SAAB 9000. Instruction - page 23

4A•2 Fuel and exhaust systems

Fuel system data (Trionic engine management system) (continued)

Inlet air temperature (AIC) sensor:

Temperature (°C) Voltage (approx)

-30

4.5

-10 3.9

20

2.4

40 1.5
60 0.9
80 0.54
90 0.41

Throttle position switch: Resistance Voltage

Pins 1 and 2 1.6 to 2.4 5 ± 0.1
Pins 2 and 3 - idling 0.8 to 1.2 0.5 ± 0.4
Pins 2 and 3 - wide open 2.0 to 3.0 4.5 ± 0.4

Crankshaft position sensor:

Resistance (pins 1 and 2) 540 ± 55 ohms

Fuel pressure regulator:

Pressure 3.0 ± 0.1 bars

Injectors:

Resistance at 20°C:

Turbo engine 12.0 ± 0.35 ohms

Non-turbo engine 14.5 ± 0.35 ohms

Flow capacity:

Turbo engine 176 ± 14 ml/30 seconds

Non-turbo engine 127 ± 10 ml/30 seconds

Maximum flow difference between injectors:

Turbo engine 18 ml

Non-turbo engine 13 ml

Idle air control valve:

Resistance at 20°C 7.7 ± 1 ohms

Fuel pump:

Type Electric immersed in fuel tank
Capacity at 3.0 bars 700 ml/30 seconds (minimum)

Fuel gauge sender unit winding resistance 33 to 370 ohms
Idle speed Controlled by automatic idle control at 850 ± 50 rpm (not adjustable)
Idle mixture Controlled by lambda sensor

Turbocharger

Type:

Models from 1985 to 1988 Garrett T3
Models from 1989 to 1990 (without catalytic converter) Garrett TEO5
1990 models (with catalytic converter) Garrett T25
1991 models (except 9000 Aero with manual gearbox) Garrett T25M
1993-on models Garrett TDO4

Fuel tank

Capacity:

1985 to 1989 models 68 litres
1990 and 1992-on models 66 litres
1991 models 62 litres

Recommended fuel

Non-turbo models 95 RON Premium unleaded or 98 RON Super unleaded

Turbo models 98 RON Super unleaded

Torque wrench settings Mm lbf ft

Crankshaft position sensor 8 6
Exhaust manifold to cylinder head 25 18
Exhaust manifold-to-turbocharger nuts:

T3/TEO5 40 30
T25/TDO4 22 16

Exhaust system section flange joints 40 30
Front exhaust pipe to turbocharger 25 18
Inlet manifold:

B202 engine 18 13
B234 engine 22 16

Intercooler-to-condenser mounting bolts 8 6
Lambda sensor 55 41
Oil cooler upper union bolt 18 13

Fuel and exhaust systems 4A•3

3.3 Disconnecting the inner cable (arrowed)

from the throttle housing sector

The fuel system consists of a fuel tank

mounted under the rear of the car (with an
electric fuel pump immersed in it), a fuel filter,
and the fuel feed and return lines. The fuel
pump supplies fuel to the fuel rail, which acts

as a reservoir for the four fuel injectors which

inject fuel into the inlet tracts.A fuel filter is

incorporated in feed line from the pump to

the fuel rail,to ensure that the fuel supplied to

the injectors is clean. The filter is located

between the battery and the false bulkhead on

models with LH-Jetronic fuel injection

sytem, or adjacent to the fuel tank on models
with the Trionlc engine management system.
The fuel injection system is of Bosch

LH-Jetronic type (models up to 1993) or Saab

Trionic type (models from 1993 on). Refer to

Section 8 for further information on the
operation of the relevant fuel injection system,
and to Section 22 for information on the

exhaust system.
A cruise control system is fitted as standard

equipment on most models. This system

allows the driver to preselect speed of the

car, and then remove his foot from the
accelerator pedal. The system is disengaged
automatically when the clutch or brake pedals

are depressed, or when the system is

switched off.

A turbocharger is fitted to certain models.

Refer to Section 17 for more information.

Warning: Many of the procedures

in this Chapter require the
removal of fuel lines and
connections, which may result in

some fuel spillage. Before carrying out any

operation on the fuel system, refer to the
precautions given in "Safety first!" and

follow them implicitly. Petrol is a highly-

dangerous and volatile liquid, and the

precautions necessary when handling it

cannot be overstressed.

