2 3 Fuel System Injection Engine OCR PDF
2 3 Fuel System Injection Engine OCR PDF
2 3 Fuel System Injection Engine OCR PDF
SERVICE MANUAL
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~ 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.
Conversion factors
1 in = 25.4 mOl 1 0101 = 0.039 in
1 tb = 0.45 I<g 1 I<g = 2.20 Ib
1 Ibf = 4.45 N 1 N = 0.231bf
11bfft = 1.36 Nm 1 Nm = 0.74 Ibf ft
1 psi = 0.07 bar 1 bar = 14.5 Ibf/in 2
1 US Iiq qt = 0.83 UKqt 1 r = 1.05 Iiq qt
1 USgal = 0.83 UKgal
" of = °C x 9/5 + 32 °C = eF - 32) x 5/9
Saab 900
022-2 Technical data
2 .5 11--I---t--+----t7rr 2, a II--+--+--+---+--+::
(36.3) Il--+__+--h {29,O,ll------+---+--l-_
'1.5 !1--.J-~+--+-_j__+_+-+__+-. 1, 0 I l - - - - f -
(21.8) ~ (114,5)11---1---1---1---+_+--+---+--+--+_ ~
en
1.0 :=b~b=:b:=~='==:=h=='="==d===(f) \b=~.b="=="==d=d=~±'=~
lb.
O5
(14.5) 10 20 30 40°C (7,'3) 10 20 30 40°C
(50) (68) (86) (104) (oF) (50) (68) (86) (104) ("11=
bar ...-.----.-----.~-r__.------,-~~--;
(ps i) II----I----f--l---f-----+-----i-
Date code
3.0 I-+---t--+--t----/---+
(43.5) II-----I---I--I--+_+_~
2.5 D---+--+--+----/-~
(36.3) Il----l____+--l____~&'_+__+__l____t____l
Saab 900
Technical data 022-3
Saab 900
022-4 Technical data
o
VJ
,
Resistance at 20 0 e (68°F) ohms I 40-60
.. l'·1
Saab 900
Technical data 022-5
3 4 5
..•. S 1/138
lambda sellilSOIi'
Signal voltage 0-1 V when system in operation. Pre-
heater resistance 4 ± 2 ohms.
Lambda sensor for Lucas fuel injection system:
Signal voltage 0-1 V when system in operation. Pre-
heater resistance <10 ohms.
~njectors
Flow capacity
2.5 (turbo, not cat. 84.5-86 and turbo cat. 85-) 104
3.0 (i) 90
Saab 900
022-6 Technical data
Saab 900
Technical data 022-7
.... ~.-<•. ""\'
_u_ h
,
-
-
900 1M 90 - " " .:,"- " fI
" " -573 9114703
,~":II~ , ..
900 iA _'~ " "
fI
, .. _u_
" -"'.68 89754.43 1
" "
~'
"
900 iM 91 " " " " " " " " " ":J~J, 9'1';470~1
900 iA' fI
" " " .. fI,- " " " " " ..568 8975443
900 iM ,
92-~ " " " " " " " " " -573 9'1'14703
__ u_
900 IA 92- " " " " " " " fI
-568 8975443
u \.
900 LM 84.5 " 2.5 -214 7501646 21-005 9375643 -706 7509862 -517 75'14904
900 LM, LA 85 " " " " " " " " " -521 75,26114
,i
90g LM 86 " " -255 7564131 " " " " * -53S' 7529092
" 87 " " 2.8 -264 7568041 -",.. " -712 7560170 -547 7536683
" 88 " " " " " " -"- " " " "
" 89 " " " " " 11-017 8978280 -761 7487010 -569 7487119
. t
ZW02
Idle' air contr. 'valve, EWO
, I
.
I
~t
AI),I(iliary air valve x gOOJ~.EU 1 -122 ' 9313909
, Cold-start valve,. KSV )( x
"
900i B202, B212 Market EU 2 -432 . 7486129
Evaporative emis,sion x Cat. cars. Marl<et ME - 7532054
canister, complete
Evaporative emissioJ1'..·~j. v
x All - 75392~6
"
canister, excl. TEV
Tank breather valve, TEV x x All -157 7539257 !'
By-pass valve )( x x All turbo -103 9390022
, ,
1)Part of APC and Ignition system
Saab 900
022-8 Technical data
II II II II II
900 LM, LA 90 14.0 " 73356 7485022 84905 8977639
900 LM, LA 91 . " 14.'1 " II II
" " D115~ 7872351 80147 7872336
EA
II II II II II II II
92- " " " "
II
1) Of Plerburg manufacture
1) Of Plerburg manufacture
\ .
-, , \
. ,
Saab900
Technical data 022-9
•
1982- Sweden 0.2-1.0 850 max. 4.5% 850
Others 0.2-1.0 850 - 850
Saab 900
I
Special tools 102-1
83 92 482 CO ~djusting key 83 93 852 Pressure gauge set for measuring fuel,
pressure in the LH system
83 93 860 Spare set of hoses for gauge set
83 92 852
83 93 878 Connector (spare part for gauge set
83 93' 852)
Saab 900
102-2 Special tools
83 93 183 Test hose for CI system 83 93 894 Jumper earthing lead for fault-tracing
in the LH system
@ SAAS @
"'... s .......l'rttono·
I'V't<)tap:-
@ 8393597 @
83 93 597 Pulse ratio meter for measuring the 83 94 i 32 Wiring harness for connection of pulse
pulse ratio of the modulating valve on ratio meter
cars with the Lambda system (certain
markets only)
83 93 514 Pressure gauge set 83 94 322 Key for throttle adjusting screw locl<-
nut
Saab 900
Special tools 102-3
J
;J 83 94 314 Key for adjusting CO
Saab 900
102-4 Special tools
r:- ------Jf~--:.
\ -- _ ....... - - _ .. q: -==-,-.
"-:r
It
~
83 94 397 Tool for fuel pump (Walbro), 83 94 462 Tool for fuel pump
M1989 ' (Bosch), M1990-
83 94 330 Key for fuel pump (Bosch), 83 94 504 Test cable for built-in fault diagnosis
-M1988 system, M1990-
,
I
Saab 900
Technical description 200-1
Saab 900
200-2 Technical description
Saab 900
Technical description 200-3
Injection engine
Saab 900
200-4 Technical description
'.~
:['
I
Saab 900
Technical description 200-5
• "t·,
The system consisfuiod' pump, a main pump
and a pressurized:rec~(~~Ji-1~he feed pump delivers
fuel from the tank t9 th~';r'eceiver in which the main
pump is mountea. When tlie receiver is full, pres-
suire builds up in it and the main pump is supplied
with fuel under pressure,
, ,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.
, ".....
Saab 900
Technical description 200-7
Fuel filter
THe fuel filter is fitted in the circuit between the fuel
accumulator and the fuel distributor. The filter con-
tains a paper filter cartridge and. a nylon strainer
Fuel filter
1 Outlet
2 Nylon strainer
3 Paper filter cartridge
4 Arrow indicating flow direction
5 Inlet
F8Jle~ d1Ds~lribu or
The fuel distributor distributes the fuel to the injec-
tors and consists of a fuel control unit and four pres-
sure regulating valves (two of which are shown), one
for each cylinder.
Saab 900
200-8 Technical description
Saab 900
Technical. description 200-9
":J"'\.....,......."'"'"""'"P'C""""~~
.I ''''' ,~ .... "" " .... .1 ... .11" I
- I
-~ I
r' t', " ,'\ " ",\,J
~~_w.~_,,-,.:.'~
I
"
"0"·
Saab 900
200-10 Technical description
,
Wallrm"'llJp Il'sgulatolr
When the engine is warm, the warm-up regulator (a
spring- loaded diaphragm valve) maintains a con-
stant control pressure above the control plunger.
When the engine is cold and requires a richer fuel-
air mixture, the control pressure is reduced. This al-
lows 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. 1
When the engine is cold, a bi-metal strip presses
against the compression spring and reduces tre
2
force of the spring acting on the diaphragm. The di-
aphragm then opens and exposes the return line to 3
the fuel tank, thus reducing the control pressure:
When the engine is running, current flows through
the heating coil surrounding the bi-metal strip.As the
4
bi-metal strip heats up it bends away from the spring arm-up regu a or, co engme
and so causes the pressure on the diaphragm, and
~Control pressure
also the control pressure, to increase. When a warm
IIlIlllIlIIDl Return , no pressure
engine is started, no reduction in the control pres-
sure takes place as the bi- metal strip is then af- 1 Diaphragm
2 Plunger
fected by the engine temperature.
3 Compression spring
4 Bi-metal strip
5 Heating coil
==
==
Warm-up regulator, warm engine
~ Line pressure
mrrmrrn Return, no pressure
Saab900
Technical description 200-11
Saab 900
200-12 Technical description
~~]ectors
The injectors, fitted in the inlet manifold, inject fuel
continuously upstream of the engine inlet valves.
A spring-loaded disc and needle valve inside each
injector open when the fuel pressure reaches ap-
prox. 3.3 bar (47 psi).
Also incorporated inside the valve is a fuel strainer.
Injector
1 Fuel strainer
2 Valve disc
3 Needle valve
Saab 900
Technical description 200-13
Air C~ea81ISII"
The air cleaner, which contains a folded paper ele-
ment, 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.
Saab 900
200-14 Technical description
T~6"Olttle [bO)dy
The throttle body is connected to the intake pipe
and, in addition to the throttle butterfly, contains the
idling air passage with idling adjustment screw, con-
nections for the auxiliary air valve hoses and for the
cold stare valve, and the vacuum outlet for ignition
advance.
,j
'I 2
j
I
3
Saab 900
Technical description 200-15
S44liS
'."
o,i
".
Saab 900
200-16 Technical description
1
4
l t t
J t
!
l
!
5
S 5709
Saab 900
Technical description 200-17
-
The oxygen sensor, fitted in the exhaust manifold,
senses the amount of oxygen in the exhaust gases
arld ,sends this information to the control module.
Via the modulating valve, the electronic control mod-
ule regulates the pressure difference in the fuel dis-
tributor to kS'ep the fuel-air mixture within the
Lambda 1 range.
Lambda 1 is the optimum fuel-air mixture for com-
plete combustion. Lambda, the Greek letter, ciq-
notes the ratio between the actual (delivered) ar ,J
theoretical fuel-air mixture.
g/km
Ideal mixture
S 5700
Saab 900
200-18 Technical description
s
U
IT
q
Catalytnc convertsr
The final phase of exhaust emission control consists
of a catalytic converter located in the front section of
the exhaust pipe.
It consists of a horiey~omb ceramic insert, the walls
of which are coated with catalytic material (platinum
and rhodium).
Cars equipped with a catalytic converter must never
be run on anything but unleaded petrol as lead de- Catalytic converter
stroys the active constituents of the catalyst and is
1 Ceramic insert
also detrimental to the oxygen sensor.
2 Passages
3 Catalytic coating
Technical description 200-19
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 de-
termined by the pulse ratio.
716
30170
Frequency of 70 Hz
A Open
8 Closed
Saab 900
200-20 Technical description
!FlUj(e~ distributor
When the pUlse ratio of the modulating valve is high, 1
a larger quantity of fuel will flow from the chamber ~
below the steel diaphragm in the pressure- C
regulating valves, thereby momentarily reducing the E
pressure below the diaphragm by about 0.2 bar (2.9 r
psi). This pressure drop increases the flow of fuel t
through the pressure-regulating. valves and, since c
'-
the opening of the metering slots remains constant, tl
a richer mixture is delivered to the engine.
If the oxygen sensor signals a low oxygen level (rich
mixture), the opGning r.hases will be shorter and a
smaller quantity of fuel will be drawn from the cham-
ber below the diaphragm in the pressure-regulating
valve. This results in a reduction of the pressure dif-
ference and fuel flow, resulting in a weakening of the
mixture.
Saab 900
Technical description 200-21
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 differ-
ence 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-
tive below a temperature of 300°C, enri: "ment to
;>92%(via terminal 11 of the cOntrol moaL \) 'ii'lill 8!-
ways be obtained while the starter motor i~ llg'i,g.&d
and for three seconds arier starting. At Em:o:Jine tem-
peratures <'19°C the pulse ratio will be 60%ror the
first three seconds after starting. Following this, the
mixture will be enriched via the cold- start valve
(temperatures below 45°C}-or via P11 (above 45°C).
A ratio of 50/50 is that prevailing under normal con-
ditions of engine load. If the Lambda sensor should
fail to emit a signal for any reason, the system will
revert automatically to this ratio.
1F1!J.j(e~ sll1IlrolCfrumerr[
The following types of fuel enrichment occur:
Cil Cold-start enrichment (via the cold-start valve or
via P11, depending on temperature)
o Acceleration enrichment (via the fuel booster
pressure switch for 140 ± 20 seconds after start-
ing)
o Rpm-governed enrichment (via the speed relay
('/38) at engine speed >3800 rpm (4600 rpm on
model year 1988 and later cars). Provides a fixed
pulse ratio of 85%. Applicable to Turbo cars only)
o Full-load enrichment (via the throttle position
switch).
Model year 1987 and earlier Turbo cars: a throttle
butterfly angle >72° gives a fixed pulse ratio
>92%, or rpm >3800 (4600 rpm on model year
1988 and later cars) gives a fixed pulse ratio
>85%.
I) Pressure-governed full-load enrichment, model
year 1988 and later
At an inlet manifold pressure of 0.25-0.30 bar a
pressure switch is actuated to effect full-load en-
richment (fixed pulse ratio of 85%).
I Normally aspirated engines in model yeaI' 1987
Saab 900
Oxygen-sensor blocking Operation of cold-start and boosting systems i'J
o
I ~
Cold-start valve
I r o I
I\.)
• G I I I 1 ~ f'-.)
Cold-start P11 for max. 120 s -f
valve + P l l ! I I I fuel shut-off
CD
(')
::::r
Enrichment functions triggered
I c~ Cold-start valve J. L e:::-
by fuel booster pressure switch
::J
(')
0)
I CoIG-5~art I I P11 for max. 120 s
c..
valve + P11 fuel shut-off CD
I I (J)
(')
"""t
I 0
Cold-start valve
I P=-
U
r-+
o
I I Cold-start I I P11 for max. 120 s :::::::l
,
I ! I I
Closing temp • .: Opening temp Closing temp , i
Opening temp
~ Coolant temperature, DC
19t2 S±3 J8i3
~ Regardless of temperature, P11 boosting has been running for 1.4 s. This function is
(pulse ratio 92% minimum) always tal~es operative when the 45 DC thermostatic switch
place while the starter motor is running and and/or TIK is/are open.
for three seconds after starting.
o Oxygen-sensor blockfng (P12) results' in a
{) Pulsed signal (0.10 s open and 0.3 s closed) fixed pulse ratio of 60% (also that obtaining
to cold-start valve occurs after starter motor during fuel shut-off).
CJ)u:=;:;=~<OQ~::::;;tm ..Q <8 (Q_ ~1- ::j" ~ .=r 3 --1 ~ "d" "Til
-
Technical description 200-23
A C@~oj~stcalll't ffQJIHlCiiUOtrll
The cold-start valve can open only when the starter ,2
motor is engaged. The time the valve remains open,
injecting fuel, is governed by the thermostatic time
switch which senses engine temperature. The max-
imum injection time of approx. 9.5 seconds occurs
at temperatures below -20°C (-4°F). At higher en-
gine temperatures the injection time becomes pro-
gressively shorter and the cold-start valve ceases to
operate at temperatures above 45°C (113°F).
, >-
'0
:0
~E
)>-
,Q.l
,t
.~
1C/)
1>-
'Q)
i;!= SOI311
·ro
1C/)
l. >-
)~ " Starter motor
)0
)0 2 Cold-start valve
IQ) 3 Hot-start relay
,i2:
ro
.>
!t
b~
i<f>
1-0
'0
!o
1
0
.......
200-24 Technical description
1
4
IE
EI
er
m
th
al
6 \'.]]!.
re
lap ragm
c(
2 Spring m
C(
3 Constriction
4 Spring contact arm If
5 Vacuum connection n;
6 Electrical terminals :~I
.:.'
,..,.
-
51
Saab 900
Technical description 200-25
.~-
8A
:2
58134
4 ~I'lJI7l-.-11
6
+10
.
L--~34--Jo+
,
SIlJS
Saab 900
Technical description 200-27
P11 relay
.::t
N
en
1 Thermostatic switch
2 Thermostatic time switch
3 Cold-start valve
Saab 900
200-28 Technical description
1 Cold-start valve
2 Hot-start relay
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.
l 2
6
15
'11
+ + N
N
%
Ul
Saab 900
200-30 Technical description
Saab 900
Technical description 200-31
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
-
The control system has the following 'tWo func- lUI
tions: ~""" ani
0
0
o 0 Turt
~ Heavy ~oadl (not fl!J~~ UuoU~e) recti
Air from the compressor flows via the delay valve
through the electric control valve which, in its nor-
mal position, allows the pressurized air to pass to
the warm-up regulator so that enrichment tal<es
place.
"The delay valve ensures that the fuel boosting sys-
tem is not activated for temporary increases in load
Which would otherwise result in unnecessarily high
petrol consumption and unnecessary hydrocarbon
emissions.
The
coq
Deviations, cars with automatic transmission of tl
(Double connections to the throttle body) bi-n
Under load, cars with automatic transmission pro- whi
duce a more powerful signal in front of the throttle '::on
butte"rfly. This signal is reduced to the desired level bar
by a constriction inside the throttle. phr
Cars with automatic transmission are not equipped in t
with a delay valve because temporary load in-
creases (pressure surges) do not occur to the same
extent as on cars with a manual gearbox.
