
rv
f}
f\ .
tlon and testing will continue.
~lovJ~
1/ \>'O\t,~ ill \,., 6\
~~,qi\~1G~d\
CkJ&,(\ ()A iJ~ ~~ ~t. V[ lulU t~1tAo4.t r
ext faUll' co e ,
\ , ~.
-\
To check whether there are any additional faults in
'\ Uk fIh.:,~, ~ "~t., \0\1>.: '(11) +v~ 1s1,ttov
tt.
'1:~
FF"
0 ~tt~~ "
:=02,5 s
\\
CtL ~ i\lt1
,
-~
de
!if,'
\t~~
~ ~
%:~:-"
1/
, Check
Engine
Code
,.
"
Sa~b900
'1 u
I"
"--....
J
U() vV'--
t;13~ l1lmu~~
tf\rn
~(j{
240-85
r}~
'U
hiA.{
('"' ~
b \ i ~ ~)
rd ~ ~l
~ --~--=----~-l)
~---------------.Q
~tIOJv ~ lf~~
I,
..
V~ rtl.,,(,r~ /,Uti
j;N~
"
~0
/'1
{;t V011
~U
1'-
(I ~L.
II
k:-ttt r- J
Ii' I.
'- r .
~ lC> fA (P.cM n ~
.;
\1/ \1/
=2,5
Check
Engine
Check
Engine
Code
.~
Saab900
240-86
"OFF".
\1/ \1/,\1/
0=1(=\(=1
L..-_ _---,
Code'
...
The memory has now been cleared, which is indicated by a continuous series of long flashes of the
"CHECK ENGINE" lamp.
d, ._.,_ _
,.,
~
r..
~ 10sek
...
~.
. \ ..
f'
I-------Q
'-----------~.
Note:
The contents of the memory cannot be cleared before code "00000" has been displayed (indicating
end of fault codes).
Saab 900
5211424.
'--p..
240-87
.
Malfunction indicated
Preliminary action
Off
Check the input signal on pin 1 of the control module and check the wiring between
pin 1 and the ignition system.
Check the ignition system.
'On
'l
versions.
On
Off
12225
On
12223
12224
On
Fault
code
12231.
. CHECK
ENGINE
'\
Saab 900
I:
240-88
I
I
I
Fault
code
CHECK
ENGINE
Malfunction indicated
Preliminary action
12232
Off
12212
Off
' ....
,
I.
<I
12213 :
Off
12222
Off
12111
Off
'I
I
I.
..
12112-
Off
12113
Off
12114
Off
000.00
Off
..
be
,-
'.1
::,,-
:'
.:,-.1'
,':>
II
,
Saab'90D
:;
240-89
CHECK
Malfunction indicated
Action
12243
Off
On
Saab 900
A With the ignition switch in the Drive position (engine switched off) enter command
555 on an ISAT.
Check whether the modulating valve
works. '
.
If not:
Check the yel:ow-white lead (GUVT) between pin 19 of the control module and
connector 394 and also the white lead
(VT) between the connector and the
modulating valve ,(390).
Atso check the green-white lead _
(GNNT) between the modulating valve
and the injector distribution block, greenred lead (GN/RD).
B Try a new modulating valve:
C Check the yellow-white lead (GUVT) between the thermostatic switch (389) and
pin 23 of the control module and the
black lead (SV) between the\thermostatic
switch and grounding point 201.
D Try a new thermostatic switch.
E Try a new control module.
240-90
Saab 900
:'
240-91
Note:
In this testing mode, the switch must be set to "ON"
before the ignition is switched on.
1 Set the switch to "ON".
2 Switch on the ignition and wait for a short flash
of the CHECK ENGINE lamp, then immediately
set the switch to "OFF",
u
\/
Check
Engine
Check
Note:
The fuel pump will run for less than a second. No 10
code will be obtained during this ~est.
Saab 900
V.
240-92
I.
Check
Engine
Code
"
Saab900
240-93
10 code
CHECK
ENGINE
Component/Signal
Remarks
Fuel signal
12411
12412
Injectors
Listen.
lAC valve
12413
CP valve
12421
12424
12431
.,
I.
.'
Saab900
240-94
N>
N
SI
01
c(
tn
AI
fL
jo
IT
til
s~
1
c
n
d
n
d
Saab 900
Fl:Iel.injection system
240-95
<,
,\
'I
Saab 900 ,
240-96
Diagnosis
Observe the following:
Never unplug the connector from the control module or disconnect any of the battery cables before
the contents of the control module memory have
been transferred to the ISAT.
The 1O-pin diagnostics socket is located under tile
rear seat on the RH side. It is protected by a plastic cover.
Turn the Ignition switch to the Drive position.
LH
...
If communication between the ISAT and the control module cannot be established, first check the
wiring between 'pins 12 and 16 of the control module and the diagnostics socket (347) .
Also check that power and ground are present at
the diagnostics socket and that the pins of the
connector are undamaged.
When the contents of the system's fault memory
have been transferred and stored in the ISAT, the
actual diagnosis has been completed. The faults
are now available in the form of five-digit codes,
following which furtheriault diagnosis work can be
continued as described in the "ISAT fault- diagnosis chart", page 100.
\
Saab900
F~~~I
injection system
240-97
--r
Saab900
240-98
I
I
When an ISAT is used to simulate signals or functions by means of command codes issued to the
control module, the.results are shown on the display
as a combination of numbers and letters (alphanumeric code).
8Bl00
11
!'
1'
Example 1:
,
I
,, I,
),
.,q
.
t
I
t
To check the position of the throttle butterfly, we enter the command 201 on the ISAT keypad.'With the
engine idling, the five alphanumeric characters appearilJg on the ISA1's display should be 8B101 .
See also "ISAT control commands, LH 2.4 (M1990)"
page 105.
I
Example 2:
Sometimes we want to check whether a signal is
high or low. To check the DRIVE signal, we enter
the command 203 on the ISAT keypad.'
If the signal is not activated the dis.~Jay will show
8BOOO, signifying that the signal is low.lf the signal
is activated the signal should be high and the ISATus
display ought to show 8B1 03.
See also "ISAT control commands, LH 2.4 (M1990)"
page 105.
The five characters in the combination of letters and
numbers (alphanumeric code) show the result of the
entered command.
Saab 900
.8Bl0l
Intermittent
67192
Malfunction indicated
OOM~~
45771
25771
45772
25772
46261
26261
46271
26271
46221
26221
42291
22291
42251
22251
58121
38121
45691
25691
Mass air flow sensor: signal faulty (too high or too low).
42491
22491
42492
22492
Fuel-air mixture faulty over a lengthy period (multiplicative when car being
driven).
42450
22450
42440
22440
42460
22460
58321
38321
45723
25723
58371
38371
Saab 900
240-100
Intermittent
67192
45771
25771
Malfunction indicated
Action
A Enter command 201 on the ISAT. Depress the-accelerator slowly from idling to
full-throttle position.