3.4 Removing the outer cable clip securing

the accelerator cable to the throttle

housing

Removal

1 Slacken the retaining clip, and disconnect

the inlet duct hose from the air cleaner cover.
2 Release the toggle spring clips, and lift off
the air cleaner cover.
3 Remove the air cleaner element (refer to
Chapter 1 if necessary). On models with an

LH-Jetronic fuel injection system, lift the
element from the lower body. On models with

the Trionic engine management system, pull
the element out of the cylindrical body.
4 Unscrew the mounting screws, and
withdraw the air cleaner body from the engine
compartment, disconnecting the air inlet duct
as necessary.

Refitting

5 Refitting is a reversal of the removal
procedure.

Removal

1 Loosen the clips, and remove the inlet air

duct from the throttle housing and inlet
manifold.
2 Where applicable, remove the EGR pipe.
3 Release the accelerator inner cable from the
throttle housing sector. The end of the inner
cable may be clamped to the sector, in which
case a small screwdriver will be required to
prise the clamp apart (see illustration).
4
Pull out the clip, and disconnect the
accelerator outer cable from the bracket on
the throttle housing (see illustration).
5
Inside the car, pull back the insulation
above the accelerator pedal. On left-hand
drive models, remove the panel on the left-
hand side of the centre console. On right-hand
drive models, note that the pedal extends over
to the left-hand side of the facia panel, and it

3.16 Using pliers to secure the end of the

accelerator cable to the throttle housing

sector

will be necessary to pull back the insulation
from this side as well.
6 On 1994 models, detach the cruise control
ball chain from the locking plate. Note the
position of the plate, to ensure correct
refitting.
7 While holding the accelerator pedal in the
depressed position, disconnect the locking
plate from the cable, and detach the cable and
bushing from the accelerator pedal inside the
car.

8 Attach a piece of string or wire to the end of
the accelerator cable, then press the cable
flange from the bulkhead with a screwdriver.
9 Pull the cable into the engine compartment,
then disconnect the string and remove the
cable.

Refitting

10 Apply a little petroleum jelly to the flange

of the accelerator cable. Connect the string or
wire to it, and draw it through the bulkhead.
Press the flange into the bulkhead, using a
large screwdriver.
11 Reconnect the cable and bushing to the
accelerator pedal inside the car.
12 Untie the string, and refit the locking plate.
Before releasing the pedal, secure the locking
plate with insulating tape.
13 On 1994 models, reconnect the cruise
control ball chain in its previously-noted
position.
14 Refit the insulation and on left-hand drive
models, refit the panel on the left-hand side of

the centre console.
15 Refit the accelerator outer cable to the
bracket on the throttle housing, and secure
with the clip.

16 Reconnect the inner cable to the throttle
housing sector, and where necessary

compress the clamp using a pair of pliers (see
illustration).
17
Turn the adjusting nut on the outer cable,
until there is a little slack in the cable with the
pedal released.
18 Where applicable, refit the EGR pipe.
19 Refit the air duct between the throttle
housing and the inlet manifold, and tighten the
clips.

3.16 Using pliers to secure the end of the

accelerator cable to the throttle housing

sector

4A•4 Fuel and exhaust systems

Removal

1 Using a bolt or similar tool, hold the sector
on the throttle housing slightly open, in order

to relieve the tension of the cable when it is
disconnected from the pedal.
2 Inside the car, remove the insulation above
the pedals. On left-hand drive models, remove
the panel from the left-hand side of the centre
console. On right-hand drive models, remove
the insulation above the passenger footwell.
3 Lift the pedal, and disconnect the inner
cable after releasing the clip.
4 Unscrew the bolts on the pedal bracket, and
remove the pedal.

Refitting

5 Refitting is a reversal of removal, but make
sure that the mounting bolts are tightened
securely. If necessary, adjust the accelerator
cable as described in Section 3.