58259
fR
~~ full throttle
(C
Via the non-return valve, the pressure vessel is in
wi
communication with the pressure generated by the - - - - - - --I Tu
compressor, thereby increasing the residual pres- I
I
sure enough to maintain the same level over a long Pn
period. mE
fur
When the throttle is fully open, the electric control by
valve is activated via the throttle position sensor, re- S\i\
sulting in immediate regulation of the control pres-
sure and corresponding fuel enrichment due to the A
"residual pressure" in the pressure vessel. Sa
51296 su
tft
fuJ
ae
Tt
at
hE
7
At
or
A'
1"
Pi
Saab900
Technical description 200-33
S 2 034
Saab900
200-34 Technical description
I) J
)
o I
o I
o I
Saab900
Technical description 200-35
-
L,H f e~ ~lJIlje«;~a@11il $Ys cem~
8202 UUIl]®C o(Q)f!1l ~D1lgh1~
Generra.~
The Bosch LH-Jetronic IL uftmassenmesser Ii
itzdraht) fuel injection system, comprising a mass air
fh:/w sensor incorporating a filament (hot-wire sen-
sor), combines the best features of different fuel in-
jection systems with measurement of the air mass
, Le. the density of the induction air is taken into ac-
count - unlike earlier fuel injection systems.
in the LH-Jetronic system, the air mass consumed
by the engine is measured, which means that allow-
ance is made for the composition of the air (temper-
ature, 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 up-
stream 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 pres-
sure has been taken into account.
The LH system has the following advantages over
earlier types of fuel injection:
o _Compensation for temperature variations.
o Adjusts the quantity of fuel to the quantity of ox-
ygen at high altitudes.
e, Fewer components.
, Lighter.
~ Fewer moving parts.
o Wider scope for adapting the quantity of fuel to
actual needs (warm-up period/acceleration
phase).
Saab 900
200-36 Technical description
-
21
Saab 900
- Technical description 200-37
<,.. -<l-
l 0(>-
5
12
-l>
Ir--l W
L(i119
n "
12 ~20
CX)
(T)
o
~
1Cf)
Saab 900
200-38 Technical description
-
Prnncipie of operation In tl
The operating principle of the system is as follows. air f
An electric fuel pump pumps fuel from the fuel wirE
tank, building up pressure in the fuel system. The the
level of the pressure is governed by the pressure moe
regulator , which maintains a constant ratio be- with
tween the- fuel pressure and the pressure in the in- moc
take pipe. As a result, the quantity of injected fuel is the
unaffected by variations in the inlet manifold pres-
sure and is influenced only by the amount of time
the injector is open.
Th,:; ·rue.1 ::" injected by the injectors (electrically
co.lytlulled solenoid valves) fitted in the intake pipe
close to the inlet valves and connected by a com-
mon fuel injection manifold .
The time the injectors remain open is determined by ThE
the engine load. ane
On M1989 and later cars the injectors are fitted with niti(
a plastic sleeve. A nozzle of new design improves fror
the long-term characteristics. cor
ce~
the
fun
mic
on
full·
tra
am
Thl
per
en!
ule
The mass air flow sensor consists of an alumin-
per
ium housing enclosing an air duct. On M1989 and
rno
later Saab 900 Turbo models with catalytic con-
tiar
verter (LH2.4), the mass air flow sensor housing is
made of plastic: Located in the centre of the duct is Th
a tube which houses the platinum filament (hot wire). ule
Jr
The temperature of the hot wire is maintained at ap-
prox. 100°C (212°F) above the temperature of the 011
inlet air, regardless of the coniposition of the air or thr
the air flow. tin
ste
The device for controlling the current required to
thr
maintain the hot wire at a constant temperature con-
sists of a bridge circuit and a detector resistor, the Th
voltage variation across which is directly propor- . to
tional to the magnitude of the inlet air mass. alii
The electrical components are located in a module Or
on the mass air flow sensor housing. Since the hot au
wire is sited inside the inlet duct it can become idl
coated with dirt which reduces its sensitivity and af- sa
fects the results of measurement. To keep the hot en
wire free from dirt, it is heated to a temperature of B~
about 100DoC (183D O F) for one second. This takes lie
place four secollds after the engine has been
switched off.
Saab 900
Technical description 200-39
Saab 900
200-40 Technical description
-
UHI 2.4 fuel injectUol1l system Co
The LH 2.4 fuel injection system has been intro-
duced on all M1988 and later cars with a 8202i en- IFl\JJE
gine and on all M19988 and later Turbo cars. This
The
system is a further development of the earlier LH 2.2
and I
fuel injection system. The improvement consists pri-
line,
marily of an expanded memory capacity for the con-
trol module, as a result of which the module is fitted The
with a 35-pin connector. oven
fuel I
Special LH 2.4 functions:
o Control module with expanded memory
e lAC valve with integral Limp-Home system pi. (
o Adaptive (intelligent) idling control system Whe
o Adaptive Lambda system tially
o Integral deceleration function (fuel shut-off) An a
the I
o Improved function for shift-up indication
bree
o New CP valve "on
o Integrated fault-diagnosis system LIppI
Pressure-switch function integrated in control raph
module fuell
umE
M1990 and later cars have additional LH 2.4 func-
mOIi
tions:
o Wider scope for diagnosis with the integrated
fault- diagnosis system
o new control module
o Possibility of carrying out fault diagnosis and fault
tracing using an ISAT ( I ntelligent SA ab Tester)
On M1-991 and later cars a number of new diagnos-
tic trouble codes, which can be read on an ISAT,
have been included in the fault diagnosis system.
Saab 900
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.
r=----
I .~7
i : a
11 n
L .
6
.J
I
~~_.~
--------
Saab 900
200-42 Technical description
Saab 900
- - Technical description 200-43
C>
'"
~
fjl.\Or-=~ VI
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 pres-
sure line between the fuel pump and the fuel injec- 2 3
tion manifold.
On model year 1986 and later cars the fuel filter is
mounted underneath the car on the right-hand side
forward of the fuel tank. .
The filter consists of an aluminium housing holding
a nylon filter and a paper element.
1 P~per slement
2 Fitt~r
3 Nylon strainer
Saab 900
200-44 Technical description
V\
ta
pi
rE
'T
Ie
Fuel pump, Saab 900il8 (1989-)
1 Main pump
2 Ejector pump
3 Filter
4 Reservoir
5 Pump delivery line
6 Return line
7 Screw top
8 8.6al
.. ,9 'Spring
"fa Breather pipe, filter
Th,e design of the tank has been modified to accom-
modate the new pump.
The pump cannot be fitted in fuel tanl~s of earlier
pattern. \
Saab 900
- ......
'Jel
Saab900
200-46 Technical description
5
~~ !===~-4
~~~6·
Saab 900
Technical description 200-47
Saab 900
200-48 Technical description
-
Fuel pressure regulatoD' fue
The fuel pressure regulator is located immediately The f
adjacent "to the fuel injection manifold and is 5 tion '"
jectio
mounted on a bracket bolted to the inlet manifold
regul
and cylinder head.
The purpose of the regulator is to maintain a con-
stant ratio between the fuel pressure immediately
upstream of the injectors and the pressure in the in-
let 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 mani-
fold.
Tile regulator has three connections: one for the fuel
line from the fuel injectio(l manifold, one for the re-
turn fuel line to the tank, and one to the inlet mani-
Fuel pressure regulator
fold. T~llB
1 To inlet manifold
The
2 Spring
3 Diaphragm "l.CCC
4 Valve rJas~
3
i Body
2 Nozzle
3 Insulation
4 Spring
5 Coil
6 Electrical terminal
7 Filter
Saab 900
Technical description 200-49
Saab900
200-50 Technical description
-
TlluotUe posotioll1 sensoli' (1991=) Idle
The earlier throttle'position switch has been super- {lH
seded by a throttle position sensor which provides
Theil
the control module with continuous and stepless in-
of air
formation on the angle of the throttle butterfly. This
air is
information is used for various purposes, including
idle a
fuel shut-off.
from
The throttle function is adaptive, i.e. the control mod-
TIle il
ule "learns" which signal corresponds to idling and
a bui
which signal corresponds to full throttle. This means
ous r
that manual adjustment is unnecessary.
maxil
Toge
toma
G stE
o be
Auxmary air valve o inc
The auxiliary air valve is mounted on the engine's co
thermostat housing and acts as a by-pass passage co
enabling air to flow past the butterfly in the throttle he
body when the engine is cold. tel
The auxiliary air valve consists of an aluminium body hi!
with a connector for the internal heating coil and o a
spigots for the hoses from the throttle body.Running For
through the aluminium body is an air passage which 254
is opened and closed by a valve disc operated by
the bi- metallic strip.
When the engine is cold,....the air passage is fully
open. When the engine is started, the heating coil is
energized and heats the bi-metallic strip which then
gradually. closes the valve.
If the engine is hot when started, the heat given off
by it acts on the bi-metallic strip and the valve re-
Auxiliary air valve
mains almost closed, opening only very slightly.
1 Bi-metallic strip
2 Coil
3 Electric terminals
4 Valve disc
Saah 900
Technical description 200-51
-
Idle air control (~AC) valve
(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.
-rhe idle air control valve is a rotary slotted valve with
a built-in two-stage motor thc,:~ maintains a continu- 2
"1"
/ ous reciprocating action, turni:~g ttl!; valve t wough a
maximum angle o'f 90 0 •
Together with the mass air flow sensor system, au-
tomatic idle control has been introduced to give:
"
Saab 900
200-52 Technical description
-
~AC va~ve with oIl"lltsgral limp" "fa"
[Home fu.on1lctuCOJIl"ll (llHl 2,,4) resn
The Limp-Home function, which comes into opera- The t
tion when a fault occurs in the lAC system, such as manif
a loose connection, causes the valve to give a fast modu
idling speed of 1200 rpm. the e
The earlier three-pin connector has been replaced quani
by a two- pin COrl'~ctor because the connector on ture.
the lAC valve is 0, wn-pin type. Wher
the v
riche
to co
intal,
As tr
of fUI
The
whic
Tem
~AC vahve 9 llHl 20402 ( 1991 ..) mCi
lowl
As distinct from earlier versions, the lAC valve now
cont
has two windings which correspond to each other in
the event of a voltage drop, such as occurs when If th
the AC system is engaged. ruptl
ule'
Whenever necessary, a spring in the valve sets it in
engi
Limp- Home mode with a small opening which gives
an engine speed of about 850 rpm when there is no
load on the valve. ~ J69
6
x
<~
c
~>-
~"
15
200
J.}
Un
LH 2.4.2 ThE
r
on i
All
rpIT
Adaptive idl~ull1g c(l)rntro~ StOI
system (lH 2.4) Ar
The adaptive (intelligent) idling control system var- ma
ies the idling speed and lAC setting continuously the
and automatically compensates for all normal vari- ing
ations. Thl
The microprocessor "remembers" the opening the tiar
lAC valve had the last time the engine was run at inl
idling speed. This system reduces the need for ser- pel
vice and the setting is constantly maintained at a
high lev~1.
0
Saab 900
- --
Technical·description 200-53
Temperrail:lUIre sensor ( Te
resistor)
The temperature sensor is screwed into the inlet
2 3
manifold flange. Its function is to provide the control
module with information about .the temperature of
tns engine. The control module then regulates the
quantity of fuel injected according to the tempera-
ture.
When starting from cold and during the first part of
the warm-up period, the engine requires a much
richer fuel-air mixture on account of the losses due
to condensation in the combustion chambers and
Temperature sensor (NTC resistor)
intake pipe.
1 Resistor
As the temperature of the engine rises, the quantity 2 Body
oi fuel injected is decreased proportionately. 3 Connector
The temperature sensor consists of a brass body
which holds a resistor of NTC type. NTC (Negative
Temperature Coefficient) resistors have a low resis-
tance at high temperatures and a high resistance at
low temperatures. The temperature sensor sends a
continuous signal to the control module.
If the signal from the temperature sensor is inter-
rupted, a signal will be simulated in the control mod-
ule which gives a function on the assumption that
engine temperature is +20°C (68°F).
Saab 900
200-54 Technical description
-----------------------'------
--------:~l\! -
COl tlrO~ module wuth expalilHdledl Mas·
memory (lH 204) The IT
The expanded memory of the control module en- filter a
ables new monitoring and control functions to be in- It conE
corporated in it. from
To accommodate the new functions, a 35-pin con- the air
nector replaces the earlier 25-pin connector. filarne
outlet
filter.
The t
The LH 2.4.2 control module is adapted to system
const
changes resulting from changed components but abov,
also contains software changes which affect other
the c
additional functions.
SinCE
Engagemel"!t of the Lambda sensor when the engine beco
is started from cold is a function of time instead of ityar
temperature as it was before. This means that the the ~
theoretical limit at which control can start is reduced aturE
from 16°C to DOC. take~
AC engagement is governed by the LH control mod- switc
ule. The
The AC relay is discontinued. 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
---.. -"'"'"'.- -----------------------------------
.....
Saab 900
200-56
Aui" cleaner
Technical description
-
Eval
The air cleaner, mounted on a bracket on the left- (lH
hand wheel arch, consists of a cylindrical container Gase(
to which an air intake is connected. Inside the con-
trappE
tainer is a folded paper element and the removable
pass'
cover is secured by means of four toggle fasteners.
gine v
The cover incorporates a connecting sleeve 'for the
Thep
mass air flow sensor which is secured by means of
by si!
two toggle fasteners.
functi
engin
Adlap~nve lambda system (LH 2.4)
The adaptive (intelligent) Lambda system compen-
sates for variations in the fuel-air mixture.
This compensation is carried out by raising or low-
ering 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 sys-
tem is necessary.
Saab 900
- - Technical description 200-57
Saab 900
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
Air induction system 232-1
El
'e.'
preheating . . . . . • . . . • . . . • . 232-1 Function check of preheater
valve (-1985) . • . . . . . . . . . . • . • . 232-3
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.
,
1 ;\{'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 Air induction system
-
On normally aspirated engines the valve is actu-
ated 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 ArOl
blended induction air, which is maintained at a tem- by nl
perature of between 23°C and 37°C (73-98°F) by mOV I
the valve butterfly, which oscillates continually be- Fore
tween the cold air and preheated air inlets. pletE
stat.
~ priat
~'~_/ posi'
6'/
":>-. ? ~\
~
-
57&1J
Notl
On Turbo engines the thermostat body is fitted in- WhE
side the preheater valve and senses the tempera- cabl
ture of the ambient air. The valve maintains an air the
temperature of between -SoC (23°F) and +SoC
(41°F).
For
_5°C
+5°
Nor
23°
37°
\.
Saab 900
- Air induction system 232-3
Note:
.
WHen pefiorming this check, make sure that the Checking the preheater valve (normally aspirated engine).
carole adopts roughly the same position as it has in
the car.
Saab 900
Fe
ct
pl
ct
. pl
Fuel system 233-1
feed pump function check . • . . . . . . 233-1 !Fuel pump, 900/516 (1989~) •. . 233-10
ChJinging the fuel pump (with feed fuel pump, Turbo (1990·) .•. . 233-30
pump), ~M19a8 . . . . . • • • . . . . . . • 233-3'
Cbanging the vuel pump (without feed
pump)• • • . . . . . . . . . . . . . . . . . 233-7
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 venti-
lated.
Note:
Make sure that the tank is at least 3/4 full before \
starting this test.
Note:
Take care to prevent the leads from touching each
other or any metalworlc
Saab 900
233-2 Fuel system
N e:
No
Mah SUi'e that the switch is set to OFF.
Me
OVI
5 Cars with CI injection system: sel
Remove the fuel pump relay. Connect test lead
with switch 83 93 886 between terminals 30 and
87 to supply the .fuel pump with power.
c
(V
Note:
Mal,e sure that the switch is set to OFF. fa
1
6 Start the feed pump by setting the switch to ON. 2
7 Carefully raise the edge of the rubber collar and
check that fuel is discharged through the safety
valve on top of the receiver. 3
CAUTION
Since a large volume of fuel may be dis-
chargE!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.
.....
Saab 900
Fuel system 233-3
-
-
.J\Jote:
Always turn off the pump's power supply by setting
the switch to OFF before connecting any test instru-
ment.
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.
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
~'.,
.'
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
233-4 Fuel system
Note: 5
On earlier pump variants, the existing feed pump
filter must be replaced with the latest version. Ac-
cordingly, plug (1), washer (2), filter (3), clip (4) and
a-ring (5) will become redundant.
+ 3 e
11
C
n
3
(
Feed pump variant fitted to cars with chassis numbers I
from AE1021336 and AE2009858, inclusive.
4:
Earlier feed pump variant
1 Plug 5
2 Washer
3 Filter
4 Clip
5 O-ring
Saab 900
-- -
To fit
Fuel system 233-5
Saab 900
233-6 Fuel system
-
6 Fit the return hose and plug in the connector.
Lower the receiver into the tanl, with the feed
pump facing rearwards.
To
-j [
2 F
fl
fl
3 [
~
4 L
r
Saab 900
Fuel system 233-7
- -
F~el plUlm~, W8U~@nJJt ~ee<dl
pwmp {rrBO~ (cal~tal~ytD(c ©@!l1lV®!rfter
e.,ars)
Tp remove
'j Disconnect the negative battery cable.
2 Remove the luggage compartment floor and
floor panel and also the circul~.r cover over the
fUel pump.
3 Disconnect the electric leads from the fuel
pump.
4- Use a spanner to 110Id the fuel pump steady and
remove the cap nut. Lift off the banjo fitting.
fll
-<::
,N
lJl
Saab 9QO
233-8 Fuel system
To ~it To cl1
1 Fit the pump to the mounting so that the distance The non
between the base of the suction strainer and the can be
2
upper edge of the rubber mounting is 236 mm screwdr
(9.2913 in).
Avoid 9
Later version fuel pumps have a new type of damage
pump bracket and clamp to eliminate noise from 3 Tighten
the pump. On refitting these parts, dimension "A"
4
should be 2-6 mm (0.0787-0.2362 in).