The display, should then show
881 01 ~88001 ~88301.
If 88001 is shown constantly, there i~ no
continuity in the wiring to the throttle position sensor. Continue with points C and
D.
If 88103 is shown, codes appear in the
wrong place or do not change:
Unplug the throttle position sensor connector.
88001 should now appear on the display. If it does not, continue with point C,
D or E.
8 If 88001 is shown, try a new throttle position sensor.
C If 88101 is shown, check the wiring between pin 2 of the control. module (200)
and pin 1 of the throttle position sensor
(203) and also between pin 2 of the control module and pin 7 of the EZK control"
module (176).
D If 88301 is shown, check the wiring between pin 3 of the control module (200)
and pin 3 of the throttle position sensor
(203) and also the TK pin on the AC relay (156).
E If 88103 is shown, check the wiring as
described in points C and D.
F Try a new LH control module.
45772
25772
46261
26261
...
.;.
Saab 900
240-101
Permanent
Intermittent
Malfunction indicated
Action
46271
26271
46221
26221
42291
22291
42251-
22251
58121
38121
45691
25691
.'
Saab900
A Check for leakage in the induction system between the mass air flow sensor
and the engine.
B Check pin 1 (ground) and pin 5 (positive
supply) of the mass air flow sensor.
C Try a new mass air flow sensor.
D Try a new LH control module.
~-
240-102
Malfunction indicated
Action
nent
42491
22491
42492
22492
42440
22440
Perma~
22450
45723
25723
D.
On the display, 88003 (P and N positions) should change to 88103 (Drive
position).
Saab 900
240-103
Permanent
Intermittent
Malfunction indicated
Action
46391
26391
A With the ignitio'n switch in the Drive position (engine sWitched off), enter command 555 on the ISAT.
Check that the modulating valve is working.
If it is not:
Check the yellow-white (GUVT) lead between pin 19 of the control module and
connector 394 and the white (VT) lead
between the connector and the modulating valve (390).
Also check the green-white (GNNT) lead
between the modulating valve and the
injector distribution point, green- red
(GN/RD) lead.
B Try a new modulating valve.
C Check the yellow-white (GUVT) lead between the thermostatic switch (389) and
pin 23 of the control module and the
black (SV) lead between the thermostatic
switch and grounding point 201.
D Try a new thermostatic switch.
E Try a new control module.
42460
22460
A Check the operation of the Lambda sensor preheating function (check that battery voltage is present across pins 1 and
2 of connector 59).
B Check the wiring between pin 24 of the
control mOQule (200) and connector 60.
C Check the wiring between pin 5 of the
control module and the braided screening round the Lambda sensor lead.
D Run the engine to warm it up. Disconnect the lead from the Lambda sensor at
connector 60 and measure the signal
voltage. It should be 0.5 V.
E Try a new Lambda sensor.
F Try a new LH control module.
Check: enter command 205 on the ISAT.
Run the engine to warm it up and check
that the display alternates between
.
8B105 (lean) and 8B305 (rich) at 20 second intervals.
If the display shows 8B005, then the sen
sor is not activated.
Saab 900
240-1 04
Permanent
Intermittent
Malfunction Indicated
58321
38321
'58371 . , 38371
Action
A With the ignition switch in the Drive position (engine switched off), enter command 553 on the ISAT: .
The valve should have a pulse rate of
about one per second.
S Check that battery voltage is present at
the distribution block 75.
C Check the wiring between distribution .
block 75 and pin 30 of the main relay
(229) .
. D Check the wiring between pin 87 of the
l<meiiQ relay and pin 1 of the lAC valve
(272).
E Check that battery voltage is present
across pin 1 of the lAC valve (272) and
ground.
F Check the wiring between pin 33 of the
control module and pin 2 of the lAC
valve.
G Check the setting and operation of the
throttle position sensor (203).
H Check that the throttle butterfly is correctly adjusted (as near as possible to
the closed position with binding).
I Try a new main relay.
J Try a new lAC valve.
K Fit a new lH control module.
A With the ignition switch in the Drive position (ermine switched off), enter command 552 on the ISAT.
The injectors should have a pulse rate of
about 15 per second.
S Check whether battery voltage is present
'on pin 30 of the main relay (229).
C Check the wiring between pin 87 of the
main relay and pin 1 of the injectors.
~O~.
Saab 900
240-105
Code
Function
Display
550
8A550
200
88100 (activated)
201
88101
88001
8P;3G I
88103
552
8A552
553
8A553
554
8A554
202
88002 (open)
88102 (closed)
555
8A555
203
88103 (activated)
88000 (not activated)
205
88105 (lean)
88305 (rich)
88005 (inactive)
900
11111
930
11011
100
207
Saab 900
(idling position)
(normal position)
null-throttle position)
(idling + full-throttle)
240-106
,.,
.,
",; ::-!
. ',-
'---_ _---'I .
'"
....
ci
><>
::>
Cl
.......
II]
en
on
.~ J69
ci
:I:
<~
'"on Cl'----/--_
n>-
15
J3
, 200
'LH 2.4.2
r
Saab 900
240-107
Colour
of lead
Component/function
BU
GY
I ~(j':''''1
1-, Ct.
- ll-
fj
6.5
c,w~M .
"
Remarks
>8 V
0.2
4.0 ..0
Idling
Full throttle
Not used
RD
+30 supply
BK
Signal ground
battery
voltage
Gro",nd connection separate from
chassis ground
!:.'
d,
OG
RDIWH
sensor~
ground signal
10
GN/RD
11
x 4"
On Durn-off
In other cases
battery
voltage
-l,~
12
14
-'-"~""""
'~~
YEo
AC .off
AC'on
voltage
1/.... ~,
'.
. fure .. :.:.~-
o.
,,:
~L!IWH AC ! Ib~d:.signal
..
j
I'
..
GViRD .I~C,
ppening.: control signal
'.,
12
0
16
GYIWH . Diagmqstieslead-L
17
18
GN/RD
AC on
AC off
x 7-11
~WM'signal-
,.'1
4-0.5.
I :
15
-.
x battery
13
x 5
Injectors
....-..
Saab 900
I
."
240-108
Remarks
Pin
Colour Component/function
of lead
19
WH
EGR valve
battery
voltage
<battery
voltage
not activated
activated
20
VT
1,
battery
voltage
Activated
Ignition on
21
YEIWH
x i
battery
voltage
ig!1\tion on
ignition off
(1.-
22
VTIWH
23
YEIWH
4.5
<4.5 V
EGR closed
EGR open
24
GN
0.6-1.0
0-0.4
rich
fean
25
BU/RD
Load signal, Tq
26
YE
x "battery
voltage
1.
,.
'
'1-
off
on
.)