Description

1 The cruise control system allows the driver
to preselect the speed of the car, then remove
his foot from the accelerator pedal. The
system is deactivated when the clutch or
brake pedals are depressed, or when the main
cruise control switch is switched off. There are

two versions of cruise control fitted to the

models covered by this manual. Both versions
have their own electronic control unit, but the
early version uses vacuum to move the
accelerator pedal cable, whereas the later
version uses a stepper motor to move the
throttle lever on the throttle housing.
2 In the event of a fault in the cruise control
system, first check all relevant wiring for
security. Further testing is best left to a Saab
dealer, who will have the necessary diagnostic
equipment to find the fault quickly.

Early models

3 The main components of the system fitted
to early models are as follows:
a) Electronic control unit: the electronic

control unit (ECU) is located below the facia

panel on the right-hand side (right-hand-

drive models) or on the left-hand side (left-
hand-drive models). The ECU stores the
speed transmitted by the speed transducer
when the "Set" button is depressed. The
system is not operative at speeds below
23 mph, nor above 112 mph.

b) Speed transducer: the speed transducer

is located on the rear of the instrument
panel. It monitors the speed of the car,
and sends signals to the vacuum pump to
raise or reduce the vacuum in order to
adjust the speed of the car.

c) Cruise control switch: the main control

switch for the cruise control system is
located on the left-hand side of the
steering wheel, and is incorporated in the
direction indicator switch.

d) Vacuum pump and vacuum valve: the

vacuum pump is located on the right-hand
side of the bulkhead in the engine
compartment. When the cruise control

system is activated, the pump runs, but
the actual vacuum produced is regulated
by the vacuum valve. In certain
circumstances the vacuum pump will
stop, in order to reduce the vacuum in the

vacuum regulator.

e) Vacuum regulator: the vacuum regulator

is located on a bracket near the
accelerator pedal. It incorporates a ball-
link chain, which is clipped to the
accelerator cable at the top of the
accelerator pedal. On right-hand-drive
models, the accelerator pedal is extended
into the left-hand footwell, and the
vacuum regulator is located under the
facia behind the glovebox position.

f) Pedal switches: switches are provided on

the brake and clutch pedals, in order to
disengage the system when either pedal is
depressed. Each switch has a double
function - electrical and vacuum. If either

pedal is depressed, the electrical

connection will be broken, and the
vacuum pump will stop. At the same time,

the system vacuum will be dissipated by
the switch's internal port.

Later models

4 The main components of the system fitted
to later models are as follows:
a) Control module: the control module

incorporates an electric stepper motor,

which operates the control cable attached
to the throttle butterfly lever on the throttle

housing. The module is supplied with the
speed of the car by signals sent from the
speedometer in the instrument panel. The
system is not operative at speeds below
20 mph, nor above 137 mph. When the
cruise control system is active, the engine
management ECU is informed of this fact
by a signal, to ensure smoother control of

the car's speed.

b) Switches: the main control switch for the

cruise control system is located on the
left-hand side of the steering wheel.
Switches are provided on the brake and
clutch pedals, in order to deactivate the
system when either pedal is depressed.

The brake pedal cruise control switch is

earthed through the brake stop-light
bulbs, via the main stop light switch - if

this circuit develops a fault, the cruise

control system will not operate.

c) Indicator light: the indicator light on the

instrument panel is illuminated when the
cruise control system is operating.

Component renewal - early

models

Cruise control switch
5
The switch is integral with the direction
indicator switch. Refer to Chapter 12 for the
removal and refitting procedure.

Speed transducer
6
Remove the instrument panel as described
in Chapter 12, then remove the upper section
of the panel for access to the transducer.

Vacuum pump
7
The pump is located on the right-hand side
of the engine compartment, on the bulkhead.

Disconnect the wiring and vacuum hoses, then

unscrew the mounting bracket bolts (see
illustrations).
The pump can be removed from
the bracket after unscrewing the bolt.

5.7a Disconnecting the wiring ...

5.7b ... and vacuum hoses ...

5.7c ... then unscrew the mounting bolts

(arrowed) and remove the cruise control

vacuum pump

Fuel and exhaust systems 4A•5

5.9a Disconnect the vacuum hose (A), then

unscrew the mounting nut (B)...

ECU

8 Remove the lower panel from under the
facia panel. The ECU is mounted on the same
bracket as the APC system module. On right-
hand drive models, the ECU is located on a
bracket to the right of the steering column.