E
E
e l.D
E ..!,
l!: n 1---- 6
N <t
1 Non-return valve
2 Fuel pipe
3 Pump bracket
4 Clip
5 Pump
6 Cap nut
A Front of car
Saab 900 -
Fuel system 233-9
---- To change the l11lorn=trsturrn va~ve 9mm
Saab 900
233-10 Fuel system
. _r~
Saab 900
-- OlUUl.giD1g the ~W~~ pump
Fuel system 233-11
10 remove
1 Disconnect the negative battery cable.
2 EJepressurize the fuel system.
:!l Expose the fuel pump.
4 Remove ti-le locking clamp, disconnect the elec-
tric leads c. -J -ruel lines.
5 Tie the fue i n;:;.s Qut of ;~1'':\ 'May.
{3 Apply tool f.,J 94397.
7 Remove the SGfeW
, top.
8 Lift: up the pump.
. )
'.,.
Saab900
233-"12 Fuel system
-------~----------------------------......:.;.~ -
9 Place the pump in the tank.
10 Fit a new rubber seal. CAli'
11 Refit the screw top. WilE
i 2 Apply the tool and tighten the top. suet
tran
13 Reconnect the fuel lines.
ven
i 4 Reconnect the electric leads and refit the lock- If al
ing clamp. fum l
15 Reconnect the negative battery cable. We,
'IS Check the operation of the pump. with
'17 Refit the cover and the luggage compartment
floor.I
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
Saab 900
- Iii Apply tool 83 94 397 as shown in the Fig.
Fuel system
-
233-15
-
-"
Saab 900
233-16 Fuel system
2 :
I,
Saab 900
- ~--
Fuel system 233-17
ft) fit
1 Position the pump before placing it in the tank
so that the pressure and return lines are in align-
ment with the longitudinal axis of the car. Tilt the
pump assembly so that the ejector part is intro-
duced into the tank first.
Position the pump inside the tank. Make sure
that it is centred between the ribs on the bottom
of the tan;'
Saab 900
233-18 Fuel system
-
3 Position the screw top so that the markings are
in alignment. Press down hard and rotate the top
-
Not
To
half a turn.
the
10'/11
-
Tig
Tht
tha
Saab900
Fuel system 233-19
-
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.
I il:j1e position of the pump must not deviate by more
than ±30° from the alignment marl,s.
Saab 900
233-20 Fuel system
Saab 900
Fuel system 233-21
-
10 replace the fuel pump fUter
1 Remove the fuel pump, see page 11.
2 Remove the ejector pump.
3 Separate the reservoir and filter unit from the top
section.
4 Fit a new reservoir with filter iind O-ring.
5 Fit the ejector pump with a new O-ring.
6 Fit the fuel pump, see page 12.
.,
~
Saab 900
233-22
FOJle~
Fuel system
lUmp fn~tef1'
--
3 Se~
sec
1'0 lrelP~aCe
The filter and reservoir are an integral unit and can-
not 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 233-23
-
6 Fit the pump, see "Fuel pump, removal and fit-
ting" on page 17.
Saab 900
233-24 Fuel system
------.:........--------------------------441 ___
To replace the fuei pump To rl
reservoir 1 RE
See "To replace the fuel pump filter", page 21. 2 RE
3m
4 Cc
5 Fi1
6 Fij
Saab 900
- Fuel system 233-25
Saab 900
233-26 Fuel system
-
5 Fi
Ejector pump
pI
To Irep~ace
1 Remove the fuel pump, see "Fuel pump, re-
moval and fitting" on page 13.
6 I
1
Saab 900
Fuel system 233-27
- -
5 Fit the ejector pump, see "To replace the fuel
pump filter", page 23.
Ir
e
4 I
(
Saab 900
-
Fuel system 233-29
- Rotate the ejector pump a quarter-turn and with-
-clraW it.
Nate:
Always fit new O-rings.
Saab 900
233-30 Fuel system
-
~ T r 0 ( 99 on) 6 1
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 well-
ventHated area.
To remove
1 Disconnect the negative battely cable. 7
2 Undo the nipple on the fuel distribution pipe to
reduce the pressure in the fuel system. Use pa-
per or a cloth to absorb the fuel that runs out.
Retighten the nipple.
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 con-
nector.
Saab 900
--
- 6 Disconnect the fuel lines from the pump. Move
Fuel system 233-31
Saab900
233-32 Fuel system
T@ fit 4
-I Fit a new O-ring on the pump.
Saab 900
Fuel system 233-33
i,
Saab 900
-
Ren
Fitti
F'ue
ReF
c'
[
I
c'
Thl
fue
be
ing
2
Fuel tank and fuel lines 234-1
--------------------------------
IIIl es
Removal of tan!{ . . . . . • 234-1 Fuel level transmitter . . . . . • 234-7
fitting of tank . . • . . . • 234-3 Replacing the roll-over valve . . 234-8
Fuel lines. . . . " • . . . 234-4
Replacing f1uel lines inside cal' . • •. 234-5
CAUTION
• I
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
Note:
Do not run the fuel pump without any fuel in the tank.
S79B7
Saab900
234-2 Fuel tank and fuel lines
2 Ch
ble
tut
3 Lifi
.'Vt
tilE
iiih
27 30 5 RE
tul
6 RE
tel
Connec t the fuel pump's switche djumpe r lead 83 93 886
across fuses 27 and 30.
fUi
7 Lc
RI
3 Discon nect the negative battery cable.
4 Remov e the cover from the fuel level transmit-
ter.
5 Discon nect all electrical leads from the tank.
6 Raise the rear of the car.
7 Remov e the filler pipe and breathe r tubes from
the fuel tanl<.
Discon nect the pressu re and return fuel lines
from the fuel accum ulator and tank and undo the
fuel line clips.
8 Remove the securing strap nuts under the tank.
9 Lower the tank.
Saab 900 -
Fuel tank and fuel lines 234-3
- -
To fit
1 Make sure that all seals are correctly fitted on
the tank.
'2 Check that the straps are correctly fitted and
blank off the ends of the filler pipe and breather
tl:lbes with masking tape.
3 Lift the tank into position and support it by the
two straps.
4 Adjust the lateral position of the tank and tighten
the straps. Remove the masking tape from the
filler pipe and breather tubes.
5 Reconnect the fuel lines, filler pipe and breather
tubes.
e Reconnect the leads for the fuel level transmit-
ter and fuel pump and refit the cover over the
fuel pump.
7 Lower the car.
B Reconnect the negative battery cable.
Saab 900
234-4 Fuel tank and fuel lines
RelP~~
IFUJle~ ~nD1le II'UJlns the (c,
Saab 900
-
Fuel tank and fuel lines 234-5
-
ReplBl~oUilg fQJl®~ ~ul!1le$ D!J'i15)u@.l®
the Calrr
'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 car-
pet from t! 'Fa sill.
2 Remove th3 ~ELe '·oJ' inq 6e :uelline·.
:3 RemO\le the InsuICI~1o;1 'felt from tile bUIl\hc-ad,
4 Disconnect the fuel lines in the engine bay,
press out the grommets and pull the lines into
the cabin,
Disconnect the return fuel line from the fuel flow
meter and the pressure line from the fuel filter.
5 Undo the clips and disconnect the fuel lines from
the fuel tank. Disconnect the pressure line from
the fuel accumulator and release the clips on the
fuel tank.
To fot
'j Clean the fuel lines by blowing compressed air
through them. Sianl, off the ends of the lines with
masldng tape.
2 Insert the fuel lines through the holes in the
bulkhead and the spring link bracl<et and con-
. nect the lines in.t~e engine bay.
3 Fit the rubber grommets in the holes in the bulk-
head 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
234-6 Fuel tank and fuel lines
Tc remove e Or
1 Burn through the old fuel line with a soldering GO Or
iron. 1 (
it
2 ~
t
3 (
41
i
S 5192 '
, Tc
trc
1
2
To fit
3
1 Use a knife to cut off a short section of the fuel
line. Cut off as short a length as possible.
2 Slide a piece of thick' rubber hose with a slit in it
onto the fuel line and clamp it in a vice. Allow
the free end of the fuel line to protrude the length
of the fitting plus 2 mm.
3 Use a hammer to drive the fitting home. Hold the
line to prevent the fitting from twisting.
4
Nt
Tr
'I!
la
Saab 900
- Fuel tank and fuel lines 234-7
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 Fuel tank and fuel lines
Id
Se
CC
CI
e)
1'0 fot 51
1 Attach the valve to the vent hose (with the long
outlet at the top). Make sure that the lugs on the Cl
valve are in line with the screw holes in the body Gl
panel. s{
2 Screw the valve in place and refit the trim in the
luggage compaliment.
C
T
C
P
C
5 2/382 - -
,
11
Saab 900
Fuel injection system 240-1
-- --..,..-----------------------=----------
240-15
lFl\,He~ aCClUlRnl!JJ~atOIl'
Checkoli1g ~he resBdI a~
Removal/fitting 240-37
pll'eSSlIJIll'te 240-·18
Saab900
240-2 Fuel injection system
Fu
ChE
.. con
fuel
Fit I
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
There is an acute danger of 'lire due to fuel
atomization in this test. Make sure that the
I area is well ventilated and that nobody is
- smoking.
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 ob-
jects (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 Fuel injection system
Th
(A
m,
fin
Saab 900
- _. Fuel injection system 240-5
A St.:4R9
N
m
~
[I).
Saab 900
240-6 Fuel injection system
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 sys-
tem) with power. Read off the voltage at the con-
nector, which should not be below 11.5 V.
o Check the continuity of the warm-up regulator coil
by connecting a multimeter in series with it. If
there is an open-circuit in the heating coil, fit a new
warm-up regulator.
Saab 900
- fhermosftatoc ~om® SWH elm
Fuel injection system 240-7
Saab 900
240-8 Fuel injection system
-
Voltage across the fuel pump
Remove the circular cover plate over the fuel pump c
in the luggage compartment and measure the volt-
age across the positive and negative terminals of the
pump while it is running. The lowest permissible
voltage is 11.5 V.
Saab900
- - Fuel injection system 240-9
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.
Saab 900
240-10 Fuel injection system
-
COl
This
Geli1lerraJ plain
Connect pressure gauge 83 92 516 as follows: poor
rlod.
Disconnect the control pressure line from the fuel
cold.
distributor and connect the pressure gauge between
test
the fuel distributor and the line running to the
seVE
warm-up regulator.
that
start
com
the 1
Can
omr
surE
If th
Cc
Note: Car
The safety device for running the fuel pump is con- per
trolled by a pulse sensor in the pump relay which is nor
actuated by the ignition pulses. OPI
Plu
Lee
sta
Co
If tl
- - - - - - - - - - - - - - -Saab
- -900- - - - - - - - - - - - - - -
- . . . .- -:.....----------------------=-------------
control pressure: engine cold
Fuel inje.ction system 240-11
Saab 900
240-12 Fuel injection system
-.--
Une pressure If tl
Close the pressure gauge valve. the
tiVE
Run the fuel pump.
If tl
Refer to the test figures in ''Technical data", section cal
022.
If the line pressure differs from the recommended •
figures, this may be due to one or more of the fol- II
lowing: o
Le,
In ihe case of insufficient line pressure: re{
(ll Insufficient pressure from the fuel pump "FI
I) Clogged filter in the tank tic
Saab 900
Fuel injection system 240-13
Saab900
240-14 Fuel injection system
-
luI'
~dl ~ lli1gj talC JlUIS mern lUi
(elll1g~llile speed! 8[IjJ CO
~©lrrn en )
Run the engine until it reaches normal operating
temperature and then connect the CO meter and ta-
chometer.
Note: Afl
If rough idling or difficulty in reducing the idling pll
speed is experienced, check the setting of the de-
celeration valve.
See section 254 in Service Manual 2:4.
Saab 900
- ------------------------------------
Fuel injection system 240-15
CQ,')U1lll1lectu~cri1
©f exhaust
e){tlractoOlIli1 <eq] lUJ~ pmsnt '1i:......._-
When using exhaust extraction equipment in the
workshop, avoid excessive depressurization of the
car's exhaust system as this could affect the results
of CO measurement.
If excessively powerful exhaust extraction
equipment is connected to a Turbo car, oil may
escape through the seals in the turbo unit.
This will result in the exhaust system becoming sat-
urated with oil and blue smoke will be emitted in the
exhaust for some considerable time afterwards. To
avoid excessively powerful exhaust extraction, A Right
conn0ct an extract hose with an open coupling. BRight
C Wrong
Saab900
240-16 Fuel injection system
·b .
Saab 900
- -
Fuel injection system 240-17
J -
B Full thrott~e
5 Disconnect the pump and che,ck to see whether
the CO reading on the gauge returns to what it
,was before.
. .
6 Push in the throttle position switch lever..
1M
Saab 900
240-18 Fuel injection system
-
o
Checki 91 he rres8dUJla~ "I-t
pressure
If acc;:eleration enrichment is to be obtained during ..
0 0
the initial phase of acceleration, the pressure vessel o 0
Checking f el enric!hment~
Tur 0) PC (1982)
" Q Run the engine at idling speed with the CO meter
connected (motor at normal operating tempera-
ture).
o Disconnect the pressure hose from the throttle
body and connect gauge 83 93 514 (pressure
gauge for checking charging pressure) and a
cooling-system tester (air pump) to the hose. Plug
the end of the spigot on the throttle body.
o Pump up the pressure to 0.6 bar (8.6 psi).
A
S21056
A Plug
Saab 900
Fuel injection system 240-19
-', ' .
S 7156
4
3,6
)
3
2,6 1'1
2
11 0,16 I
0,32 B
!-~I.r--..LI-4""i_--;-_--y _
Saab 900
240-20 Fuel injection system
-
dJlIS Ulil1gl he ~hlw(Q)t ~® 3 C
t~
lblUlUe8"f~y sft©p
4a
., Check that the throttle butterfly is accurately
centred in the throttle body.
2 Turn the adjusting screw until it just mal<es con-
tact with the stop (throttle fully closed).
3 Turn the adjusting screw another 1/3 turn and
locl< it. This provides a clearance of approx. 0.05
mm (0.002 in) between the buttetily and the
throttle body.
5 (
lFalll,ll~t d1HagBllosD~~ C~ ~ystem
In the fault diagnosis procedure described below it S~~
is assumed that the engine has no mechanical faults
'f th
and that the ignition system is in proper working or-
whil
der.
the
Starting trouble: engine cold 240-20
cau
Starting trouble: engine hot 240-21
Poor running during warm-up
period 240-23
Poor running, engine hot 240-24
Poor performance, low top speed 240-25
Excessive fuel consumption 240-27
Erratic CO content and idling speed
hard to adjust " 240-28
Saab900
Fuel injection system 240-21
-
;3 Checl< that the auxiliary air valve is open when
the engine is cold.
4 a Check the CO content (engine hot)
Saab900
240-22 Fuel injection system
2 a
b
v
-- S 2/126
3C
(
p
i1
4 (
3 a Check the CO content (engine hot). I
b Check the pulse ratio, see section 254, Ser- t
vice Manual 2:4 (US specification)
Ched< the hot-start reiay, see "Cold-start valve -
performance and sealing" on page 240-9.
Saab 900
- Fuel injection system 240-23
Saab900
240-24 Fuel injection system
o 1
Saab 900
- Fuel injection system 240-25
S 5206
Saab 900
240-26 Fuel injection system
-
o If the control plunger is sticl~ing, separate the fuel E~
distributor from the mass air flow sensor, taking 1
care to prevent the control plunger from falling out.
Remove and inspect the control plunger (avoid
2
touching the sealing surfaces). Wash the plunger
in clean petrol, refit it and also refit the fuel dis- 3
tributor. Do not dismantle the fuel distributor more
than this.
4
55209
Saab900
Fuel injection system 240-27
55209
S 5212
"
Saab 900
240-28 Fuel injection system
2
2 Check whether any parts of the mass air flow
sensor are sticking, as follows: 3
M
If the control plunger is sticking, separate the fuel
distributor from the mass air flow sensor, taking care 11
to prevent the control plunger from falling out. Re- 1
move and inspect the control plunger (avoid touch-
ing the sealing surfaces). Wash the plunger in clean ,.
f.
petrol, refit it and also refit the fuel distributor. Do
not dismantle the fuel distributor more than this.
Saab 900
- 3 Check that the disc in the auxiliary air valve is
Fuel injection system 240-29
not sticking.
To remove ~
1 Thoroughly clean the area round the fuel con-
nections on the fuel distributor.
2 Disconnect the fuel lines from the fuel distribu-
tor. Disconnect the lines to the injectors before
disconnecting the control pressure line to avoid
damaging adjacent lines when the control pres-
sure 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
240-30 Fuel injection system
-
1'0 fit La
1 Make sure that the air cleaner element is cor-
rectly positioned and then bolt the fuel distribu- se
tor to the air cleaner.
2 Connect the fuel lines to the fuel distributor. l'(»
3 Fit the rubber duct between the mass air flow 1
sensor and the throttle body.
2
5
Fue~ distri IUItor
The fuel distributor must not be dismantled for re-
pair but should be replaced if it is faulty.
~..--.._---- -,-.-_.
When separating the fuel distributor from the mass
air flow sensor, take care to prevent the control
plunger from falling out.
If the control plunger has been removed, it must be
cleaned thoroughly in petrol and reassembled.
Avoid touching the plunger sealing surfaces.
When fitting the fuel distributor, make sure that the
O-ring is located in its groove. Tighten the three re-
6
'.' taining bolts to a torque of 3.2-3.8 Nm (2.4-2.8 Ibf
ft).
Saab 900
- Fuel injection system 240-31
1t Saab 900
240-32 Fuel injection system
7 Fit
fo fit it.
1 Place the counterweight on the lever but do not piE
tighten the screw fully.
Til
2 Place the adjustment arm in the lever so that the
soc!<et head of the adjusting screw is visible.