\
\
27
YE/RD
. '-~'"
J,"-
battery
voltage
0
not activated
activated
battery
voltage
1
valve open
valve closed
28
to
Not used
29
GYIWH Coding
30
OG
DRIVE signal
Not used
battery
voltage
0
31
R, D, 1, 2 and 3
P, N and man vxl
Not used
32
BN
battery
voltage
0
not activated
activated -15"C)'
33
BUIWH
5-11
No-load idling
34
GN
Rotating wheel
Stationi;iry wheel
battery
voltage
ignition on
35
x
x
o or 12
.) Use the ISAT"s pulse measuring function and check that pulse duration and
frequency change as the throttle is opened.
Saab' 900
240-1 09
Pin
Colour Component/function
of lead
GY
battery
voltage
GN/RD
battery
voltage
0
Remarks
at idling speed
above idling speed
10
Not used
11
Not used
15
12
0
33
BUIWH
5-12
34
at idling speed
above idling speed
valve fitted
valve not fitted
Not used
..
Saab900
240-110
Fault diagnosis,
LH 2.4 and LH 2.4.2
Addition'al fault codes and
command codes
On model year 1991 and later cars, the LH 2.4 and
LH 2.4.2 fuel injection systems incorporate a number of additional fault codes that can be retrieved by
means of an ISAT.
There f),fa also more command codes, so that the
numb6r IJi usable codes now amounts to more than
20.
Like the table of command codes, the fault code table contains all the codes but those that have been
added for model year 1991 are specially marked.
All fault codes beginning with 4 or 5 are permanent
faults wtiile those beginning with 2 or 3 indicate that
the fault is of an occasional or intermittent nature.
Saab900
240-111
battery conditiDn
engine cDndition
8
charging system
cable cDnnectiDns
grounding pDints
ignition system
Saab 900
240-112
6 Since all signals round the 12 V level are proportional to .battery voltage, the levels should
only be used as guidance.
7 0 V signals denote ground but readings slightly
above 0 V may be obtained on a sensitive multimeter.
B Readings of the voltage on inputs and outputs
must only be taken with the ignition switched on
or with the engine running.
9 The black diagnostics socket is located under
the rear seat on the RH side.
It is protected by a plastic
CO~Jer.
Saab 900
240-113
I
4 Withdraw the rubber gasket and lift up the contact strip.
Saab 900
240-114
Breakout' box
I:
For taking test readings on the control module, primarily in the TC/ABS system, a breakout box is now
available to. facilitate fault diagnosis. This breakout
box, which has part No. 86 11 006, can of course
also be used for diagnosing faults in the LH system.
V
fl
n
SAAS
e
e
e
eeeeeeeee
eeeeeeee
e e e e.. e. e,. e3' e e
e e e e.... G'l., a 0 G
0 e
'" "
'"
e .. ~1l .e .. eso e.. (} "Ii]} I~) ,.~J
t
04
!I
12
13
,.
15
16
1&
19
20
23
2'
25
2li
21
:IS
!IIi
31
3a
4S
:'
Saab 900
41
10
III
c
1
11
21
22.
32
33
..
J!l
!l~
S:>
~I
(j)
240-115
xxxxx12345
I
Example 1:
To check the position of the throttle butterfly we enter command 201 on the ISAT keypad.
With the engine running, the last five characters on
the ISAT display should read 88101.
Example 2:
Sometimes we want to check whether a signal is
high or low. To check the DRIVE signal we enter the
command ~03 on the ISAT keypad..
If the sig~al is not activated, 88000 will appear on
the display to indicate that the signal is low.
If the signal is activated, it should be high and the
ISAT display should show 88103.
Saab 900
240-116
Intermittent
Faulty component/signal
Action, see
page
42241
22241
119
42251
22251
119
42252
22252
119
42291
22291
119
42440
2...::440
-i20
42441
22441
120
42442
22442
120
42450
22450
120
42451
22451
120
42452
22452
120
42460"
22460"
120
42491
22491
120
42492
'22492
120
44221
?422.1
123
44261
24261
124
45641"
25641"
125
45651
25651'
125
45691'
25691'
Mass air flow sensor, signal faulty (too high ono'o low)
125
45723
25723
127
45771*
25771
128
45772"
25772
128
26221
132
26271
132
Electronic EGR
134
137
46221'
;
"
"
-'
46271'
~.
58121
38121
58321
38321
138
58322"
38322
142
58371'
38371
Injector faulty
140
58372"
38372
142
"
38382
142
58382
67192"
ROM fault
Saab 900
240-117
Command codes
LH 2.4 and LH '2.4.2
Code
Function/signal
Display text/example
22A
803.6' = 3.6 V
804.7 = 4.7 V
228
8attery voltage
8010.6
8007.3
= 10.6 V
= 7.3 V
23A
80000
80012
= 0 %(valve closed)
= 12 %
100
200
Checks AC status
88100
88000
= activated
= not activated
201
88101
88001
88301
88103
(idling position)
(normal position)
(full-throttle position)
(idling + full-throttle)
202
CP valve position
88002 (open)
88102 (closed)
203
88103
88003
= active
= not active
204
Shift-up indication
88104
88004
= lamp on
= lamp off
205
88105 (lean)
88305 (rich)
88005 = not active
.<
= enrichment pre-ignition
= enrichment knocking
206
PRE-IGNition signal'
88106
88006
207
Ignition pUrses
239
80035
80043
= 35%
= 43%
*) when functioning normally, the ISAT should alternately show 88006 and
88106
Saab900
240-118
Code
Function/signal
Display
~extlexample
249
Speed
801000
805500
= 1000 rpm
= 550Q rpm
250
Coolant temperature
800-30 = -30C
80+130 = +130C
279
Ex. 80030
382
550
8A5,550
552
Activates injectors
553
8A553
554
Activates CP (1 Hz)
555
8A555
800
Ends communication
900
11111
930
11011
Saab 900
= 30
= activated
= activated
(USA-West only)
240-119
2/42241
2/42251
2/!\2252
2/,:12 .~91
'--Q
7 Cl' 4.0
11
cv
(3'28:":8)
., '"
r' -la
1
RO " .
1l.L
BlJ 25.0
C'l' 10.0
G25
G2
'"ci
o
c
'"'"
I'
O
II
I
II
31
J'
2.0
19
2J
200
LH 2.4.2
22
,.
I I\....
=12 Volt
Malfunction indicated
Incorrect voltage level (below 10 V or above 16 V)
applied to pin 4 of the control module.
Fault symptom
Car runs poorly or will not start.
Test procedure
1 Check the battery and also the starting and
charging systems.
"
f" ;
ule.
Saab 900
240-120
60
20
0-0,4 Volt
(0,6-1,0 Volt)
24
200
LH 2.4.2
2.
GI ... n l
Malfunction indicated
88105 (lean)
88305 (rich)
88005 (inactive)
Fault symptom
Poor drivability because the fuel-air mixture is too
rich or too lean.