Vacuum regulator

9 The vacuum regulator is located on a
bracket near the left-hand end of the
accelerator pedal. Access is gained by
removing the glovebox (right-hand drive
models) or lower facia panel (left-hand drive
models). Take care not to damage the rubber
gaiter when removing and refitting the
regulator. The ball-link chain should be fitted
to the accelerator cable clip near the top of the
accelerator pedal, so that all slack is taken up
without moving the cable (see illustrations).

Pedal switches

10 The switches are located on the same
bracket as the stop-light switch. Access is
gained by removing the lower facia panel.

When refitting the switches, adjust them so
that there is a clearance of 1.0 mm between
the threaded part of the switch and the
actuator tip. Make sure that the pedals are
fully released before adjusting the switches.

Component renewal - later models
Control module

11 The control module is located beneath the
right-hand side of the facia on right-hand-drive
models, or behind the battery on left-hand-
drive models.
12 On right-hand drive models, remove the
module from its bracket, and disconnect the
wiring (see illustration). On left-hand-drive
models, first remove the battery as described
in Chapter 5A, then disconnect the wiring plug
from the control module. Unscrew the three
mounting bolts, then lift the module from its
location as far as the throttle cable will allow.
Open the throttle butterfly lever, then
disconnect the cable from the sector on the
throttle housing, and release it from the holder.
13 Refitting is a reversal of removal

Clutch and brake pedal switches

Note: Refer to Chapter 9 for details of the

stop-light switch.

14 Remove the lower panel from under the
facia. Disconnect the wiring from the switch,
then prise the switch from the pedal bracket
using a screwdriver.
15 Refitting is a reversal of removal.

Cruise control switch

16 Remove the upper and lower steering
column shrouds with reference to Chapter 10,

then disconnect the wiring plug. Unbolt and

remove the switch.
17 Refitting is a reversal of removal.

6 Traction control system

(TCS) - description and
component renewal

Description

1 Fitted as an option on earlier models, and as
standard on later high-specification models,
the Traction Control System (TCS) prevents
uncontrolled wheelspin under acceleration
and on slippery surfaces. The TCS works in
conjunction with the Anti-lock Braking System
(ABS) described in Chapter 9. The main
components of the TCS are as follows.

a) Electronic Throttle System: The TCS

uses an electronic throttle system (ETS) in
addition to a cable to operate the throttle
butterfly in the throttle housing. The ETS
comprises a pedal potentiometer and a
throttle potentiometer/motor. When the
driver depresses the accelerator pedal
with the system in operation, the

potentiometer sends an output signal to

the ETS electronic control module. Under
normal conditions, the control module will
activate the throttle motor, and position
the throttle butterfly directly in relation to
the pedal position. When wheelspin is
detected within the pre-programmed
operational speeds, the control module
determines how much the throttle butterfly
should be closed in order to reduce the
torque from the engine until the wheel
regains traction. Throttle repositioning is

normally applied only at speeds above
approximately 30 mph. The throttle
potentiometer informs the control module
of the throttle butterfly position.

5.12 Cruise control module on later right-

hand-drive models (removed from its

mounting bracket)

b) ETS control module: the ETS control

module is located on a bracket beneath
the left-hand front seat, and on automatic
transmission models, the traction control
ASR (anti-spin) module is mounted on top
of the ETS control module. On manual
transmission models, the traction control
module is integrated into the ABS control
unit. The ETS control module uses
information from the TCS/ABS control unit
(manual models) or ASR module
(automatic models) to determine when
wheelspin is occurring.

c) TCS/ABS hydraulic actuator: the

TCS/ABS hydraulic actuator (see

illustration) consists of a unit containing
solenoid valves and a pump, integrated
into the front brake hydraulic circuits. The
system uses the ABS wheel sensors to
detect wheelspin via the ABS control unit
mounted on the battery tray. The ABS
control unit is specific to TCS models, and
outputs a signal to the ETS control
module when wheelspin is detected. At
speeds below approximately 30 mph, the
actuator solenoid valves are activated, to
allow the pump to pressurise the relevant
front brake circuit until the spinning wheel
slows to a rotational speed corresponding

6.1 TCS/ABS hydraulic actuator

5.9b ... and remove the vacuum regulator

(arrowed)

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