.666~~l
5 Coat the balls with silicon grease and fit them in
place, followed by the springs, seals, shims and 9 P
circlips. a
tt
s
d
Note: p
The circlips are stamped out and must be fitted with n
the sharp edge facing outwards. 1 Clrclip
2 Shim
3 Seal
4 Spring
5 Ball
Flnl
the
Sel
Saab 900
- ..----------------------
1 Fit the sensor plate retaining screw and tighten
Fuel inJection system 240-33
Sash 900
240-34 Fuel injection system
Saab 900
Fuel injection system. 240-35
-
IMjec~©Il'S Q ft(Q) c~eaUl1
If an injector atomizes the fuel imperfectly or if it
leaks under opening or closing pressure, the cause
of this could be small particles of dirt having fas-
tened in the valve seat. It is sometimes possible to
remove such particles by forced flushing of the in-
Jector, asfollows:
SSblIfj .
Perfect atomization Acceptable atomization
Saab 900
240-36 Fuel injection system
t".
P<
c~
N
p,
v
s
Fit in reverse order.
Saab900
- Fuel injection system 240-37
To remove
1 Clean the ~rea round the fuel connections.
2 Undo the connections and remove the fuel ac-
cumulator.
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.
Note:
Avoid loosening the fitting on the outlet side to pre-
vent aluminium swarf from the threads entering the
system.
• L
Saab 900
l
240-38
C~ ~8.!le
Fuel injection system
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 po-
sition and so shuts off the supply of fuel to the cyl-
inders.
Vac
Whl
lene
tion
mal
ope
Saab 900
- --._---------------------_......:..------------
Fuel injection system 240-39
S207G
{)
Vacuum valve
Saab 900
240-40 Fuel injection system
--
The
the~
Closing function The tl
The throttle position switch is closed across termi- low L
nals i and 2 only in the idling position. 111ghe
As a result, terminal 30 of the deceleration relay and tempi
the TRK terminal of the time relay receive a ground [T1ost l
<::r nal (see the description of the relevant relay func- most.
r, 1 fIJf fUri:her details). Cons
C :e 'hc"! \mttle t"Jitelily has opened beyond 72°, cold-
th .. s\l1/itch closes acro~s terminals 2 pnd 3 and a (106:
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).
Saab 900
- --~---------------------~-----------
Fuel injection system 240-41
hermostaiic swu~clhJ
45/38°(; aB101
therMostaitnc Urns switch
TM thermostatic switch closes at temperatures be-
low 45°C (112°F). If the temperature has been
higher than this, the switch will not close until the
.emperature has dropped to 38°C (1 GO°F). The ther-
mostatic switch is connected in series with the ther-
mostatic 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 45°C (112°F). '.
Turbo ~ngines
The function is the same except that the thermo-
static 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
t
240-42 Fuel injec~ion system
----
Term
lambda COIntIl'O~ mo«:h.!l~e
Pin 2
The control module regulates the Lambda system
by means of the following main functions: Pin 4
Pin 'I
o Lambda sensor monitoring
necti
comparator
Pin '\
o integrator Brcl/I
o output stage Pin !
Yelle
Pin ~
'"...
:(l Pin
i'I
III
Red.
Pin
I ----, I
Yell(
Pin'
Red
Pin
I I
?in
I I
I I
I 5 I Fu
L -~
Wh
ne£
dial
dirr
"
bell
6 ThE
inci
ant
sw'
The monitoring function checks that the operation of crease, thereby enriching the mixture.
the Lambda sensor and the regulating function of At a preprogrammed control speed, the integrator
the modulating valve coincide within given param,')- controls the signal voltage from the output stage to
ters. If incorrect values are received or a malfunc- enrich or weaken the fuel-air mixture.
tion is detected in the Lambda SenS(;lr, for instance, The control speed is optimized to provide tile best
the regulating function is disabled and a fixed pulse possible conversion of the exhaust gases in the cat-
ratio of 50%is selected for the modulating valve. alytic convel1er. The Lambda value is kept within
Different fixed pulse ratios can also be obtained by extremely narrow limits and as close tOA-as possi-
grounding certain terminals of the control module. ble.
The control function of the comparator is governed
by the relationship between the actual sensor volt-
age and the reference voltage programmed in the
comparator.
If the fuel-air mixture is lean, the sensor voltage will
be lower than the reference voltage and cause the
opening duration of the modulating valve to in-
tor
to
6
1 Diaphragm
~st
2 Spring
at- 3 Constriction
lin 4 Spring contact arm
si- 5 Vacuum connection
6 Electrical terminals
Saab 900
240-44 Fuel injection system
-
Tome rre~alY 1P11 DE
Time function· 3 seconds as
For a period of three seconds after starting, terminal Thl
11 of the Lambda control module is grounded and a Wll'
fixed pulse ratio of 92%ls selected (starting enrich- abc
ment). 45'
Time iunciion • i 40 ± 20 seconds aftt
" For a period of -140 seconds after starting, the wt
fuel shut- off function during deceleration is dis- pie
abled (no grounding via terminal X2 of the re- po
lay). This applies to non-Turbo cars \!\lith a man- lay
ual gearbox only. thE
ter
2 Cold engine (below 45°C) se
Acceleration enrichment is available when the co
fuel booster pressure switch (79) has been ac- La
tivated via the cold-stali valve (94), which is
grounded via the thermostatic switch (97) and
thermostatic time switch (92). A grounding sig-
nal is also applied to the TKK terminal of the re-
lay at the same time
3 Hot engine (above 45°C)
Acceleration enrichment is available for 140 sec-
onds if the fuel booster pressure switch (79) has
been activated. There will be no grounding sig- pi
nal applied to the TKK terminal via the thermo-
static switch (97) and the thermostatic time
pi
switch (92). Terminal TIP is activated and ap-
plies a grounding signal to terminal 11 ;)f the
Lambda control module, resulting in a pulse ra- p
tio of 92%being selected.
11
1112 b 14
TKK IS 16 X2 Ii 31 12 Xl b
TIP PIal TD~
liO -11
X2
17
~
8
31 19 87\
12 30 4 S
87\6
pin 87 +12 V supply when fuel pump relay pin 50 +12 V supply when starter motor en-
102 activated gaged
pin TIP +12 V supply +54 when vacuum switch pin 31 Ground
activated
pin 11 Grounded when above functions acti-
pin TKK Ground via cold-start valve 94, thermo- vated (for i 40 seconds only)
static switch 97 and thermostatic time
switch 92 pin)(2 Same as pin ii, not connected
Saab 900
- Fuel injection system 240-45
Terminal pins
Saab 900
240-46 .Fuel injection system
Saab 900 .
Fuel. injection system 240-47
-----------------------_~-=------------
Lambda
The Lambda system itself incorporates a Lambda
sensor (136) which continuously supplies the con-
trol module (135) with data on the oxygen content of
or the exhaust gases. On the basis of this data and the
n- signals received from the Lambda system's various
sensors and relays, the control module regulates the
amount of fuel injected via the modulating valve
(139). (The valve is controlled by grounding of ter-
minal15.)
The control unit (135) and relays 105 and 106 are
supplied with current from terminal 87 of relay 102.
The time relay (106), which is supplied with control
current (+50 supply) when the ignition switch (20) is
in the Start position, is used during the starting
phase. This relay increases the supply of fuel via the
2
control module and the modulatii"g ial'/8 (139).
The thermostatic switch (97) senE uS (;IG ell[Jiri") It:m-
perature and opens when the temperature is above
+25°C, thus breaking the circuit to the cold-start
valve (94).
The fuel booster pressure switch (79) is used to
control fuel enrichment during acceleration. When
the engine is cold, the switch opens the cold-start
valve (94). When the engine is hot, a signal goes
instead to the time relay (106), which increases the
supply of fuel via terminal 11 of the control module
(active for a maximum of 140 ± 20 seconds after
starting).
Saab 900
240-48 Fuel injection system
-
The speed relay (105) is used in conjunction with Cc
the solenoid valve (260) and throttle position switch Thl
(203) to shut off the fuel during engine overrun. en!
When the accelerator is released, the throttle posi- ter
tion switch grounds relay 105. This function is also
Fa
operative if engine speed exceeds approx. "1375
vic
rpm. Note that this relay is fitted only on cars with a
manual gearbox.
4
The thermostatic switch (99) opens at +45°C and
closes at +38°C. One 0'1: the purposes of this switch
7
is to improve the fuel enrich'ment function.
9
Socl<et 120 is provided for the connection a special 2C
measuring instrument and is used in connection with
setting the pulse ratio. The socket is live when the 2~
ignition switch is in the Drive position.
5~
Saab900
Fuel injection system 240-49
- -_.-------------------------=------------
component locatiorns
The component locations are the same for 8-valve
engines with CI fuel injection and the Lambda sys-
tem (EU), fuel injection engines and Turbo engines.
For further details of component locations, see Ser-
vice Manual 3:2.
4 Stalier motor on LH (induction) side of 139 Modulating valve (Lambda) in engine bay
engine on inside of LH tie plate
7 Grounding point on radiator member 1L:4 Pressure switch under dash to left of
9 Grounding point in luggage compartment steering wheel behind knee shield (be-
20 Ignition switch on centre console be- hind flasher relay holder)
tween front seats 147 Ignition pulse amplifier in main fuse box
22A Fuse holder in main fuse box in engine in engine bay on LH wheel arch
bay on LH wheel arch 152A 29-pin connector (white)
59 Two-pin connectors '152C 29-pin connector (blacl<) in main fuse box
one in main fuse box in engine bay on in engine bay
LH wheel arch, one in luggage compart- 156 AC compressor relay in main fuse box in
ment adjacent to fuel pumps engine bay on LH wheel arch
one socket (120) in engine bay on LH 158 Distribution terminal block, negative
wheel arch 159 Distribution terminal block, positive 15, in
60 Single-pin connectors main fuse box in engine bay on LH. wheel
one in main fuse box in engine bay on arch
LH wheel arch 201 Grounding point, engine
one in engine bay on RH wheel arch 203 Throttle position switch on throttle body
77 Starter interlock switch (automatic trans- 260 Fuel shut-off solenoid valve (Lambda) on
mission) under centre console adjacent rubber duct above air cleaner
to selector lever
79 Fuel booster pressure switch in engine
bay on inside of LH tie-plate adjacent to
fuel filter
82 Thermostatic time switch on coolant ther-
mostat housing
-94 Cold-start valve above throttle body
95 Auxiliary air valve adjacent to thermostat
housing at front of engine
96 Warm-up regulator on thermostat housing
at front of engine
97 Thermostatic switch, 45°C (Lambda), on
inlet manifold
99 Thermostatic switch, 25°C (Lambda), on
thermostat housing
100 Diode (Lambda), adjacent to deceleration
relay 105 and time relay 106
102 Fuel pump relay in main fuse box in en-
c;n.3 ba)l on LH wheel arch
\'08 iu"f pump in mel tank under luggage
compartment floor
105. Deceleration relay, injection engines only,
behind trim forward of RH front door
106 Time relay behind trim forward of RH
front door
'135 Control module (Lambda) on RH side
under rear seat
136 Lambda sensor on exhaust manifold
138 Speed relay (manual gearbox Turbo cars
only) behind trim forward of RH front
•
door
t.
i
Saab 900
240-50 .Fuel injection system
-
Checking Fa
General
sy:
1 Connect pulse meter 8393 597.
Fal
2 Turn the ignition I<ey to the Drive position. The
1
pulse meter should indicate 100%. The modu-
lating valve and fuel punlP should start and run
for a short time. .
3 Start the engine. 2
.aJ Cold engine (below 19°C):
The pulse meter first indicates 0%, then
90%and after three seconds a steady pulse 3
ratio of 60%.
b) Hot engine:
The pulse meter first indicates 0%, then
90%and after three seconds a fluctuating 4
pulse ratio of around 50%.
4 Checking full-load enrichment (Turbo)
a) Rev up the engine to more than 3850 rpm. 5
The pulse meter should indicate 85%.
b) Actuate (close) the throttle position switch.
The pulse meter should indicate 92%.
Saab 900
-
Fuel injection system 240-51
-
Fal.iJ~~ ©]Dag~l}(OSOS (C~alr~, C~
sys~emA(EU)
Fau~~ sympttoms
1 Starting difficulty (engine cold): see checking/
fault diagnosis
"A Starting with cold engine, below 4!'.i"C".
? Erratic idling/poor response during the: 1Jl1::Jnn-up
, ne, 'Ot:: see checl<ing/fault diagnosis '\:l Em;d1-
l ment during the warm-up period, bel'me<f 4S0C",
9 Poor acceleration in first few minutes after
starting/backfiring in inlet manifold: see
checking/fault diagnosis "C Enrichment via the
cold-start valve, below 45°C".
4 Stalling on overrun: see checldng/fault diagno-
sis
F "Deceleration function".
5 Fuel starvationlbackfiring above 3800 rpm- or
, at full throttle: see checl{ing/fault diagnosis
"G Enrichment at engine speeds above 3800
rpm".
Checking
1 Connect a test lamps between the cold-start
valve's brown (BR) lead and ground. The lamp
should light up when the starter motor is en-
gaged. .
Note:
The thermostatic switch (97) must be closed (tem-
perature below 38°C).
Saab 900
240-52 Fuel injection system
Note: b
The connector must be plugged in during this test.
Checking c
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 Nor
lead between pins 3 and 4. The
2 When the starter motor is engaged the pulse ra- forI'
tio should be 92 ± 10%. con
3 After three seconds the pulse ratio should
Mo
change to 60%(cold engine. temperature below
25°C) or 50%(engine temperature above 25°C). FU{
(94
fault diagnosis (97
(Electrical testing) swi
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
Fuel injection system 240-53
Mode of operation
Fuel enrichment is effected by the cold-start valve
(~4) 'and controlled by a 45°C thermostatic switch
'97), a thermostatic time switch (92) and a pressure
switch (79).
Saab 900
240-54 Fuel injection system
-
Checking Chi
1 Connect a test lamp to the brown (BR) lead of 1
the cold-start valve (94) and ground and connect
pulse meter 8393597. Start the engine.
2 Cold engine (below 45°C)
When the throttle is opened rapidly the test lamp
should light up briefly. Pulse ratio 60%.
3 Engine cold on starting, warms up during the 2
test.
Wf~en the throttle is opened rapidly the test lamp
should light up. When the 45 Q C thermostatic
switch (97) opens, the lamp should go out. Each
time the throttle is opened rapidly the pulse ratio
should change to 92%. This function continues F211
in operation for a period of 140 seconds after
starting. i
4 Hot engine (above 45 C)Q
Saab 900
Fuel injection system 240-55
Checking
1 Cold engine
Run the engine at idling speed. After three sec-
onds the pulse ratio should be 60%and remain
steady at this figure until the temperature rises
above 25°C. The pulse meter should then begin
to fluctuate.
2 Hot engine
Disconnect the red/yellow (RD/GL) lead from the
thermostatic switch (99) and connect it to
ground.
The pulse ratio should be fixed at 60%.
Checking
Check whether fuel enrichment continues for more
than -140 seconds.
Note:
The 45°C thermostatic switch (97) and the 25°C
thermostatic time switch (99) must be open and
three seconds must have elapsed after the engine
has been started.
Saab 900
240-56 Fuel injection system
-
Fault diagnosis (electrical testing) Fau
1 Remove time relay Pi 1 (106). 1
2 Connect one of the leads of a test lamp to +12 2
V. 3
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
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
Fuel injection system 240-57
c:<D .l:
0
ell
'3
E :t: 'C
0
.l:
Fault diagnosis ~ 0 ==
<Il ~ ell E
'I::
I:: iii >
2! I::
<D' 0
,." > 'iii ~c::
c: c:: 'iii :t:: >
0 0 0
2:J Ol
c: 8
~(I) ii c..
(I) .c ~ ltl
ffi E <Il '3
'C
.c
"iii
0
(l)
2i0 e Qj
:J
'C
0 E
Cl « ~ u. 2 j
Saab900
240-58 Fuel injection system
Checking
When the throttle butterfly closes, the pulse ratio
should rise to 92%.
Saab 900
l- Fuel injection system 240-59
General
The adjusting"screw on the mass air flow sensor is
seated by a metal plug to prevent inadvertent ad-
ll,lstmeni.. The mixture is preset at the factory and
shculd not R]I(1JJ'~1iVi1llly require readjustment unt81
replacement 01 "lr:: i1'\l.ass aii' flow sensor Ole-
.comes necess3u'l, .
Readjustment 0)' . e rrlix1'.ll'l.3 may be necessary,
however, if the mas", ail' flow sensor has been re-
paired or if fault diagnosis shows that the mixture
setting is incorrect.