CHECK ENGINE lamp alight.
If any of the codes is displayed continuously, it indicates that the Lambda sensor is not working properly.
Test procedure
Note:
During the car's running-in period (up to 500 km),
any of trese fault codes may be generated without
an~ fn.U actually existing.
In th~::;e ,ases, check carefully to see whether the
fault co _, is generated again after it has been
cleared.
1 With the engine warmed-up, enter command
code 205 on the ISAT. The following codes
should appear on the display one after the other
in a continuous cycle.
Saab 900
240-121
2/42440
2/42442
2142451
2/42460
'\\1//
CHECK
ENGINE
/11\'\
2/42492
2/42441
2/42450
2/42452
2/42491
r==J
I
20
0-0,4 Volt
(0,6-1,0 Volt)
24
200
LH 2.4.2
. J
28
to
point 3.
If not, check:
fuse No.1 of the Lambda sensor.
the BU/RD lead between pin 1 and fuse No.1 of
the Lambda sensor connector for continuityl
shorting.
the BK lead between pin 2 of the Lambda sensor
connector and ground for continuity/sh.orting.
:Saab 900
240-122
2/42440 '\.\1//
CHECK
2/42442
ENGINE
2/42451
//1\'2/42460
2/42492
2/42441 ,
2/42450
2/42452
2/42491
.20
0-0,4 Volt
(0,6-1,0 Volt)
,.
200
LH 2.4.2
J
,.
If it does not, check the GN and BK leads between pin 24 of the control module and the
Lambda sensor for continuity/shorting.
7 If the fault persists in spite of the above tests, fit
a new Lambda sensor and check system operation afresh by entering command code 205 on
the ISAT.
8 Try a new control module.
4 Check the induction system for leaks by listening for the sound of air escaping.
5 Check the fuel pressure and operation of the fuel
pressure regulator.
Relative to the pressure in the inlet manifold, the
fuel pressure should be:
3.0 bar (all LH 2.4.2)
2.5 bar (LI-:I 2.4 Turbo)
3.0 bar (LH 2.4 i)
240-123
2/44221
1 I
21
27
rLrU1J1Jl
88107
88007
I ~l
,.
20
200
LH 2.4.2
25
,.
01 .... nl
"""
~
J6S[P
~
00000000000000000
"E "f
"" "" 1i "
0000000000000000
ci
%
~
;::
H1D-7! ~117
~
""
~ ~ ~
,..2936-
"~
;::
-,
>1'6,
1
343
1
1 01, 01/APe ,
""------~
Malfunction indicated
No speed signal received by the control module from
the ignition system.
I
Fault symptom
~;
~~t?::
Test procedure
1 Check whether the voltage on pin 1 of the control module is higher than 6.5 V while the starter
motor is engaged.
If it is not, check the BU lead between pin 1 of
the LH control module and the ignition system
for continuity/shorting.
.
2 If necessary, further fault diagnosis should be
carried out as described for the relevant ignition
system in Service Manual 3:2.
Saab 900
240-124
2/44261
12J<
123U
CU/WH 2.5
ell WH D,7,S
J19
123
~/WH 1~
1'"
I'"
0-75 Volt
Sl
;;
GNfwH 2.5
J77
0/12 Volt
~
ii
;!i
I
"
r--
Malfu'nction indicated
Speed sensor signal faulty or absent.
Fault symptom
Poor idling.
Test procedure
1 Check that the speedometer is working properly,
2 With the control module connector unplugged,
measure the voltage across pin 34 of the connector and ground.
The voltage should swing between 0.5 and 5.0
V when either of the front wheels is spun round.
If it does not, check the GN lead between the
speed sensor and pin 34 of the connector.
3 Check whether the Cruise Control func ion (if fitted) works properly (the speed signal is taken
from the same sensor in the speedometer).
4 Try a new sensor in the speedometer.
5' Try a new control module.
Saab 900
6 Volt
11
'\
on
.0
"-\1//
2/45641
2(45651
2145691
JO
N \;229
tJ---~
(22B:H)
e.5
e7B 57
e'
:.
CHECK
ENGINE
//1\"-
S f
Ii S
~!
~ ~
J37
I
850 rpm:802.2 =2,2 Volt
~12
13
Ii
..,
21
27
20
Volt
24
200
LH 2.4.2
125328
':
..
, 0;.. ....
,'.r
-.
Test procedure
1 Enter command code 22A on the ISAT and
check that the display shows the following:
Saab 900
;~~,
240-126
2/45641
2/45651
2/45691
'\\1//
CHECK
ENGINE
//1\'\
J37
=12 Volt
13
lS 7
.,
IS
2'
27
II
20
2.
200
LH 2.4.2
115328
Saab 900
240-127
2/45723
D
I
on
ci
~L
JO
...L. 26
200
LH 2.4.2
~12
Volt
(P,N)
Malfunction indicated
DRIVE signal absent or faulty.
Fault symptom
Test procedure
1 Enter command code 203 on the ISAT and
check that the display shows the following:
With the selector lever in position D: 88103 (activated)
with the selector lever in position P or N: 88003
(not activated)
.2 Check fuse No. 13.
3 Check whether battery voltage is present on pin
2 of the selector lever switch contacts (31, 76).
If it is not, check the WH and GNIWH leads between the switch and the fuse and also the GN
lead between the fuse and the +54 distribution
terminal.
4 With the selector lever in position D, check
whether battery voltage is present on pin 1 of
the selector lever switch.
S~ab
900
240-128
2/45771
2/45772
'\.\1//
CHECK
ENGINE
//1\"-
1,1-1,5
2,6-3,0
kO~d7
kO~
Malfunction indicated
Signal from throttle position sensor (LH 2.4.2) or
throttle position switch (2.4) absent or faulty.
Fault symptom
It should be 5 V.
II
Saab900
240-129
203
2/45771
2/45772
"-\1//
CHECK
ENGINE
//1\"-
=0,2 Volt ~
200
LH 2.4.2
JI
22
=4,0 Volt
~cfJ
Saab 900
'.
240-130
2/45771
2/45772
CHECK
ENGINE
//I\'\.
19
'8
20
200
LH 2.4A
25 28 1
~
-
~dJ
1 With 1he ignition switch in the Drive position, enter command code 201 on the ISAT.
The following codes should then be shown on
the ISAT's display:
accelerator untouched (idling): 88101
~8B101
~dJ8BOO1
\~8B301
Note:
8efore continuing with further fault diagnosis, make
sure that the throttle position switch is correctly adjusted. With the engine idling, there should be continuity across pins 1 and 2 of the switch,
2 With the throttle position switch (in idling position) connected and with the control module connector unplugged, check that pin 2 of the control
module connector is properly grounded.
Saab 900
240-131
'.\1//
2/45771
2/45772
CHECK
ENGINE
/ I \ '.
,--_=====~~/
18
19
20
~ 8B101
~c/8B001
200
LH 2.4},
\~
3 With the throttle position switcltt!{i'n full-throttle
position) connected and with U:llfcontrol module
unplugged" check that pin 3"01 the control module connector is properly grounded.
If it is not, check the GN/RD lead between pin 3
of the control module and pin 3 of the throttle
position switch for continuity/shorting.
4 Check that pin 2 of the throttle position switch is
properly grounded.
5 Try a new control module.
Saab 900
8B301
240-132
2/46271
2/46221
CHECK
ENGINE
R
~
//1\'\
tL-!
:;
iii
~n
;; r. 7
~ C7
:;
~
I ~I
d
x
I'
...
...
"
J70
<0
n ..
29
I.
>
., .
IJ
200
LH 2.4.2
"
"
-,
Malfunction indicated
Temperature sensor, signal faulty or absent
Fault symptom
Poor drivability, q-lECK ENGINE lamp alight.
Test procedure
1 Enter command code 250 on the ISAT.
The engine temperature should now be shown
on the display, e.g. 80+080 if the temperature is
+80C.
2 With the temperature sensor connector unplugged, measure the resistance of the temperature sensor. See the table on the next page.
Saab 900
240-133
'\\1//
2/46271
2/46221
CHECK
ENGINE
//I\'\,
I
ci
'"ci
"m
:0'"
'"
J70
:;~
2.
,e
13
, e
200
LH 2.4.2
,
4 The resistance should be that shown in the table (a few ohms higher is acceptable).
If it is not, check the YE lead between pin 13 of
the connector and pin 1 of the temperature sensor connector for continuity/shorting.
5 Check the BK lead between pin 2 of the temperature sensor connector and the grounding point
on the engine for continuity/shorting.
Table
of
Ohms ( 10 %)
~.
,-
....,
-20
-4
14000
-10
14
9000
32
5800
10
50
3800
15
58
3000
20
68
2600
25
76
2000
30
86
1700
80
176
320
Saab900
~.
r:
,~,
240-134
Electronic EGR
Background
Since component faults have occurred on several
EGR systems and in order to comply with the emission control requirements that are met by the electronic EGR system in the cars concerned, an imPr.oved solution has been developed which consists
primarily of modifications to the LH control module
software.
Cars Ccli1cemed
All model year "\ i;"90-91 California-specification
Saab 900 Turbo cars as well as model year 1992
cars up to and including chassis numbers:
N2002860 (Trollhattan)
N7002782 (Uusikaupunki)
Action
Remove the EGR system and fit a new LH control
module as follows:
1 Remove the EGR valve retaining screws, remove the EGR pipe from the exhaust manifold
and lift away the valve and pipe.
Plug the pipe connection in the exhaust manifold by means of plug 81 23739 and replace the
EGR valve by flange 93 58177, seal 75 07 973
and two screws 80 19 895.
Saab900
240-135
I
3 Remove the vacuum tank and its vacuum hoses.
Plug the hose outlet on the intake pipe and the
outlet on the pressure pipe by means of rubber
plug 83 35 614.
.'
,,
Saab 900
240-136
Saab900
240-137
5/38121
229
CHECK
ENGINE
(22B:H)
//1\"\
I
=12 Volt
1J
6 7 D
21
27
20
2"
200
LH 2.4.2
Malfunction indicated
If grounding is not OK, check the BK lead between pin 1 of the mass air flow sensor and
grounding point G7 on the intake pipe.
Fault symptom
Starting difficulty, poor drivability and high fuel consumption
CHECK ENGINE lamp alight.
Test procedure
If fault code 2/45691 occurs at the same time, it is
advisable to deal with that fault code first
3 If the fault persists, fit a new mass air flow sensor, clear the fault code memory arid take the
car out on a road test. Afterwards check whether
the fault code is generated afresh.
4 If the fault code is generated afresh after fitting a
new mass air flow sensor, fit the old one back in
place again and try a new LH control module instead.
Saab 900
240-138
5/38321
I.
13
&
21
21
20
24
200
LH 2.4.2
r
"
25
28
Malfunction indicated
lAC valve malfunctioning
Faulty symptom
Poor running when idling.
Saab 900
240-139
229
5/38321
(228:H)
SJll
GR/VT 0.75
~8B101
~tfJ 88001
200
LH 2.4A
, 1 With the ignition switch in the Drive position, enter command code 553 on the ISAT. Check
whether the lAC valve is working (1 Hz) by listening to it.
,.
'
..
.J;,
,\
.,
.;
Sasb 900
240-140
J67
5/38371
CHECK
ENGINE
//I\'\.
~12
Volt
10-20 Ohm
18
lJ
200
LH 2.4.2
..
.,
If it is not, check the BUiRD lead between pin 1
of each connector and pin 87 of the main relay
for continuity/shorting.
Malfunction indicated
Injectors malfunctioning
Fault symptom
Poor drivability, engine misfires.
CHECK ENGINE lamp alight.
Test procedure
Note:
The fault may also be due to lack of sparking in one
of the cylinders. It may therefore be necessary to
carry out fault diagnosis on the ignition system, see
the relevant section in the Service Manual.
1 With the ignition switch in the Drive position, enter command code 552 on the iSAT.
Check that all injectors are working (15 Hz) by
listening to them.
If the injectors are working, continue fault diagnosis but be alert to the possibility of intermittent
faults.
2 With the ignition switch in the Drive position,
check whether battery voltage js present on pin
1 of each injector connector.
Saab 900
240-141
J67
'\\1//
5/38371
CHECK
ENGINE
//1\'\
~12
10-20 Ohm
18
1.1
200
LH 2.4.2
,
Saab 9.00
Volt
240-142
3/58322
3/58372
3/58382
CHECK
ENGINE
//I\'\.
J76
27
20
24,
200
LH 2.4.2
(114ft ']1
Malfunction indicated
Malfunctioning of the evaporative emission canister
purge valve (CP).
".
Fault symptom
Test procedure
1 With the ignition switch in the Drive position, enter command cope 554.
Check that the valve is working by listening to it
(1 Hz).
2 Check whether battery voltage is present across
pin 2 of the valve and a good ground.
If i! is not, check the GYIWH lead between pin 2
of the valve connector and pin 87 of the main
relay for continuity/shorting.
3 Measure the resistance of the valve across pins
1 and 2.
It should be 40-60 ohms.
If it is not, fit a new valve.
Saab 900
240-143'
Main relay
Pump relay
E3
Pressure switch
E4
E5
E6
Injectors
Replacemen , see
E7
E7A
E7B
E7C
E7D
E8
E8A
E8B
E8C
E8D
E8E
Full-load enrichment
Warm-up period
E9
E10
B1A
Line pressure
Fuel pressure regulator
B1E
11
12
.M1
Residual pressure
Fuel pump delivery pressure
"
Fuel pump delivery flow .