Saab 900
Fuel injection system 240-61
I
pressuJe : : : 240-156
Fuel pump delivery
flow :~ , 240-156
Hult diagnosis using the LH
system tester; LH 2.2 and LH
2..4 240-65 Checking the electrica:1 system
Diagnostic trouble codes, LH 2.2 240-67 Main relay 240-158
Diagnostic trouble codes, LH 2.4 240-68 Fuel pump relay 240-159
Fault diagnosis chart, LH 2.2 240-69 Pressure switch " 240-160
Fault diagnosis chart, LH 2.4 240-75 Temperature sensor : 240-160
Throttle position switch
(checking/adjusting) 240-161
ault diagnosis with integrated Injectors 240-163
Mass air flow sensor 240-164
fallJt diagnosis system, LH 2.4,
Hot wire (filament) burn-off,
9005 (US) 240-80
function 240-165
Diagnostic trouble codes, CO content (checking/adjusting) 240-166
LH 2.4 (M1989-) 240-87 Fuel injection system, basic setting
Diagnostic trouble codes, (cars with catalytic converter) 240-1.66
LH 2.4 (M1990-) 240-89 Signals to control module ; 240-168
Input signals to control module 240-1.6.8
Control module connections 240.-1069
. Fault diagnosis using an ISAT, Control module signals to
injectors 240-171
LH 2.4 (M1990-) 240-94
Diagnostic trouble codes, .. Fuel shut-off on starting
Full-load enrichment
240-172
240-173
LH 2.4 (M1990), ISAT .240-99 Warm-up period 240-174
Fault diagnosis chart, LH 2.4 (M1990), . Idling compensation on start of
ISAT 240-100 AC compressor (cars with auxiliary
~ontrol commands, LH 2.4 (M1990),
air valve) 2.40-175
ISAT 240-105 Idling speed compensation on start of
AC compressor (cars with idle air
control (lAC) valve) 240-175
Fault diaga (J,s'$; uS3ng an ISAT, Lambda (oxygen) sensor 240-176 ..,
LH 2.4.2 and LH 2.4 Induction system 240-177
Auxiliary air valve 240-179
(M1991-} 240-106
Idle air control valve (lAC) 240-179
Control module connections, LH 2.4.2, Basic setting of throttle butterfly, LH 2.2.240-180
test data 240-107 Basic setting of throttle butterfly
Fault diagnosis, LH 2.4 and LH 2.4.2 240-110 (LH 2.4) 240-180
Diagnostic trouble codes, LH 2.4 Idling speed adjustment (not cars with
and LH 2.4.2 240-116 catalytic converter) 240-181
Command codes, LH 2.4 and LH 2.4.2.240-117 Idling speed adjustment
Fault diagnosis chart, LH 2.4 and (cars with catalytic converter) 240-182 p
LH 2.4.2 240-119
Saab 900
240-62 Fuel injection system
Component replacement
Control module 240-185
Main relay and pump relay 240-185
Temperature sensor 240-186
Throttle position switch 240-186
Fuel injection manifold with If
injectors 240-187 v
Mass air flow sensor 240-188 V
Fliel filter 240-189 \/I
Fuel pressure regulator ·.240-189
~
Auxiliary air valve 240-190
Idle air control valve, lAC 240-190 j
Air cleaner : 240-191 i:
.:-r,
,- 3
Saab 900
Fuel injection system 240-63
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.
Saab900
240-64 Fu.el tnjection system
Connection of exhaust
-
extraction equipment A
When using exhaust extraction equipment in the
workshop, avoid excessive depressurization of the
~=B
car's exhaust system as this could affect the results Whe
of CO measurement. cert~
gran
If excessively powerful exhaust extraction
see
equipment Is connected to a Turbo car, 011 may
escape through the seals in the turbo' unit.
This will result in the exhaust system becoming sat-
-#:
Nott
uratod wllh oil G..,d Jlue smoke win be emitted in the
....... .. exha",st 10r some \.oonsiderat?Je time afterwards. To Befe
avoid ljlxce.sslv~Ly."power.fu"exhaust extraction, ·testE
connect an' extract hose with an open coupling. , Ri~ht 'on l
BRight ,. tent
C Wron.g "FaL
tem,
It is
_H t
Colour codes ule'~
The following colour codes are used in the Service , infol
Manual. Colour codes can be used alone or in com- the I
bination with each other, e.g. BURD, GUVT, etc. be II
-M1991 M1991- Thi~
disc
BL blue Code English
For
BR brown BK Black
it to
GL yellow BN Brown testl
GN green BU Blue Be
GR grey GN Green Mar
sysl
OR orange GY Grey elee
dia~
RD red OG Orange
• 8
SV black RD Red
•C
VL violet VT Violet • I(
IE
VT white WH White
•E
YE Yellow • IiE
PK Pink
• F
It i~
rna
3
4
Saab 900
Fuel injection system 240-65
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 intermit-
teAt faults recorded in the control module. See under
l(Fault diagnosis with integrated fault diagnosis sys-
lem, LH 2.4".
It is important to do this first, since connection of the
(H tester to the control module interrupts the mod-
ule'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.
Saab 900
240-66 Fuel injection system
600'
E10'
Be alert to the possibility of interference from com- FO O:
ponents connected to the wiring concerned. Also E10:
check that the wiring is in good condition and not
1;00
the cause of defective grounding.
E10
Always make absolutely certain that you refer to the
correct wiring diagram for the car model, model year EOO
and type of LH system concerned. 'EOC
I'
r' EO(
,EH
Note:
E21
Reference values for some of the parameters that
are to be checked are preprogrammed in the micro- EOI
processor incorporated in the LH system tester. E1
In some cases the nominal values fall within very EO
narrow limits. Consequently, under certain condi- E1
tions, a fault may be indicated when, in fact, no fault
EO
exists.
This can only happen in extreme situations which EC
are far removed from normal driving conditions. E(
Examples of spurious faults that may be indicated E'
under such extreme conditions include the following: El
LH 2.2 LH 2.4 E
E002 Excessive warm-up period, e.g. E
E013
thermostat fault or prolonged E
idling in extremely cold
weather. E
E020 E020 Prolonged engine braking,
E
faulty signal level from Lambda E
sensor. (
E207 E207 Prolonged full-throttle accelera- . I
tion, HLM voltage abnormally
high I
E113 E118 Engine overrewed, overrev
cut-out triggered, excessive
boost pressure
Saab 900
Fuel injection system 240-67
Saab900
240-68 Fuel injection system -
Saab 900
Fuel injection system 240-69
,j
:.
i/S Mi,988- onwards (Turbo): pin 17 of the EZK con-
trot module (176), pin 7 of amplifier (147) (Turbo).
C Fit a new LH control module.
I
(E010)
(E017)
E002 2 Shorting in temper- A Check the wiring between pin 2 of the control mod-
ature sensor (NTC) ule (200) and pin 1 of the temperature sensor (202)
It circuit. . 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 ~
Saab 900
240-70 Fuel injection system
~
E006 6 Mass air flow sen- E
A Model year 1988 and later: check the wiring be-
I sor (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'
E007 7 Mass air flow sen- A Check the wiring between pin 7 of the control mod- -I!i
sor (2 5), no signal. ule (200) and pin 5 of the mass air flow sensor ~,
(205).
8 Check the wiring between engine grounding point
I~~
201 and pin 4 of the control module (200).
C Fit a new mass air flow sensor (205).
I'
E107 7 Mass air flow sen- A Check the wiring between pin 7 of the control mod-
: sor (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 1\
(filament) burn-off takes place.
C Fit a new mass air flow sensor (205).
E008 8 Mass air flow sen- A 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 mod-
off function ule (200) and pin 1 of the mass air flow sensor
(205).
C Fit a new LH control module (200).
i\
t
Saab 900
Fuel injection system 240-71
E009 9 Main relay, no 12 V A Check for 12 V supply on the +30 distribution termi-
f
supply nal (230).
B Check the wiring between the +30 distribution termi-
nal (230) and pin 30 of the main relay (229).·
C Check the wiring between pin 87 of the main relay
(229) and pin 9 of the control module (200).
o Check the wiring between pins 30 and 86 of the
main relay (229).
E Fit a new main relay (229).
I
E109 9 Main relay, 12 V A Check battery voltage at distribution block (75)- is
supply too low at least 10 V.
B Check the wiring between the distribution block (75)
and pin 30 of the main relay (229).
(
C Check the wiring between pin 87 of the main relay
(229) and pin 9 of the control module (200).
~, o Fit a new main relay (229).
'"
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 A Check the wiring between pin 11 of the control
(299) not ground- module (200) and grounding point 201.
ing. B Check for good ground at the engine grounding
point (201).
Saab 900
240-72 Fuel injection system
E014 14 Mass air flow sen- A Check the wiring between pin 14 of the control
sor, break in CO module (200) and pin 6 of t~e mass' air flow sensor
adjusting circuit. (205).
B Fit a new mass air flow sensor (205).
E017 17 Pump relay (102) A Check the wiring between pin 17 of the control
control circuit faulty. module ,(200) and pin 85 of the pump relay (102).
B Check the wiring between pin 86 of the pump relay
(102) and pin 87 of the main relay (229) (Turbo: via
pressure switch 144).
C Check the wiring between pin 30 of the main relay
(229) and the +30 distribution terminal (230).
D Fit a new fuel pump relay (102).
E Fit a new main relay (229).
F Fit a new LH control module.
E018 18 No +15 supply. A Check the wiring between pin 18 of the (;-:)(1,,"01
. module (200) and the distribution terminal ('. ';9).
: 8 Check whether +12 V battery voltage is applied to
the distribution terminal (159) when the ignition is
switched on.
Saab 900
Fue! injection system 240-73
E120 20 Lambda sensor A Set the Lambda system to the corret;l value.
(136), signal too .8 Check the voltage across the Lambda sensor be-
low, tween the connector (60) and ground.
C Check whether a +12 V supply is present- across
;J t'
pins 1 and 2 of the connector (59)
D Check the wiring between pin 5 of the control mod-
ule (200) and the braided screening round the sig-
nallead.
I
E Check the Lambda sensor (136) preheating func-
tion.
F Check the fuel pressure (line pressure)
G Check the induction system for air leakage.
'i
H Check for air leaks in the exhaust system between
the engine and the Lambda sensor.
I Check the operation and delivery flow of the injec-
-,' tors.
. , J Fit a new Lambda sensor.
Ii
K Fit a new LH control module (200).
E220 20 Lambda sensor A Set the Lambda system to the correct value.
(136), signal too 8 Check the voltage across the Lambda sensor be-
high tween the connector ,(60) and ground. I
,
F Check the oper.ation and delivery flow of the ,injec-
tors.
. G Fit a new Lambda sensor (136). I
E021 21 Main relay '(229) A Check for 12 V battery voltage ·on the +30 distribu- I
Saab 900
240-74 Fuel injection system
E024 24 No load signal to A Check the wiring between pin 24 of the LH control
ElK (not Turbo) module (200) and pin 8 of the ElK control module
(176).
B Fit a new LH control module (200).
El
E025 25 Control module pin A Check the wiring between pin 25 of the control
25 not grounding. module (200) and grounding point 201.
B Check for good ground at engine grounding point
201.
Saab900
Fuel injection system 240-75
('
E101 Starter motor revs
too low.
Note:
A Check battery voltage and capacity.
B Check the wiring betWeen the positive terminal of
the battery and pin 30 of the starter motor and be-
I
Engine temperature tween the negative terminal of the battery and
above +10°C grounding points 7 and 211.
: C Check the operation of the starter motor.
E102 2 Throttle position A Check the setting and operation of the throttle posi-
sensor (203) con- tion sensor.
tacts constantly B Check the wiring between pin 2 of the control mod-
closed (when en- ule (200) and pin 1 of the throttle position sensor.
gine revs increased C Check the wiring between pin 2 of the control mod-
from idling to 2500 ule (200) and the EZK control module.
I' rpm). D Check the operation of the EZK ignition system.
Saab 900
240-76 Fuel injection system
E005 5 LH control module A Check the wiring between pin 5 of the control mod-
pin 5 not grounding ule and gro\.mding point 201.
to grounding point B Check for good. ground at grounding point 201.
201.
E006 6 No cO!l.,inuity in dr- A Check the wiring between pin 6 of the control mod-
cuit between LH ule (200) and pin 2 of the mass air flow sensor
Control module pin (205).
6 and pin 2 of the S Check the wiring between pin 1 of the mass air flow
mass air flow sen- sensor (205) and the engine grounding point (201).
sor (205) C Fit a new mass air flow sensor (205).
E007 7 No signal between A Check the wiring between pin 7 of the control mod-
pin 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)
o
Fit a new LH control module.
E008 8 Mass air flow sen- A Repeat the "SET 2500 RPM" test for at least 3 sec-
sor (205), no hot onds.
wire (filament) burn- S Check the wiring between pin 8 of the control mod-
off 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).
o
Fit a new LH control module (200).
Saab 900
Fuel injection system 240-77
,
Fault code Control Malfunction indi- Action
module pin cated
No.:
E108 8 Hot wire (filament) A Check the wiring between' pin 8 of the control mod-
burn-off function ule (200) and pin 4 of the mass air flow sensor
constantly acti- (205).
vated. B Fit a new LH control modl,.lle
E009 9 Main relay (229), no A Check whether +12 V battery voltage is present at
power supply. the +30 distribution terminal (230).
B Cheek the wiring to pin 30 of the main relay (229)
,
.
E109 9 Main relay (229),
supply voltage too
A Check the battery voltage at the +30 distribution
terminal (23).
I
low. B Check the' wiring to pin 30 of the main relay (229)
, and from pin 87 of the main relay to pin 9 of the
control module.
, C Check the alternator and charging system for low
charging voltage.
~
E018 18 No pulses to injec- A Check the WiFing between pin 18 of the control
, tors (201;». - module (200) and pin 2 of the injectors (206).
B Check the wiring between each injector and pin.87·
I~
of the main relay (229).
" C Check whether a +12 V supply is present at pin 30
1 of the main relay (229).
o Fit a new main relay (229).
E Fit a new LH control module.
f
E020 20 Pump relay (102) A Check the wiring between pin 20 of the control
control circuit faulty. module (200) and pin 85 of the pump relay (102).
B Check the wiring between pin 86 of the pump relay
, (102) and pin 87 of the main relay (229) and be-
tween pin 30 of the main relay and the +30 distribu-
tion terminal (230).
C Fit a new p~lmp relay (102).
C Fit d l1'aw main relay (229).
E Fit a new LH control module (200).
Saab900
240-78 Fuel injection system
,,"'
E024 24 Lambda sensor, no A. Check the wiring between pin 24 of the control
signal. module (200) 'and the connector (60).
B Check tHe wiring between pin 5 of the control mod- ~
E124 24 Lambda sensor, A Check the voltage across the Lambda sensor be-
signal too low. tween 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 mod-
ule and the braided screening round the signal I:,'
, 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
11
E224 24 Lambda sensor, A Check the voltage across the Lambda sensor be-
signal too high. tween connector 60 and ground. 1'1'
B Check whether a +12 V supply is present between 'j
tion.
F Check injector operation and delivery flow. "
G Fit a new Lambda sensor.
L ~ll :j
Saab 900
Fuel injection system 240-79
-.("1',
Fault code Control Malfunction indi- Action ~
module pin cated ,',
,
No.:
E025 25 No load signal to A Check the wiring between pin'25,of the LH control
EZK (176). module (200) and pin 8 of the E?K control module
(176).
B Fit a new LH control module (200)'.
I", £033 33 lAC valve, no signal A Check whether the throttle butterfly is correctly ad-
, from pin 33. justed (as near to the closed position as possible
without binding).
B Check the operation and setting of the throttle posi-
~. tion sensor (203).
C Check the wiring between pin 33 of the control
I
r
I, 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
i (229) and the +30 distribution terminal (230).
,Ii
I, G Fit a new main relay (229).
H Fit a new lAC valve.
I Fit a new LH control module.
.
-
E035 35 No supply from the A' Check the wiring between pin 35 of the control
+15 distribution ter- module (200) and the +15 distribution terminal
minal (159). (159).
B Check whether a +12 V supply is present at the dis-
t tribution terminal '(159) when the ignition Is switched
on.
.'
Saab 900
240-80 Fuel injection system
,I
memory can store information on minor faults.
!
) - Note:
I
If a serious fault occurs repeatedly, each occurrence
I will be recordedih the memory and the "CHECK
I\
, ENGINE" lamp will light up. Once the fault has been
I. rectified, it may-be necessary to clear the memory by
I
I
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
Fue.l injection system 240-81
Note:
All code indication and testing will.be abortedwhefl!
:the ignition is switched off.
I • "
• I
.'
.
....
\ - +. , ',.~
• ~ '. I
.:..:;....
• ~... ..=~ .....
Saab 900
~
@r~ftJ~-k ~~10<.l I ,~
. ", \ULkt c;l {. u~\IA.v ).t, 'to l~(,I.1 'hI
(9.' /J1J\..!p. uk
\J)fj'U ~C 1Jc,. ~ 0 0 {6fl lr\<k~~__ r ~ B
F
".~ 'fMJ~ 1
d
immediately to "OFF".
f6 ~\"ll}f ttt( ~ '5a),~'4~' Vj~lJ+
N tAw 60 -t.f 1 .
/'
1/"
I ;'
Check
Engine
:;;:2,.5 S I
Note: I
,The fault codes starts and finishes with a long flash
of the "CHECK ENGINE" lamp.
!These long flashes have nothing to' do with the code
itself but serve merely to ind:,,~ate the 'begi(lning and
ehd 'of the code. '.:1 '';,
4--.Jr-----------Q
---0 ;.
" .};
'h '~
• l.:" . ,
Fault code,
The, entire sequence takes place as shown in the
diagram. .
Saab·900
240-·84 Fl)el injection system '
,I"'r .J
Note:
If testing is carried ,out with the engine switched off, \
'l~~ ~i\-\V~
'. ~ \
I~ \W, V~~~
.
the first code flashed will be "1 2 2 3 1" (no speed ~"\{)~ ~:., 1 \t ~ \,u) fA ~ ~ 11 'L 'J J
signal). Engage the starter motor for about 5 ( , ,n
seconds.1m-If the fault code disappears, the ignition \pt..~ ~~Iv'-~ \r~ wlv oS},' .)
signal is OK and the fault is elsewhere in the sy~tem. (i rv
{il L.J' ~ II\-.A-. b _~ Ih< \ lAW r' f} t.
As soon as acknowledgement has been received, I. .I"v "'\.OW 'l,,~' \I "'" VV\ VI ,~
allow the ignition switch to return to the Drive posi- ~111.t-~ IA-/)\
f\ . (.,~ ~ k itO M~ 'VtvIJ.~,)
tlon and testing will continue. ~lovJ~ tt.
1/ \>'O\t,~ ill \,., 6\
~~,qi\~1G~d\
ext faUll' co e ,
CkJ·&,(\ ()A iJ~ ~~ ~t. V[ lulU t~1tAo4.t r
\ , ~. -- \
To check whether there are any additional faults in '\ Uk fIh.:,~, ~ "~t., \0\1>.: '(11) +v~ 1s1,ttov
o~cJ\i. W·~ ~(i\ (Jo~.~.