Leakage in induction system
Auxiliary air valve
Basic eettin'J -of thrc,ttle- butterfly
'J'
M1B
Electrical
B
I
M
M1A
Fuel system
B1C
B1D
0-187
AC compressor
Oxygen (Lambda) sensor
B1
B1B
Pi-1~':: {
Fuel
Induction
Mechanical: removing and fitting of
constituent components
Saab900
240-144
Fault symptom
Note:
Malfunction
indicated/possible cause
1 2
"
Test procedure
Test reference
E1, E2
123
3
6
3 456 7
12
Check by connecting an
E5
ammeter across pins 2 and
3 of the throttle position
switch
9 Mass air flow sensors (HLM) Check that the hot wire (fila- E7A
ment) is intact, that the
burn- off function is OK, and
that the connections are
good
7 8
12345
345
11
4 5
Induction, system
7 8
Saab 900
B1 D81 E
240-145
Note:
Fault symptoms that can be traced to points 4 and 5
may also be attributable to the "Limp-Home" function.
Malfunction
indicated/possible cause
1 2 3 4 5 6 7 8 9 Temperature sensor (NTC
resistor)
6 7
Test procedure
Test reference
E8A
E8A
234
234
Saab 900
E8A
240-146
Malfunction indicated/possible
cause
Test procedure
a. Electrical system
b. Fuel pump
c. Fuel system
d. Induction system
d. Air leakage.
e. Injectors
.-
f. Temperature sensor
(NTC resistor)
g. Control module
g. Poor contaCi:,
n~l
input signals,
inoperative.
h. Malfunction, leakage.
Saab900
240-147
System or component
Malfunction indicated/Possible
cause
Test procedure
a. Electrical system
b. Temperature sensor
(NTC resistor)
c. Induction system
c. Air leakage.
d. Control module
e. Malfunction, leakage.
"
g. Incorrect setting.
h. Incorrectly adjusted or
defective.
"
Saab900
240-148
3 Erratic idling
System or component
Malfunction indicated/possible
cause
Test p~ocedure
a. Temperature sensor
(NTC resistor)
c. Incorrect setting.
d. Induction system
d. Leakage.
e. Injectors
f. Fuel system
g. Control module
h. Malfunction, leakage.
i. Electrical system
j. EGR valve
Saab 900
240-149
Malfunction indicated/possible
cause
Test procedure
b. Incorrect setting.
c. Induction system
c. Leakage.
d. Inject'ors
e. Fuel system
f. Control module
g. Temperature sensor
(NTC resistor)
h. Electrical system
resistance.
sensor
(see section E10).
j.
"
Saab 900
240-150
5
Symptom or component
Malfunction indicated/possible
cause
Test procedure
a. Control module
b. Electrical system
c. Injectors
d. Opening duration.
d. Turbo/APC
d. Malfunction
g. Induction system
g. Air leakage.
h. Fuel system
i. Temperature sensor
(NTC resistor)
Saab 900
Fuel injection'system
240-151
Malfunction indicated/possible
cause
.
Test. procedure
a. Fuel system
a. Pressure regulator
b. t:ljectors
b. Malfunctioning.
c.
c. Temperature sensor
- (NTC resistor)
c. Inoperative.
d. Incorrectly adjusted.
f. Incorrectly adjusted.
g. Electrical system
h. Control module
Saab 900
240-152
Symptom or component
Malfunction indicated/possible
cause
.
Test procedure
a. Induction system
a. Leakage
b. Throttle butterfly
b. Incorrectly adjusted.
c. Fuel system
d. Injectors
d. Malfunctioning.
f. Turbo/APC
f. Malfunctioning.
g. Temperature sensor
(NTC resistor)
h. Electrical system
i. Control module
Saab900
240-153
Malfunction indicated/possible
cause
Test procedure
a. Induction system
a. Leakage
b. Fuel system
b.
leril~'
d. Temperature sensor
(NTG resistor)
d. Malfunctioning.
e. Electrical system
f. Control module
g. EGR valve
Saab 900
240-154
Checking/fault diagnosis
81 Checking the fuel system
Tools:
LH fuel pressure gauge equipment 83 93 852
Vacuum pump
Multimeter
1 Disconnect the banjo coupling at the inlet to the
fuel injection manifold and connect the fuel pressure gauge using the existing seals. Tie up the
pressure gauge so that it hangs vertically to obviate reading errors.
2 Remove fuse No. 30. Connect the jumper lead
with switch between fuse No. 30 and fuse No.
27, 28 or 29 to supply the fuel pump with current.
Saab 900
240-155
Use the cooling system tester to raise the pressure in the fuel pressure regulator. The line pressure should now increase by as much as corresponds to the movement of the needle on the
pressure gauge, see 'Technical data".
B1C
".
Saab900
240-156
810
CAUTION
Check that the voltage across the fuel pump terminals is at least 11.5 V.
Note:
If the fuel filter has been fitted the wrong way round
it cannot be refitted but must always be replaced by
a new one.
Check the relief valve in the pump. If it is defective, fit a new pump.
('
""
Saab 900
"
240-157
E2.
Saab900
240-158
E1
Tools:
Multimeter
Saab 900
E2
240-159
Tools:
Multimeter
Jumper lead with crocodile clips
8393894
u.
'27,
n
30
3 Ascertain whether the relay operates by checking for voltage between the Limp-Home connector's grey/red (GRJRD) lead and ground (at the
wiring harness on the RH wheel arch).
If no voltage is present, fold back the carpeting
and remove the relay.
Check for' voltage between relay pin 30 (red; RD)
and ground and between relay pin 86 (brown/
white; BRNT) and ground.
If no voltage is present, check the red (RD) lead
between pin 30 and the positive terminal, and
the brown/white (BRNT) lead between pin 86
and main relay pin 87 (pressure switch, Turbo).
If voltage is present, use jumper lead 83 93 894
to connect pin 85 (violet; VL) to ground.
Check for voltage on relay pins 87 (blue/red;
BURD) and 8lb (grey-red; GR/RD). .'
If no voltage is present, fit a new relay.
If voltage is present, check the grey/red (GR/
RD) lead from the Limp-Home connector to re. lay pin 87b.
Saab 900
240-160
E3
Tools:
Multimeter
E4
Tools:
Multimeter
1 Unplug the control module connector and remove the cover.
2 Measure the resistance of the NTC resistor as
shown in the table by connecting. the multimeter
test prods to the control module connector pins
2 (yellow; GL) and 11 (black; SV). Alternatively,
unplug the NTC resistor connector and simply
measure the resistance across the pins.
Saab 900
240-161
E5
Tools:
Multimeter
1 Unplug the control module connector and remove the cover.
2 Connect the multimeter between control module
connector pins 3 (grey; GR) and 11 (black; SV).