I'r(.~e system, continue~escribed below.
V :it ~[e ~ftch to "ON" ,
8 After a short flas
. ~ 0 ~ V-tt.l~~ l: ~ the swi.!Shd~1"
of the "CHECK ENGINE"
FF" U
CtL ~ i\lt1
, -~
de
!if,'
\t~~
%:-
~:-"
~ ~
'1:~ ( 0 ~tt~~ "
\
\
\\ 1/
, Check
:=02,5 s
Engine
Code
Sa~b900
Fuel injection system 240-85
t;13~ l1lmu~~ tf\rn ~(j{ 3) . -:1,(~"'~\~ baA j VIA-F.U~
9 Follow the sa\n~vprocedure to obYainthe fault t\. III e-lo..o tCl-H f% ef~lA..t( to/7L
code for a third stored faUlt, if any. If no third f a u l t , . ('"' ~
has been stored, or all the faults have been rec- \:.~Lt.. ~\Md':t
tified, this will be indicated by a continuous se- ~. 'U
r}~ b \ i ~ ~)
ries of long flashes. hiA.{ ~{D V . rd ~ ~l .
~ --~--=----~-l)
~---------------.Q I ,
~tIOJv ~ lf~~ . I,
To restart the test procedure I
I
I
I
If for any reason you want to obtain the fault codes
..
again, starting from the first fault, proceed as fol- II
lows: • ~ . ~
1 Set the switch to "ON", V~ rtl.,,(,r~ /,Uti ~U
2 After two short flashes, set the switch to "OFF" " /'1 . 1'- (I ~L. ( Ii' I. '- r .
I
and.the code for fault No. 1 will be flashed once ~0 {;t V011 k:-ttt r- J ~ lC> fA (P.cM n ~
j;N~ Vdl <.t rJFf'" 't ~ov1 ~1 ~4~ !f:tJOuv' ~~"~J
.;
\1/ \1/
Check Check
=2,5 s Engine
Engine
Code ,
.~
I
Saab900
240-86 Fuel injection system
\1/ \1/,\1/
0=1(=\(=1 L..-_ _---,
Code'
~. I-------Q
'-----------~. 5211424.
Note: '--p..
Saab 900
Fuel injection system 240-87
Note:
The proposed action given in the following table
should be regarded primarily as the starting point for
further fault diagnosis. The self-diagnosis function
incorporated hi the LH 2.4 system has two advan-
tages: the ability to store data on occasional (inter-
mittent) faults; and the ability to check the effect of
action taken to rectify a fault.
.
Fault
code
12231.
. CHECK
ENGINE
Off
Malfunction indicated
Saab 900
I:
f
I 240-88 Fuel' inject~on system
I
,
I
;
i
, I
II
,
Saab'90D
Fuel 'injection system 240-89
12243 Off Speed transmitter sensor, no sig- A With the cOntrol module connector
nal (USA-West and LH 2.4.1) plugged in:
(9000) Check the volta~e across pin 34 of the
control module aRd ground. When -either
of -tllS' ftont wReels is rotated, the voltage
Shi ,'d'~ wing between about 1 and 11 V.
~1 nolo '
ChecK'the ,gr.een lead (GN) be!W,een the
•
speed transmitter sensor (132) 'and pin
34 of the control module.
Also check the black lead (SV) from the
sensor to ,grownding point 3 and the
green-white!ead (GNNT) to pin 15 of the
ignition switch (20).
B Try a new speed transmitter sensor.
C Try a new control module.
12245 On EGR function faulty (USA-West) A With the ignition switch in the Drive posi-
tion (engine switched off) enter command
555 on an ISAT.
Check whether the modulating valve
works. ' .
If not:
Check the yel:ow-white lead (GUVT) be-
tween 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, green-
red lead (GN/RD).
B Try a new modulating valve:
C Check the yellow-white lead (GUVT) be-
tween 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.
Saab 900
240-90 Fuel injection system
Saab 900
Fuel injection system 240-91
Note:
In this testing mode, the switch must be set to "ON"
before the ignition is switched on.
I
set the switch to "OFF",
u V.
\/
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
240-92 Fuel injection system'
\ \ /
/
\ /
Check
Engine
Code
"
Saab900
Fuel injection system 240-93
.,
I.
I
.'
Saab900
240-94 Fuel injection system
1
c
n
d
n
d
Saab 900
Fl:Iel.injection system 240-95
Note:
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.
Saab 900 ,
240-96 Fuel injection system
Diagnosis
Observe the following:
• Never unplug the connector from the control mod-
ule 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 plas-
tic cover.
• Turn the Ignition switch to the Drive position.
I
LH # 1
Saab900
F~~~I injection system 240-97
---
r
c I
Saab900 .
240-98 Fuel injection system·
)!
11
!'
1'
I
Example 1:
, To check the position of the throttle butterfly, we en-
I ter the command 201 on the ISAT keypad.'With the
,, I, engine idling, the five alphanumeric characters ap-
),
.,q
.
t
pearilJg on the ISA1's display should be 8B101 .
I
t See also "ISAT control commands, LH 2.4 (M1990)"
1 page 105. .8Bl0l
I
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
Fuel injection system 240-99
Saab 900
240-100 Fuel injection system'
67192 ROM faulty (control module fault). Try a. new control module.
45771 25771 Throttle position sensor (203): A Enter command 201 on the ISAT. De-
idling contacts not breuf-ing circld press the-accelerator slowly from idling to
when engine speed increased from full-throttle position.
idling to 2500 rpm. The display, should then show
881 01 ~88001 ~88301.
If 88001 is shown constantly, there i~ no
continuity in the wiring to the throttle po-
sition 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 con-
nector.
88001 should now appear on the dis-
play. If it does not, continue with point C,
D or E.
8 If 88001 is shown, try a new throttle po-
sition sensor.
C If 88101 is shown, check the wiring be-
tween pin 2 of the control. module (200)
and pin 1 of the throttle position sensor
(203) and also between pin 2 of the con-
trol module and pin 7 of the EZK control"
module (176).
D If 88301 is shown, check the wiring be-
tween pin 3 of the control module (200)
and pin 3 of the throttle position sensor
(203) and also the TK pin on the AC re-
lay (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 Throttle position sensor (203): full- See fault code 45771/25771 above.
throttle contacts constantly closed.
46261 26261 Temperature sensor (202): signal A Check the wiring between pin 13 of the
constantly activated. control module (200) and pin 1 of the
t1m,. 3rature sensor (202).
8 (;h·e,~·.'( the wiring between pin 2 of the
temr ~\ature sensor and grounding point
201.
C Check for good ground at the grounding
point.
D Check the temperature sensor.
E Try a new LH control module.
...
.;.
Saab 900
Fuel injection system 240-101
46271 26271 Temperature sensor (202): temper- Check the resistance of the NTC resistor
atur'e above +160°C. and ,the resistanoe between pin 13 of the
control module and grownd.
The resistance should be 2280-2720 ohms
at 20°C or 290-365 ohms at 80°C, mea-
sured with the connector unplugged from
the control module.
46221 26221 Tempereture sensor (292): temper- See fault code 45721 /2"J~17i 2' ~Ne. ~-
58121 38121 Mass air flow sensor (205): no hot A Check the wiring between pin 8 of the
wire (filament) burn-off function. control module (200) and pin 4 of the
mass air flow sensor (205).
B Check the wiring between pin 5 of the
mass air flow sensor and pin 87B of the
main relay (229).
C Try a new mass air flow sensor.
o Try a new LH control moaule.
45691 25691 Mass air flow sensor:-signal faulty. A Check for leakage in the induction sys-
tem 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.
.'
Saab900
240-102 Fuel injection system .
42492 22492 Fuel-air mixture faulty for length~' A First che I< the sys~em \or air or fuel
period when car is being driven leakage,or, alternatively, the preheating
(multiplicative adaptive fault, function of the Lambda sensor.
Lambda system) 8 CheQk the induction system for leaks and
qJso check that it is in proper working
order.
C Try a new control module.
42440 22440 Fuel-air mixture too rich. A Check all screws, hoses, hose clips,
O-rings, etc. for leaks and make sure
that they are properly tightened.
8 Check the induction system for leaks and
also check that it is in proper working
order.
C Check whether voltage is present across
the pins on the Lambda sensor connec-
tor.
D Check the fuse for the Lambda sensor
preheating function.
E Check whether the Lambda sensor fluc-
tuates between 0 and 1.5 V (sensor hot).
F Fit a new Lambda sensor.
G Try a new control module.
Check: enter command 205 on the ISAT.
During the engine warm-up period, 88105
(lean) and 88305 (rich) should be shown on
the display alternately (about 20 seconds
each).
42450 22450 Fuel-air mixture too lean. See fault code 42440/24440 above.
Saab 900
Fuel injection system 240-103
42460 22460 Lambda &ensor (136) signal faulty. A Check the operation of the Lambda sen-
sor preheating function (check that bat-
tery 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 screen-
ing round the Lambda sensor lead.
D Run the engine to warm it up. Discon-
nect 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 sec-
ond intervals.
If the display shows 8B005, then the sen··
sor is not activated.
Saab 900
240-1 04 Fuel injection system
'58371 . , 38371 Injectors (206) - injection pulses A With the ignition switch in the Drive posi-
malfunctioning tion (ermine switched off), enter com-
mand 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~. .
D Check the wiring between pin 18 of the
control module (200) and pin 2 of the
injectors.
E Try a new main relay.
F Try a new lH control module.
Saab 900
Fuel injection system 240-105
•
552 Activates injectors (15 Hz and 1.5 ms 8A552
opening duration)
Disconnects the fuel pump.
553 Activates the lAC valve (1 Hz). 8A553
554 Activates the CP valve (1 Hz). 8A554
202 Checks position of CP valve. 88002 (open)
88102 (closed)
555 Activates EGR valve (1 Hz) 8A555
(USA-West only).
203 Checks status of DRIVE signal. 88103 (activated)
88000 (not activated)
205 Checks status of Lambda sensor. 88105 (lean)
88305 (rich)
88005 (inactive)
900 Clears all fault codes and resets all 11111
"adaptive" values to the basic levels.
930 Resets all "adaptive" values to basic level. 11011
100 Transfers ,all fault codes from the control
module memory to the ISAT.
207 Displays control module identification code At the request of Saab Automobile A8
(last 4 digits of 80sch spare part number).
Saab 900
240-106 Fuel injection system'
lo'
,.,
.,
1
1 •
",; ::-!
. ',-
'---_ _---'I .
....
'"
ci
>-
<> ~
z ::>
Cl
....... II]
en
n
~ on
.~ J69
ci
:I:
<~
'"on Cl'----/--_
n>-
15 J3
, 200
'LH 2.4.2
r
Saab 900
Fuel injection system 240-107
3 Not used
4 RD +30 supply x battery
I
voltage
5 BK Signal ground ·0 Gro",nd connection sepa-
!:.' rate from
chassis ground
d, BUIWH Mass air-.flow sensor~ ground signal x 0
7 OG Mass 'air .flow sensor, signal x 2 . Idling with engine ."
running
Full throttle with engine
running
8 RDIWH Mas~ ·Eiir. flow sensor, hot wire (fiIa- x 4" On Durn-off
ment) bUfr.r 6ff 0 In other cases
9 BUIWH Voltage supply from main relay x battery
voltage
-l,~
I'
14 ~L!IWH AC ! Ib~d:.signal
.. j x 12 AC on
I :• •
0 AC off
..
15 GViRD ·.I~C,
'.,
ppening·.: control signal x 7-11 No-load idling and
,.'1 hot engine
l
....-..
Saab 900
240-108 Fuel injection system '
28 Not used
31 Not used
.) Use the ISAT"s pulse measuring function and check that pulse duration and
frequency change as the throttle is opened.
Saab' 900
Fuel injection system 240-1 09
11 Not used
34 Not used
.. ~
Saab900
240-110 Fuel injection system
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 num-
ber 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 ta-
ble 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
Fuel injection system 240-111
Saab 900 -
240-112 Fuel injection system .
Saab 900
Fuel injection system 240-113
I
4 Withdraw the rubber gasket and lift up the con-
tact strip.
S Plug in the connector.
Saab 900
240-114 Fuel injection system .
Breakout' box I:
For taking test readings on the control module, pri- V
marily in the TC/ABS system, a breakout box is now fl
available to. facilitate fault diagnosis. This breakout n
box, which has part No. 86 11 006, can of course SAAS III a
also be used for diagnosing faults in the LH system. et
eeeeeeeee
2 3 04 5 6 1 8 !I 10 11
c
1
e
12 13
eeeeeeee
,. 15 16 n 1& 19 20 21 22.
e
23
e e e e.. e. e,. e3' e e
2' 25 2li 21 32 33 ..
G
0 e e e e e.... G'l., a 0 G
'" "
e .. ~1l .e .. eso e.. (} "Ii]} I~) ,.~J
J!l
'" :IS !IIi 31 3a
e 4S 41 • !l~ S:> ~I
(j)
:'
Saab 900
Fuel injection system 240-115
xxxxx12345
I
Example 1:
To check the position of the throttle butterfly we en-
ter 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 Fuel injection system
Saab 900
Fuel injection system 240-117
Command codes
LH 2.4 and LH '2.4.2
*) when functioning normally, the ISAT should alternately show 88006 and
88106
Saab900
240-118 Fuel injection system .
Saab 900
Fuel injection system 240-119
2/42241
2/42251
2/!\2252
D
2/,:12 .~91
'---
11 cv
(3'28:":8)
., '"
7 Cl' 4.0
U
8
,
Q
C'l' 10.0
RO " . r' -la
1
1l.L
G25
•
BlJ 25.0
0
G2
-
'"ci
o
c
- I
~
'"'"
I' J' 2.0 19 2J
O II
II
I
31
I I\....
22
200
LH 2.4.2
,.
=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. "
2 With the ignition switched off, check that battery
voltage is present on pin 4 of the control mod-
f" ; ule.
l If it is not, check the red lead and yellow lead
connected to distribution block 75 adjacent to
the battery tray for continuity.
3 Clean and check the connections at the follow-
ing grounding points:
• battery
.. grounding point G2 behin'd the battery
• grounding point G25 on the gearbox
• grounding point G7 on the engine
Saab 900
240-120 Fuel injection system .
2/42440 ' \ \ 1 / /
2/42442 CHECK
ENGINE
2/42451
2/42460 //I\'\.
2/42492
2/42441 !
2/42450
2/42452
2/42491
60
20 24 0-0,4 Volt
200
LH 2.4.2
(0,6-1,0 Volt) i
. I
J 2.
GI ... n l
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.
Saab 900
Fuel injection system 240-121
2/42440 '\\1//
2/42442 CHECK
ENGINE
2142451
2/42460 /11\'\
2/42492
2/42441
2/42450
2/42452
2/42491
r==J
I I
I
20 24 0-0,4 Volt
200 (0,6-1,0 Volt)
LH 2.4.2
. J 28
:Saab 900
240-122 Fuel injection system
2/42440 '\.\1//
2/42442 CHECK
ENGINE
2/42451
2/42460 //1\'-
2/42492
2/42441 ,
2/42450
2/42452
2/42491
3 With the ignition switched off, unplug the If it does not, check the GN and BK leads be-
Lambda sensor preheating connector and mea- tween pin 24 of the control module and the
sure the resistance across the sensor connec- Lambda sensor for continuity/shorting.
tions (WH-WH). 7 If the fault persists in spite of the above tests, fit
The resistance should be 4-8 ohms. a new Lambda sensor and check system oper-
ation afresh by entering command code 205 on
In the event of an open circuit or high resistance, the ISAT.
fit a new Lambda sensor.
8 Try a new control module.
4· Check the induction system for leaks by listen-
ing 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) .
If the fuel pressure is incorrect, fit a new pressure
regulator. "
6 With the engine idling, measure the sensor sig-
nal across pin 24 of the control module and a
good grounding point.
The signal should swing between 0 and 0.4 V
(lean) and 0.6- 1.0 V (rich) when the engine is
hot.
Saab 900
Fuel injection system 240-123
2/44221
rLrU1J1Jl 88107
88007
I 1 I I 1
I I ~l
6 7• 21 27 9 20 ,.
200
LH 2.4.2
,.
1 25 J
.
01 .... nl
J6S[P
"""
~
"E "f
~ ~
~
00000000000000000
0000000000000000
I
ci
"" "" 1i "
~ ~ 0
%
~
0
;:: N
~
H1D-7! ~117 • •
~ ~
~ ~ ~ "" ~
Malfunction indicated
No speed signal received by the control module from
the ignition system.
I Fault symptom ~;
Saab 900
240-124 Fuel rnjection system
2/44261
D
12J<
CU/WH 2.5 123U
ell WH D,7,S
J19
123
~/WH 1~
1'"
~
z
u
I'"
GNfwH 2.5
Sl
;; 0-75 Volt
J77
~
0/12 Volt 6 Volt
0
ii
;!i
0
"
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 con-
nector 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 fit-
ted) 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
Fuel injection system 240-125
4 11 "-\1//
e'N \;229
JO
2/45641
tJ---~ CHECK
e.5
5
e7B 57
(22B:H)
J 2
2(45651 ENGINE
:. 2145691
on
.0
'\
S f
//1\"-
~ Ii S
~! ~ ~
,
J37
I
850 rpm:802.2 =2,2 Volt
13 Ii 7 B 21 27 Q 20 24
200
LH 2.4.2
.., 125328
Malfunction indicated ,.". If it is not, check the BNIWH lead between pin 5
Signal from mass air flow ser:tsPF:mGIt~ or absent. of the mass air flow sensor and pin 87 of the
. " a:; ;'O~ main relay for continuity/shorting.
,'.r 1
Test procedure
1 Enter command code 22A on the ISAT and
check that the display shows the following:
-802.0 = 2.0 V on idling
• 805.0 = 5.0 V on full throttle
2 Chec\~ t~e induction system for leaks by pres-
sw;izhg J miid listening for the sound of air es-
caping.