Check that the circuit is closed.
If there is a break in the circuit, check the grey
lead from pin 3 of the connector to the throttle
position sensor and the black lead from pin 11
of the connector to ground, and the black/white
lead from the throttle position sensor to ground.
3 Move the throttle butterfly and check the reading on the multimeter. If the sensor is in proper
working order, the circuit should be broken the
moment the butterfly leaves its idlingposition. If
it is not, adjust the position of the throttle butterfly (see M1, "Basic setting of throttle butterfly".)
Adjust the throttle position sensor by slackening
the screws securing it to the throttle body. Turn
the throttle position sensor until it abuts against
the integral idling position stop. Tighten the
throttle position sensor retaining screws.
Check that the circuit between control mOdule
pins 3 (grey; GR) and 11 (black; SV) is broken
when the thmttle butterfly leaves its idling position stop.
Saab" 900
240-162
---
SV/VT)
Saab900
240-163
Tools:
Multimeter
-~------------!'-~OI:Q:
Readings m~\st be taj(en rr: tile rear of the control
module connec..10r lJliilh ns cover. removed.
25
13
24
12
11
23
22
21
Saab 900
20
19
1B
17
16
15
14
10
GNIRD
GNIRD
SV
BlNT
BRNT
8
7
ROM
BlNT
OR
sv
OR
3
2
1
GR
GL
BL
240-164
E7A
Tools:
Multimeter
5525'1
531VT
(6)
5360R
(5)
5525'1
(4)
To component
VT)
2
3
4
5
6
,<;iSaab900
~.
Vn
240-165
Note:
The Limp-Home function takes over automatically' if
the hot wire (filament) breaks.
Saab900
240-166
E7C
,'--------------------,
E7D
Note:
There are no specified intervals at wti'ich the basic
setting of the fuel injection system shou.ld be
checked or adjusted.
.
This setting establishes a reference point for the LH
system and does not affect vehicle performance.
Recalibration is necessary only if the performance
of the engine has been disturbed by major work on
it, such as replacement of the electronic control
module, the NTC resistor or the mass air flow sensor, or by a major overhaul, cylinder head work or
timing chain replacement.
"i'
Saab 900
SG
2
1
240-167
S
S
a
1
I
4 Plug the wiring harness into the mass air flow
sensor again.
Note:
The movement of the needle will not be rapid and
there may be a pause between each movement.
8 If adjustment is necessary, turn the p'otentiometer screw in the mass air flow sensor as follows:
a If the needle remains stationary at the higher
end of the scale or spends most of its time at
this end, turn the screw anticlockwise until the
needle stays roughly the same lengtp of time at
both ends of the scale.
b If the needle remains stationary on the lefthand side of the scale, turn the potentiometer
screw until it stays roughly the same length 01
time at bcith ends of the scale.
9 Fit the plug 'back in the mass air flow sensor.
Saab900
(
J
,.,
240-168
E8
Tools:
Multimeter
Jumper lead with crocodile clips 83 93 894
Before carrying out any checking work on the control module, unplug its connector. Also unplug the
mass air flow sensor connector and the connector
between the ignition system and the distributor.
Note:
Instrument readings must be taken at the rear of the
control module connector with the cover removed.
E8A
Saab 900
240-169
A
GNlRD
GN/RD
SV
AIC BlNT
GRNT
25
24
GURDAIC
GN X-test
23
SV
BLNT
22
BRNT
GlNT
'RDNT
GNNT
"21
20
19
18
VI:
17
RDNTAC
16
15
14
LAMBDA
OR
VLNT
BLNT
SV
OR
GR
SV
GL
v.r
BL
GN/RD
SVNT
BURD ElK
GN/RD
RDNT
OR
BLNT
SV
OR
GR
GL
BL
''S
'J
2
3
4,
5
6
7
8
9
10
11
12
13
~W
14
15
16
17
18
19
20
21
22
23
24
25
Saab900
240-170
Se
le v..-,
u~clt;:'
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Saab900
L"~
.,..:.. '...\.0
\ C~}
0-'-"-'\
'-.J""--
' .
'IN- iu..
~\
,,'\-
EBB
Tools:
Screwdriver or stethoscope
Multimeter
~ p~ I.>/'-?J\./'--;.)l....
Tachometer
Note:
Do not use a test lamp when checking the control
module's output signals to the injectors.
\\. u<<.v
\,v"
\.Jc."
l L, L.><?k '"
~:.
Note:
Polarity: Red (+) prod to the blueired (BURD) lead
and black (-) test prod-to the green/red (GR/RD)
lead rT'l.~;
,
/ ' /.
/
~ ~~
(7 c.ev..
j . ko
(..'-l:'-
lA
"<J ......l,...,_
Lo.~ v-.:
Engine temperature
DoC (32F)
20C (68F)
80C (176F)
fcA.. \ \
I."",
Voltage
1V
0.6 V NOTEI
0.3 V approx.
,:s,)
Saab 900
240-171
240-172
0../"~e.s"r
.' \ \
I
f \
I'
T- ~
C", ("'0'....
)... \e~ v.,CL.
l-,~~.~, \.) \ \ \-.;>
\l ~ \"'-.l"",1 ~,,'
(.
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.t
t'-I,
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c..~
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-h. L.
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'- J . ; ~ :" ,
'S:>"'c...c~
,c...~.?\~l ..
\?Q~~ 'v-.fr.J.-:J..~\.(;.
1.1'
L.::\:::~\
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I.Ac...
"'-"'
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r--A1o,'"
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t
fL.'\,
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b/~!1
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G...
V'-
~('- ~
V
v-
\"j
~""v~Ql..\.L-
2:
'10
Saab 900
\) ,.
240-173
ESD
Tools:
CO meter
Multimeter
1 Connect the CO meter and exhaust extraction
equipment.
2 Start the engine and warm it up.
3 Peel back the rubber dust excluder on the connector of one of the injectors.
Unplug the throttle position sensor connector
and pull up the rubber dust excluder. Connect a
jumper lead to pins 3 and 18 of the throttle position sensor connector.
4 Check whether the CO content rises by about
1%. If it does not, connector the multimeter test
prods to the injector connecting pins.
Note:
Polarity: Red test prod (+) to the blue/red (SURD).
lead and black test prod (-) to the green/red (GRlRD)
lead.
Check whether the voltage rises by about 0.1 V.
5 If. it does not, check the leads running to the
control moduLe. See section E5 "Checking the
- throttle position sensor". If these leads are OK,
, -try another control module.
6 Check and adjust the CO content as described
in section Eye.
Saab 900
240-174
E8E
Tools:
Multim eter
CO meter
Tachom eter
1 Conne ct the tachometer, CO meter and exhaus t
extraction equipment.
Note:
Polarity: Red test prod (+) to the blue/red (SURD )
lead and black test prod (-) to the green/red /GR/RD)
lead.