3 Check that ~)lil 1 of the mass air flow sensor has
a ·good connection to ground.
If not, check the BK lead between pin 1 of the
mass air flow sensor and ground for continuity/
shorting.
4 With the ignition switch in the Drive position,
check whether battery voltage is present on pin
5 of the mass air flow sensor.
Saab 900
240-126 Fuel injection system .
'\\1//
2/45641
CHECK
2/45651 ENGINE
2/45691
//1\'\
J37
13 lS 7 IS 2' 27 II 20 2.
200
., 115328
LH 2.4.2
Saab 900
Fuel injection system 240-127
2/45723
D
I
on
ci
8
~L JO ...L. 26 J
~12 Volt
200
LH 2.4.2
(P,N)
Malfunction indicated If it is not, but is present on pin 1, fit a new se- ": ~;
DRIVE signal absent or faulty. lector lever switch. 1~:.
S~ab 900
240-128 Fue.l injection system
'\.\1//
2/45771 CHECK
2/45772 ENGINE
//1\"-
n 1,1-1,5 kO~d7
2,6-3,0 kO~
Malfunction indicated If the resistance is not correct, fit a new throttle
position sensor.
Signal from throttle position sensor (LH 2.4.2) or
throttle position switch (2.4) absent or faulty. 3 With the ignition switch in the Drive position.
measure the voltage on pin 1 of the throttle po-
Fault symptom sition sensor's connector.
Idle control not working properly. It should be 5 V.
CHECK 'ENGINE lamp ,alight.
If it is not, check the GN/RD lead between pin 1
of the throttle position sensor's connector and
Test procedure (LH2.4.2) pin 10 of the control module for
1 With the ignition switch in the Drive position, en- continuity/shorting.
ter command code 279 on the ISAT.
The following throttle openings should be shown
on the display:
with the accelerator floored: 80085 = approx.
85 degrees (open)
• with the accelerator untouched: 80000 =. approx.
o degrees (closed)
2 Measure' the resistance across pins 1 and 3 of
the throttle position sensor.
The correct resistance is as follows:
IIwith the accelerator floored: approx. 1.1-
1.5 kohms
• with the accelerator untouched: approx. 2.6-3.0
kohms,
Saab900
Fuel injection system 240-129
"-\1//
2/45771 CHECK
203
2/45772 ENGINE
//1\"-
•
200 =0,2 Volt ~
LH 2.4.2
~cfJ
JI 22
=4,0 Volt
Saab 900
240-130 Fuel injection system
'\.\1//
2/45771 CHECK
2/45772 ENGINE
//I\'\.
19 '8 20 H
I 200
~8B101
LH 2.4A
25 28 1
~ ~dJ8BOO1
~dJ \~8B301
-
Saab 900
Fuel injection system 240-131
'.\1//
2/45771 CHECK
2/45772 ENGINE
,--_=====~~/ / I \ '.
19 18 20 H
I
~ 8B101
200
LH 2.4},
~c/8B001
\~ 8B301
Saab 900
240-132 Fuel injection system
'\\1//
2/46271
CHECK
2/46221 ENGINE
~
R
:;
tL-!
//1\'\
iii
~
~n
;; r. 7 :; "
~ C7 ~ ~
n ~ ~
I ~I I' l
...
d
x
~
N
~ ~
J70
...
n
<0
n ..
29 I. >
200
IJ ., .
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
+80°C.
2 With the temperature sensor connector un-
plugged, measure the resistance of the temper-
ature sensor. See the table on the next page.
nthe' 3sista ICE ., not OK, fit a new temperature
sensor.
3 If the resistance.3 OK, plug in the temperature
sensor 'connector and unplug the control mod-
ule connector.
Measure the resistance across pin 13 (YE) at the
rear of the connector and a good ground.
Saab 900
Fuel injection system 240-133
'\\1//
2/46271 CHECK
2/46221 ENGINE
//I\'\,
I
ci '"ci
"m ~
~
'"
J70
:0'" -
:;~
2. ,e • 13
•, e
200
LH 2.4.2
,
,-
the connector and pin 1 of the temperature sen- ....,
sor connector for continuity/shorting. r: ,~, -
-20 -4 14000
5 Check the BK lead between pin 2 of the temper-
ature sensor connector and the grounding point -10 14 9000
on the engine for continuity/shorting.
0 32 5800
6 Try a new control module.
10 50 3800
15 58 3000
20 68 2600
25 76 2000
30 86 1700
80 176 320
Saab900
240-134 Fuel injection system
Electronic EGR
Background
Since component faults have occurred on several
EGR systems and in order to comply with the emis-
sion control requirements that are met by the elec-
tronic EGR system in the cars concerned, an im-
Pr.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, re-
move the EGR pipe from the exhaust manifold
and lift away the valve and pipe.
Saab900
Fuel injection system 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 Fuel injection system
Saab900
Fuel injection system 240-137
"\\1//
229
(22B:H)
5/38121 CHECK
ENGINE
//1\"\
=12 Volt
1J 6 7 D 21 27 8 20 2"
200
LH 2.4.2
Fault symptom 3 If the fault persists, fit a new mass air flow sen-
Starting difficulty, poor drivability and high fuel con- sor, clear the fault code memory arid take the
sumption car out on a road test. Afterwards check whether
CHECK ENGINE lamp alight. the fault code is generated afresh.
4 If the fault code is generated afresh after fitting a
Test procedure new mass air flow sensor, fit the old one back in
If fault code 2/45691 occurs at the same time, it is place again and try a new LH control module in-
advisable to deal with that fault code first stead.
1 With the connectors unplugged from ·the control
module and mass air flow sensor, .check the
RDIWH lead between pin G of the control mod-
ule and pin "~ (}"{ the mass c.;r flow sensor.
2 With the connectors plugge." in and the ignition
switch in the Drive position, t:;i1eck that battery
voltage is present on pin 5 01 the mass air flow
sensor and that pin 1 is properly grounded.
If no voltage is present, check the BNIWH and
GNIWH leads between pin 5 of the mass air flow
meter and pin 87B of the main relay.
Saab 900
240-138 Fuel injection system
5/38321
D
I. • 13 6 7 & 21 21 g 20 24
200
LH 2.4.2
r 1 25 J 28
"
Saab 900
Fuel injection system 240-139
5/38321
229
(228:H)
D
SJll
GR/VT 0.75
I
~8B101
~tfJ 88001
200
LH 2.4A I
Y
, 1 With the ignition switch in the Drive position, en- 6 Try a new !IAC valve and repeat the test as de-
ter command code 553 on the ISAT. Check scribed in point 5 . ' .
whether the lAC valve is working (1 Hz) by lis- 7 Try a new control module.
tening to it.
2 Check the adjustment of the throttle position
switch by entering command code 201 on the
ISAT.
With the accelerator untouched the ISAT should
show 8B1 01, which should change to 8B001
when the accelerator is floored (when the idling
contacts open).
3 With the ignition switch in the Drive position and
the control module connected, check whether
battery voltage is present across pin 1 of the lAC
,.
' .. valve connector and a good ground.
.J;,
,\
.,
.;
If it is not, check (with the ignition switched off)
the BUlRD+GYIWH lead between pin 2 of the
lAC valve and pin 87 of the main relay for
continuity/shorting.
4 With the ignition switched off, check the BUIWH
lead between pin 2 of the lAC valve and pin 33
of the control module for continuity/shorting.
5 If no fault can be found, clear the fault memory
and drive the car. Check whether the fault code
is generated afresh: .
Sasb 900
240-140 Fuel injection system"
J67 '\\1//
5/38371 CHECK
ENGINE
//I\'\.
~12 Volt
10-20 Ohm
18 ~ lJ 6 ..
200
LH 2.4.2
.,
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.
Saab 900
Fuel injection system 240-141
J67 '\\1//
5/38371 CHECK
ENGINE
//1\'\
~12 Volt
I
10-20 Ohm
18 ~ 1.1 6 1
200
LH 2.4.2
,
Saab 9.00
240-142 Fuel injection system
'\.\1//
3/58322
CHECK
3/58372 ENGINE
3/58382
//I\'\.
J76
27 g 20 24,
200
LH 2.4.2
.
(114ft ']1
Malfunction indicated 4 With the ignition switched off and the control
module and valve connectors unplugged, check
Malfunctioning of the evaporative emission canister
the YE/RD lead between pin 1 of the valve con-
purge valve (CP).
nector and pin 27 of the control module connec-
tor for continuity/shorting.
Fault symptom 5 Try a new control module.
". Poor drivability and poor idling control.
CHECK ENGINE lamp alight.
Test procedure
1 With the ignition switch in the Drive position, en-
ter 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
Fuel injection system 240-143'
I
=
E7B = BUrn-off
E7C CO content, %
E7D = Fuel system basic setting
(cars with catalytic converter)
E8 Control module Replacement, see page 240-185
E8A Control module input signals
E8B = Control module signals to injectors
E8C Fuel shut-off on starting
E8D = Full-load enrichment
E8E Warm-up period
E9 AC compressor
E10 = Oxygen (Lambda) sensor
E = Electrical
B Fuel
I Induction
M = Mechanical: removing and fitting of
constituent components
Saab900
240-144 Fuel injection system
"
Malfunction Test procedure Test reference
indicated/possible cause
Saab 900
Fuel injection system 240-145
Note:
Fault symptoms that can be traced to points 4 and 5
may also be attributable to the "Limp-Home" func-
tion.
1 2 3 4 5 6 7 8 9 Electrical leads and connec- Check the leads and con- E8A
tions broken nections and remedy as
necessary
Saab 900
240-146 Fuel injection system .
a. Electrical system a. Low voltage, break in wiring, a. Check battery voltage. Minimum
poor connection, faulty relay, acceptable: 11.5 V.
pressure switch. Check the main relay and pump
relay (see sections E1, E2).
Check the wiring and connections
for continuity, good Ctlll~act,
corrosion (see sec ion E8).
Check the pressure switch (Turbo)
(see section E3).
b. Fuel pump b. Fuel pump inoperative, poor b. Check fuel pump operation,
delivery capacity. pressure, delivery capacity
delivery flow.
(See sections B1 D, B1 E.)
c. Fuel system c. Leakage, faulty pressure c. Check the fuel system for leakage
regulator, blockage in return (see section B1).
line. Check the line pressure (see
section B1).
Check the pressure regulator (see
section B1 B).
d. Induction system d. Air leakage. d. Check the induction system for air
leaks downstream of the throttle
butterfly using pressure testing
equipment and by eye between
the mass air flow sensor and the
throttle butterfly.
(See section 11.)
f. Temperature sensor f. Inoperative, break in wiring, poor f. Check the temperature sensor,
(NTC resistor) connection. using a multimeter.
(See section E4.)
g. Control module g. Poor contaCi:, n~l input signals, g. Check all control module input
inoperative. signals, using a multimeter.
(See section EBA.)
h. Auxiliary air valve h. Malfunction, leakage. h. Check the auxiliary air valve using
a multimeter. (See section 12.)
Saab900
Fuel injection system 240-147
b. Temperature sensor
(NTC resistor)
b. Inoperative, break in wiring,
poor connection, .
b..Check the temperature sensor
using a multimeter.
(See section E4.)
I
c. Induction system c. Air leakage. c. Check the induction system for air
leaks downstream of the throttle
butterfly using pressure testing
equipment and by eye between
the mass air flow sensor and the
throttle butterfly.
(See section 11.)
d. Control module d. Poor contact, no input signals. d. Check all control module input
signals, using a multimeter.
(See'section E8A.)
e. Auxiliary air valve e. Malfunction, leakage. e. Check the auxiliary air valve
(idling control valve), using a
multimeter. (See section 12.)
f. CO content too low or too f. Incorrect setting. f. Check the idling speed and CO
high content as per specifications.
Check the resistance of the mass
air flow sensor.
(See section E7C.)
"
g. Basic setting incorrect g. Incorrect setting. g. Check the idling speed and pulse
(cars with catalytic ratio as per specifications. Check
converter). the resistance of the mass air flow
sensor.
(See section E7D.)
h. Throttle position switch h. Incorrectly adjusted or h. See "Checking the throttle position
defective. switch".
(See section E5.)
"
Saab900
240-148 Fuel injection system
3 Erratic idling
b. Mass air flow sensor/CO b. CO content too low or too high, b. Check the mass air flow sensor
content hot wire (filament) broken. for insufficient or excessive CO
content. Check whether the hot
wire (filament) is intact.
(See section E7C.)
c. Basic setting incorrect c. Incorrect setting. c. Check the idling speed and pulse
(cars with catalytic ratio as per specifications. Check
converter). the resistance of the mass air flow
sensor.
(See section E7D.)
f. Fuel system f. Pressure too low. 1. Check fuel system line pressure
and operation of the pressure
regulator.
(See section B1.)
g. Control module g. Poor contact, no input signals. g. Check all control module input
signals using a multimeter.
(See section E8A.)
h. Auxiliary air valve h. Malfunction, leakage. h. Check the auxiliary air valve.
(See section 12.)
i. Electrical system i. Break in wiring or poor i. Check the wiring and connections
connections. Poor grounding. (see section E8).
Check the' ground connections or
engine and battery grounding
points.
j. EGR valve j. Inoperative. Sticking valve. j. Check the EGR system, see
section 254 in the Service Manual.
k. Oxygen (Lambda) sensor k. Poor contact. Incorrect k. Check the oxygen (Lambda)
resistance. sensor.
(See section E10.)
Saab 900
Fuel injection system 240-149
a. Mass air flow sensor/CO a. CO content too low or too high. a. Check the mass air flow sensor
content hot wire (filament) broken. for insufficient or excessive CO
content. Check whether the hot
wire (filament) is intact.
(See section E7.)
b. Basic setting incorrect b. Incorrect setting. b. Check the idling speed an pulse
(cars with catalytic ratio as per specifications. Check
converter). the resistance of the mass air flow
s.ensor.
(See section E7D.) I
c. Induction system c. Leakage. c. Check for leakage in the induction
system using pressure testing
equipment.
(See section 11.)
e. Fuel system e. Quantity, delivery flow, e. Check the fuel system line
pressure. pressure and delivery flow.
(See section B1.)
f. Control module f. Poor contact, no input signals or 1. Use a multimeter to check all
signals weak. control module input signals.
(See section E8.)
h. Electrical system h. Broken 'Wiring or connections. h. Check the wiring and connections
Poor grounding or ground (see section E8).
connections. . Check the grounding and the
engine and battery grounding
points.
i. Oxygen (Lambda) sensor i. Poor conta '.. Incorrect i. Check the oxygen (Lambda)
resistance. sensor
(see section E10).
j.
"
Saab 900
240-150 Fuel injection system
a. Control module a. Defective wiring in the a. Check that control l'Dodule pins 9,
connector. 11, 13, 17 and 25 make good
contact.
(See section E8.)
b. Electrical system b. Alternator. Low voltage, break b. Check the electrical system in
in wiring, poor grounding. regard to open:Jioil I]'f '18
alternJtcr {see trtJ !::h::;tr~~;.
system section) and check bculery
voltage E1, E2, E8.
e. Throttle position switch. e. Incorrectly adjusted, throttle e. Check the throttle position switch
butterfly sticks. using a multimeter. Check that the
microswitch is correctly adjusted
and that the throttle butterfly does
not stick.
(See section E5.)
f. Mass air flow sensor f. Hot wire (filament) burn-off f. Check the mass air flow sensor to
function inoperative, broken hot see whether the hot wire (filament)
wire (filament). is intact and that the burn-off
function is working properly.
(see section E7.)
g. Induction system g. Air leakage. g. Check the induction system for air
leaks downstream of the throttle
butterfly using pressure testing
equipment and by eye between
the mass air flow sensor and the
throttle butterfly.
h. Fuel system h. Fuel pre:..sU! too low or too h. Check the line pressure in the fuel
high. Poor ct.rJacity. system.
(See section B1.)
i. Temperature sensor i. Inoperative, break in wiring, poor i. Check the temperature sensor
(NTC resistor) connection. using a multimeter.
(See section E4.)
j. Oxygen (Lambda) sensor j. Poor contact. Incorrect j. Check the oxygen (Lambda)
resistance. sensor.
(See section E10.)
Saab 900
Fuel injection'system 240-151
1. Basic setting incorrect f. Incorrectly adjusted. f. Check the idling speed and pulse
(cars with catalytic ratio as per specifications. Check
converter) the resistance of the mass air flow
sensor.
(See section E7D.)
g. Electrical system g. Broken wiring or connections. g. Check the wiring and connections.
Poor grounding. (See section EB.)
Check the grounding of engine
and battery.
h. Control module h. Poor ·contact, no input signals h. Check all control module input
or signals weak. signals, using a multimeter (see
section EB).
Saab 900 .
240-152 Fuel injection system
c. Fuel system c. Insufficient fiow/low voltage. c Check the fuel pump delivery flow.
(See section 81 E.)
Check the voltage supplied to the
fuel pump. Minimum acceptable:
11.5 V
(See section B1 E.)
e. Mass air flow sensor. e. Broken hot wire (filament). e. Check the mass air flow sensor to
Burn-off function inoperative. see whether the hot wire (filament)
is intact and that the burn-off
function is working properly.
(See section E7.)
h. Electrical system h. Break in wiring or connections. h. Check the wiring and connections.
Poor grounding or ground (See section E8.)
connections. Check the grounding and the
engine and battery grounding
points.
i. Control module i. Poor contact, no input signals or i. Check all control module input
signals weak. signals, using a multimeter.
(See section E8.)
Saab900
Fuel injection system 240-153
e. Electrical system e. Broken wlring or connections. e. Check the wiring and connections.
Poor grounding. (See section E8.)
/
Check the grounding of the engine
and battery.
f. Control module f. Poor contact, no input signals or f. Check all control module input
weak signals. signals, using a multimeter.
(See section E8.)
g. EGR valve g. Inoperative. Valve sticking. g. Check the EGR system. See
Service Manual, section 254.