Engine temperature
Voltage
OC (32F)
20C (68F)
BOC (176F)
0.6 V NOTE!
0.3 V approx.
1V
Saab-900
EgA
240-175
Tools:
Multimeter
Tachometer
1 Connect the tachometer and exhaust extraction
equipment. Start the engine and warm it up.
2 Press the AC button. E~lgine spee I s!-ltJuld then
drop noticeably and then return to n<'/~:mal idling
speed again.
3 If it does not:
II
Check whether voltage is present at the AC com.pressor's single-pole connector at the compressor (red; RD).
Check the AC unit's electrical system (power supply to the electromagnetic clutch).
Check whether voltage is present at the lAC valve
and whether it opens (see section 854, Service
Manual 8:3).
Check whether voltage is present at the AC unit's
115C (240F) thermostat (see section 854, Service Manual 8:3).
Also check that the yellow (GL) lead between the
lAC valve and the AC unit's 115C (240F) thermostat and the black (SV) lead to the alternator
grounding point are OK.
E9B
Saab900
240-176
It
E10
'.
The oxygen (Lambda) sensor provides one of several input signals that are processed by the control
module to determine the correct fuel-air mixture.
Other input signais incl~de en~ine rpm, e~gine temp~ratUf.~. ~ccelerator position and air mass.
The i:>xyg~n (Lambda) sensor used in the LH system. incorporates an electric preheating function
which ena'Jles the temperature to' be raised quickl)
so that accurate monitoring of the composition of the
exhaust gases is ensured.
1 Unplug the two-pin connector from the wiring
harness.
2 Use the multimeter to measure the resistance
across the two white connections of the oxygen
(Lambda) sensor. The correct resistance is
about 4 ohms.
II,
~71
ri
1.1 dL'I' .. ~
(Til
~.
-,
t'
(71
~!-rr i~
(1~J-(""'t'i
t.r1'---n
..
1
Saab900
240-177
11
Tools:
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Saab900
240-17.8
Saab900
240-179
Multimeter
Torch
Before starting to check E', J ;"U}dliai)~ air valve, unplug the control module ar-'j t :J:;\i1aI'Y air valve connectors.
Note:
Checking is to be carried out when the engine is cold
(below 30C/86F).
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Saab 900
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240-180
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Note:
Basic setting should always be carried out with the
engine cold; temperature about 20C (68F), and
the ignition switched off.
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Saab 900
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240-181
M1 A
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Note:
Saab900
injection system
TSI tachometer
Nut driver for the butterfly adjusting screw locknut,
8394322
Jumper leacf"with switch 83 93 886
1 Remove the induction hose from the throttle
body.
Open the throttle butterfly fully and wash the inside of the throttle body round the butterfly, using a cloth soaked in ben~ine or the equivalent.
Note:
It is extremely important for the gearbox oil to be at
normal operating temperature.
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Saab 900
240-183
I
5 Undo the two throttle position sensor retaining
screws and rotate the sensor clear of the throttle
butterfly.
Also make sure that the throttle cable does not
interfere with the movement of the throttle butterfly (cable slack).
6 Start the engine and disconnect currentconsuming items like the AC, headlamps, seat
heating elements, etc.
Note also that adjustment must not !;>e carried
out when the radiator fan is running.
7 Connect the jumper lead with switch (83 93 886)
to the single-PQj81est socket focated adjacent to
thn r}gh>hal1d wheel arch (green/red lead).
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Saab900
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240-184
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Saab 900
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240-185
Component replacement
Control module
1 Di.sconnect the negative battery cable.
2 Remove the sill scuff plates from the right-hand
Side
, oJ the car.
Phil away the door weatherstrip at bottom front.
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Saab,gOO
240-186
Temperature sensor
1 Remove the clips for the crankcase ventilation
hose from the camshaft cover.
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a. r 4" drive
Before refitting, thoroughly clean the mating surfaces and temperature sensor.
Also check the condition of the copper washer.
Fit in reverse order.
Note:
Do not forget to reconnect the ground leads for the
LH injection system at the point where the fuel pressure regulator is fastened to the cylinder head.
Saab900
240-187
Note:
Scrupulous'cleanliness must be observed when carrying out work on the fuel injection manifold and
injectors.
Wash the areas round the injectors, the fuel injection
manifold and the intake mari.fold. Blow clean and
dry with compressed air.
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Note:
Use a spanner on the flats at each end to hold the
injection manifold steady.
Note:
In the event of fuel leakage, always wipe up the fuel
with a cloth or the like.
Saab 900
240-188
To fit
Before refitting, inspect the O-rings. If damaged, fit
new ones.
To facilitate fitting and reduce the risk of damage,
smear the O-rings sparingly with petroleum jelly (Vaseline).
1 Fit the injectors in the fuel injection manifold.
2 Mount the fuel injection manifold complete with
injectors on the intake manifold.
Check that the injectors are correctly located
and pushed fully hOJl1B in tilE: ir([~.:e manifold,
and that the flange of the fuel injection manifold
lines up with the groove for the clip in the injector. Fit the clips.
Fit in reverse order.
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Saab900
240-189
Fuel filter
1 Thoroughly clean the area round the two fuel line
connections.
2 Prevent the filter from turning by applying a
spanner to the flats on the filter and banjo fitting
and disconnect the fuel lines. Remove the filter.
Note:
To prevent swarf from the threads from getting into
the fuel system, do not remove the fitting on the
discharge side.
Note:
If the filter has been fitted the wrong way round it
must not be refitted. Fit a new one instead.
regulator from
the
Note:
Do not forget to reconnect the LH injection system
ground leads at the point where the pressure regulator is fastened to the cylinder head.
Saab 900 .
240-190
Saab 900
240-191
Air cleaner
1 Unplug the mass air flow sensor connector and
release the two clips securing the air cleaner
housing cover. Withdraw the mass air flow sensor and tum it to one side out of the way.
2 Remove the air cleaner housing cover by undoing-the four clips.
3 Lift off the housing cover.
4 Lift out the filter element.
S Fit a new filter element, making sure: :it:, {~<m~\I2:d
in the air clear er housing.
6 Refit the housing over. Turn the cover to line up
the clips and to bring the spigot for the mass air
flow sensor in line with the inlet to the turbo unit.
Fasten the clips.
7 Reconnect the mass air flow sensor, lining up its
ridge with the groove in the air cleaner housing
cover. Fasten the clips.
8 Plug in the mass air flow sensor connector.
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Saab 900
240-192
531VT
537 RONT
536 OR
557 BRNT
552SV
535 BLNT
537 RONT
531VT
557BR NT
B
536 OR
535 BLNT
552SV
Saab 900
240-193
30~ ~,
30~ ~
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A Main relay
B Pump relay
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Saab Automobile AS
Trollhattan, Sweden