Saab 900
240-154 Fuel injection system
Checking/fault diagnosis
81 Checking the fuel system
Tools:
• LH fuel pressure gauge equipment 83 93 852
• Test hose for return flow
• Graduated measuring beaker, 2 litre
• Jumper lead with switch 83 93 886
• Cooling system tester with hose
• Vacuum pump
• Pressure testing equipment No. 83 93 514
• Multimeter
Saab 900
Fuel injection system 240-155
".
Saab900
240-156 Fuel injection system
CAUTION
The pressure must not exceed 6.0 bar (83 psi).
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.
('
""
Saab 900
Fuel injection system 240-157
Saab900
240-158 Fuel injection system
Saab 900
Fuel injection system 240-159
Saab 900
240-160 Fuel injection system
Saab 900
Fuel injection system 240-161
E5
Tools:
Checking and adjusting the
throttle position sensor I
• Multimeter
Saab" 900
240-162 Fuel injection system·
1
Control module conne'ctor pin 12
(green/red; GN/RD)
Grounding point on engine (black/white;
SV/VT)
Control module connector pin 3 (grey; GR)
---
3 2 1
Saab900
Fuel injection system 240-163
-~-------------
!'-~OI:Q:
Saab 900
240-164 FueJ injection system·
5525'1
531VT
(6)
5360R
(5)
5525'1
(4)
Pin To component
No.
1 Control module connector pin 8 (red/white; RD/
VT)
2 Main relay pin 87b (brown/white; BRIVT)
3 Control module connector pin 6 (blue/white; BU
VT)
4 Engine grounding point 552 (black; SV)
5 Control module connector pin 7 (orange; OR)
6 Control module connector pin 14 (white; Vn
,<;iSaab900
~.
Fuel injection system 240-165
Note:
The Limp-Home function takes over automatically' if
the hot wire (filament) breaks.
Saab900
240-166 Fuel injection system· .
Note:
There are no specified intervals at wti'ich the basic
setting of the fuel injection system shou.ld be
checked or adjusted. .
"i'
Saab 900
Fuel injection system 240-167
3
S
a
S
1
I
4 Plug the wiring harness into the mass air flow
sensor again.
5 Connect pulse ratio meter 83 93 597 to the test
point adjacent to the evaporator housing by
means of the adapter lead in 83 94 132.
6 Start the engine and run it until the radiator fan
cuts in.
7 If the basic setting is correct, the meter needle
will swing back and forth between both ends of
the scale.
Note:
The movement of the needle will not be rapid and
there may be a pause between each movement.
Saab900
240-168 Fuel injection system
Note:
Instrument readings must be taken at the rear of the
control module connector with the cover removed.
Saab 900
Fuel injection system 240-169
A B
GNlRD GN/RD
GN/RD
SVNT 25
GN/RD
BURD ElK 24
SV
AIC BlNT
GRNT
GURDAIC
GN X-test·
GlNT
-
23
22
SV
BLNT
BRNT
I
'RDNT "21 RDNT
LAMBDA 20
OR OR
VLNT 19
BLNT BLNT
GNNT 18
SV SV
VI: 17
OR OR
RDNTAC 16
GR GR
SV 15
GL GL
BL
v.r 14 BL
''S
'J
5 Connect the jumper lead with crocodile clips to b )C;t'c>lltc>vL l,JlF'~D~ I 'P'-'" fa \ ~ I' k -1 .....i---
pin 17 of the connector and ,ground. Se le v..-, ,I G... u~clt;:' t.,,-,,"':.. " '.. , '--, t, ,,\f:..j.,)~
With the ignition switched on, check for voltage \. r:::.'~ t' J ('" ~t~q:: ?,~Oo-lc,uc.~ ,.,' ?c'F\\" -)-. \r-
~n pins 87 and 87b of the fuel pump. relay (or )\s..DI.J. ..... "'\'-\\o?~-\.~\ ?~"" 21- ?-g'i-b
listen for th.e sound of the pump ~tartlng up). If \.J~'-L>.. lu..~ "'-0. \.>::: ~ \ "'-~ l-.cle C. t'v-?v-,A \\1'-.. .
no voltage. IS present, check the violet (VL) lead Vo-U v-oo.... ~ v'e\..e ~~~Qu.tk.C;;J -\- (? W\2 lAD,J\
between pm 17 of the control module connector
•
l?'"'->' '- s\~L,'~ L 'i '~\
..... ,
\.. I ' _~
~s;,-l, , 2lE' c:: ~
\ - "<
and pin 85 of the fuel pump relay. L'·' I'" { \ 1 , ' -....
V&I:> '\"::>"C' u... ""o.S?c: ,,-, \ <\!I.oD\A'\ '-"0 \'-,' ,\.1:;'
6 With the ignition switched on, check whether -J 'i I ~
voltage is present between pin 18 of the control (. VL..j l}@'&.:? .......... \ \f...6'2. \' f< I..... "1:1_
modul~ c?nne(' or an? pin 25 f the c?ntrol mod- Cc~~{ L '
,
~ L\o 4..-~dt~ l IJ-,., c.-... r'': ~
ule. If It IS net, GI,3CK th3 r lcklwhlte (SVNT) \.AL>-. v--e-(\l? t!C'I"-po-d,Lo.- ~t.' ~ .\
lead between pin 25 of the I,;ontrol module and I \ I~ . i.e " - I )
one of the grounding points on the engine. b ~~<;"i t \<;~ '-c...<'" 2.c...f'(c~c..'~
. ~e 2.G. ~ L\......, \ 21..1!>'-.-\.v. L . i- '
7 Plug in the distributor connector. Check for· an _ i' '-, - , ~ ~ 1..0.. ..\ I?' \\ ~
ignition pulse on pin 1 of the control mo~ule by ~fe'\... ~""':<" ~:--- .Ill k()\..-~ Vook)",
connecting a test lamp to ground and pin 1 of ~J.-.l.>..\ '-'- \ G... 1>,
\ r
V' '2~ J '" \ I '\ .
ll"-lv....",,-,oJ \..,'\ "'-J.
the control module connector. Switch on the Ig- ~ e-l, '"'- ~ v.... ,~~.V "'-C' \:2 \." ,~'--..\. 00 ) '-'.j~)r
nition. 10ev...~ G-- ~\\.~ \s.\J IlJt j ~tt"Ltf'\.., .-,? '
Model year 1985 and earlier cars: lA.-..&<z.. l ? t' 2. S- l~o LJ v.o l" ,'Lo ""'-
V'-.
The test lamp should light up weakly for about a vv.6A..L,...\.,.v..... ~ -\<?O~~ /> -
lJo-c..( '>.-\..... \-..~,~ '" .L- v 2t? h. \.-- 0-
second and then shine with a brighter light. If It • ~\JJ~""v... '-',. C) 1 Cv"'~. ,.
does not, check the blue (BL) lead between pin ¥I 2L"ffAra-~~,-,-t::' I J . h_ \ ....
1 of the control module connector and terminal ~,~-qP\1 -LZ ( .J( ,,(:It.,.. \"C)2..~~t" IlDv!'- Lf">
1 on the ignition coil ~~ ~ ~~-\-~I.J $.
-:- C> .
Model year 1986 and later cars: -\ I.-v-. '? (.,.,~ ~ 20- ~ \?\:... v.. ~ : p; Y\ "'v.. 1\
~<1;> _kou\lA.' l--.,-.:) '-'-..e-J-v..-\. ""'- .1 ~ \."" 3.e-
The test lamp should light up. If it does not, l"\ \ I I 1
check the blue (BL) lead between pin 1 of the 1lJ-.<> \;':>li::> ,.\ ....;:,-
\J -
2\.ct)",--~e('\.,. \ \c\ ",. D\..;-
\ ._
control module and the TD-O pin of the ignition· ~c crt: L--...-" to... ~~ \..-. \2 l~, /\ l.' \ \ .
\ ( \ 'I' \ l>. '(0'" t> I<
pulse amplifier. ",'C L_' V-C' <- \ , -c L- t::>( ' ' - f.,r.t A
..;y. \ \ • tx'
8 Use the multimeter to check other wiring func- ;: 6- PG..; {.c"-. :2 (" r:.-:r, ! I '6f ~/~, I , .\
fr ,
,~.A l, '
tions (broken leads or corrosion) between the I}-, p / 1\i 0 - ' ,
'Y . connecting pins ~f the control module. V1...0O"!?j ~,~ Iv <;;.:fl ~ (\
V\......... n
\ C~}
0-'-"-'\
.,..:.. '...\.0
'-.J""-- ~\
~ t\)..~\..c.-.... .
Saab900
Fuel injection system 240-171
Note:
Do not use a test lamp when checking the control
module's output signals to the injectors.
Note:
Polarity: Red (+) prod to the blueired (BURD) lead
and black (-) test prod-to the green/red (GR/RD)
lead rT'l.~; , / ' /. /
~ ~~ (..'-l:'- "<J ......- A.. '..~ -(~ '- r.=; ( . . . tJ~ ':' C" •
(7 c.ev.. j . ko
lA l,...,_ _ It' J .-;>ti~ :~/,~", ,,- I (" r"1. lIr>-l~.p\... ~,
5 If the engine runs erratically when idling, check ,:s,) ..... ,,_ ....... ,c--t........
J
during the warm-up period that all injectors ~re
working properly. This can be done by placing a
sr.rewdriver or stethoscope against the black
metal part of the injector. A clicking sound
sh uld be heard if the injector is working.
Saab 900
240-172 Fuel injection system
mor~ .injecto~s, refer to section E6 "C~,ecking )... \e~ v.,CL. l-,~~.~, \.) \ \ \-.;>
the Injectors . 1 ~,,'
\l ~ \"'-.l"",- \ , ~ J _ • i .t· C .r \1
(. t'-I, ,~l ~t~ 1.., c..~ 1.1' ,....
b If th,e inje,ctors can b~ heard clic~in,g but the \)~\.,), ~ l.:.£>l.J)c .... ::..
engine stili runs erratically when Idling: ""1 ~ \1;;'.".:\\: ~~'\1. ' U<>...t: -h. L.
Remove one connector at a time from the in- lv-.. ~ \ <:>l,: 1(, l... \ \:; ,"-
• • Q>~~ 3 ..... k L.::\:::~\ "'c. '
jectors. Use a small screwdnver to relieve the I.Ac... ~ ), c\. '-e'f"",~,:"",~l':';.-"'"
tension in the spring clips. This should cause F"\ Q I \ '- J . ; ~ :" , • •
. -._-.~
c)
E8C Fuel shut-off on starting
When the starter motor is turning the engine over,
the fuel supply will be shut off if the accelerator is
floored (72° butterfly angle).
1 lift up the dust excluder on one of the injectors
and connect the test prods to the two injector
pins.
Polarity: red test prod (+) to the blue/red (SURD)
lead and black-test prod to the green/~ed (GRI
RD) lead. .
2 Engage the starter motor and check for voltage
across the injector.
3 Press the accelerator to the floor.
b/~!1 - 0 F! V
~0 C,~ V'- v-£ \"j t':>\ V.... ,~ b,::: \.-,.
G... ~('- ~ ~""v~Ql..\.L- 2:
~~bG--\ &~1d.c' \A \..A <1> '10
\r'~ V>A ~ju ~ l,1
\Ar-e.L~ , ~ rC.. [,.\'~D '->0.. -\.
-,J-,
\,.,. '1('-",
(){~- °t~ \) ,.
Saab 900
Fuel injection system 240-173
Tools:
cars with catalytic
converter) I
• 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 con-
nector 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 po-
sition 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.
Saab 900
240-174 Fuel injection system
Note:
Polarity: Red test prod (+) to the blue/red (SURD )
lead and black test prod (-) to the green/red /GR/RD)
lead.
Saab-900
Fuel injection system 240-175
II
3 If it does not:
Check whether voltage is present at the AC com-
.pressor's single-pole connector at the compres-
I
sor (red; RD).
• Check the AC unit's electrical system (power sup-
ply 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
115°C (240°F) thermostat (see section 854, Ser-
vice Manual 8:3).
• Also check that the yellow (GL) lead between the
lAC valve and the AC unit's 115°C (240°F) ther-
mostat and the black (SV) lead to the alternator
grounding point are OK.
Saab900
240-176 'f.
Fuel injection system .
~71 ri ~.
II, 1.1 dL'I' .. ~ -, (71 ~!-rr i·~
; t' I
(Til (1~J-(""'t'i
t.r·1'---n
..
1
Saab900
Fuel injection ~ s'ystem 240-177
.
. ....
~
Saab900 I
240-17.8 Fuel injection system
Saab900
Fuel injection system 240-179
Note:
Checking is to be carried out when the engine is cold
(below 30°C/86°F).
'.
"
;\
Saab 900 I
'I
240-180 Fuel injection system
/
M1 Basic setting of throttle
butterfly, LH 2.2
1 Make sure that the butterfly is mounted centrally
in the throttle body.
2 Screw in the adjusting screw until it touches the
stop (butterfly fully closed).
3 Turn the adjusting screw a further 1/3 turn and
secure it in this position with a locknut. This will
ensure a clearance between buttf3rf1y and throt-
tle body of approx. 0.05 mm (0.002 in).
4 Check that the length of the throttle cable does
not prevent the .iDutterfly from reaching the idling
speed position, nd that there is no play at the
accelerator pedal.
5 Check that the butterfly opens fully when the ac-
celerator is floored.
Check and adjust the throttle position sensor.
Note:
Basic setting should always be carried out with the
engine cold; temperature about 20°C (68°F), and r;)1~~",","": /h-L,,('(.""
the ignition switched off.
"2.3 l,-/
(
.'t,£~~ l.. !
Basic setting cannot be carried out accurately when
the engine is hot due to excessive clearance be-
tween the throttle butterfly and the throttle body (be-
cause the inside diameter of the throttle body in-
creases more than the diameter of the throttle
butterfly as the temperature rises). .' .
1 Undo the throttle position sensor retaining
screws and rotate the sensor clear of the thrdttle
butterfly'
Make sure that the throttle cable is slack.
Saab 900
Fuel injection system 240-181
~.
Note:
The engine must be at normal operating tempera-
ture.
Saab900
i
240~ 182 F~~I injection system
Note:
It is extremely important for the gearbox oil to be at
normal operating temperature.
,,;,- .
Saab 900
Fuel injection system 240-183
~"ll
(
'1 oJl,r?-v"'-"'~
. ~~
~.if."'"
(. t ~... _
1.-(-'.. 1,
...
."(1,.(
"( ,,·t, ~
> •• J
~'i.
... ~.
Saab900 '
240-184 Fuel injection system
f)f, I ==:tr:lL~
~cr 'i"" u,~
, ., 'rJ..I_~ ,flo N"\P'-"'\.,91
II
1'/'-'" v ~-" I!
\}~.~-
10 Switch off the engine. ;i' ...
IJ J~.,-:: 1:\
t ~rAA-J'-tl1/~( ~(~,{ ~~)
ViJJ,A1..~'\.. 1 nrr-t"'1.t, J"-' fA'" v..-.
II'
I
.
. .. r . (' ,W< CQ / ~)
() 1- "A~.(p
f' /
Saab 900
Fuel injection system 240-185
Component replacement
Control module
1 Di.sconnect the negative battery cable.
I
2 Remove the sill scuff plates from the right-hand
Side
, oJ the car.
Phil away the door weatherstrip at bottom front.
"
3 Remove the plate holding the carpet in place on r
tf;1e wheel arch and fold back the carpet.
~.~ih~(~~·~
4 UFlplug the control module connector by releas-
ing
the clip and lifting it diagonally upwards and tl-L
outwards.
5 Remove the control module retaining screws
from the whee~ arch.
..Fit in reverse order.
f2e.~( ~tr
MaIn r~lay and pump relay
1 Remove the air. duct retaining screws and move
the duct out of the way.
'. , '
. ,¢
.ff:': t-.~ '6
~' ........
, .-
,
Saab,gOO
240-186 Fuel injection system
Temperature sensor
1 Remove the clips for the crankcase ventilation
hose from the camshaft cover.
f .
2 Remove the fuel pressure regulator complete
with bracket from the cylinder head.
3 ~nplug the temperature sensor connector.
4 Drain off about 4 Iitres of coolant so that it will
not run out of the aperture when the tempera-
ture sensor is removed.
[j Un~crew ~f-:e temperature sensor and remove it,
.:isllY,) a. r 4" drive long socket..
Before refitting, thoroughly clean the mating sur-
faces and temperature sensor.
Also check the condition of the copper washer.
Fit in reverse order.
Temperature sensor tightening torque: 20
Nm (14.8 Ibf ft).
Note:
Do not forget to reconnect the ground leads for the
LH injection system at the point where the fuel pres-
sure regulator is fastened to the cylinder head.
Ii
Saab900
Fuel injection system 240-187
Note:
Scrupulous'cleanliness must be observed when car-
rying 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.
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 Fuel injection system .
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 (Va-
seline).
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 injec-
tor. Fit the clips.
Fit in reverse order.
.'
Saab900
Fuel injection system 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:
Fuel still under pressure. Wipe up any escaping fuel
with a cloth or the like.
Note:
Do not forget to reconnect the LH injection system
ground leads at the point where the pressure regu-
lator is fastened to the cylinder head.
Saab 900 .
240-190 Fuel injection system
Saab 900
Fuel injection system 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 sen-
sor and tum it to one side out of the way.
2 Remove the air cleaner housing cover by undo-
ing-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
I
cover. Fasten the clips.
8 Plug in the mass air flow sensor connector.
, '
Saab 900
240-192 Fuel injection system
531VT
537 RONT
536 OR
557 BRNT
552SV
535 BLNT
537 RONT
531VT
557BR NT B
536 OR
535 BLNT
552SV
Saab 900
Fuel injection system 240-193
I
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Saab900
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Saab Automobile AS o
Trollhattan, Sweden