Haynes Saab 90, 99 & 900 Owners Workshop Manual 1850104352, 9781850104353

Citation preview

(Terry Davey)

©HAYNES 1/982

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ITY

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ithe. 2v0 EDINBURGH CITY LIBRARIES Reference Department q THIS BOOK MUST NOT BE REMOVED UNDER ANY PRETEXT FROM THE REFERENCE DEPARTMENT. INFRINGEMENT OF THIS RULE RENDERS THE OFFENDER LIABLE TO PROSECUTION.

Before leaving the Library readers must return the books to one of the attendants at the issue desk, or they will. be held responsible for them.

Readers are required to take care of the books. Writing or drawing with pen or pencil on any part of a book, or turning down the leaves, or cutting or mutilating them, will be treated as serious damage. CONVERSATION IN THE REFERENCE DEPARTMENT IS ANNOYING TO STUDENTS, AND IS NOT PERMITTED. Class.

:

Location.

>

Accession.

Saab Owners Workshop Manual A

K Legg

Models

T Eng MIMI

covered

All Saab 90, 99 and 900 models; Saloon, Coupe and Hatchback, including Turbo, 16-valve and limited edition versions; 1985 cc Covers most mechanical features of Convertible Does not cover Saab 9000 models

ISBN 1 85010 435 2 © Haynes Publishing Group 1981, 1986, 1988 All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

Printed in England

(765-5P4) ABCDE FGH

Haynes Publishing Sparkford Nr Yeovil Somerset BA22 7JJ

Group

England

British Library Cataloguing

in Publication

Legg, A. K.

Haynes

:

5

Publications,

Inc

. 861

Lawrence

Newbury

Park

Drive

? : California 91320 USA

rer ‘|

Bue we ine

Saab 90, 99 & 900 owners workshop manual

— (Owners Workshop Manuals). 1.

Automobiles — Maintenance and repair

|. Title

629.28'722

Il. Series

TL152

SBN) -85010-435gO ae

Data

ETS TETS

| EDINBURGH CITY LIBRARIES

Acknowledgements Thanks are due to the Champion Sparking Plug Company Limited who supplied the illustrations showing the sparking plug conditions and to Duckhams Oils who provided lubrication data. Certain other illustrations are the copyright of Saab (Great Britain) Limited, and are used with their permission. Special thanks are also due to Saab (Great

About

this manual

[ts aim The aim of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work

must be done (even should you choose to get it done by a garage), provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads. The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Then the tasks are described and photographed in a step-by-step sequence so that even a novice can do the work.

/ts arrangement The

manual

Britain) Limited and Saab-Scania of Sweden for the supply of technical information, to Sykes-Pickavant who provided some of the workshop tools, and to all those people at Sparkford who assisted in the production of this Manual.

is divided

into thirteen

Chapters,

each

covering

a

logical sub-division of the vehicle. The Chapters are each divided into Sections, numbered with single figures, eg 5; and the Sections into paragraphs (or sub-sections), with decimal numbers following on from the Section they are in, eg 5.1, 5.2, 5.3 etc.

Introduction

to the Saab

The Saab 900 was first introduced in early 1979 and was similar to the existing 99 Combi Coupe, but with a longer more sloping bonnet, front spoiler and deeper windscreen. The body is of rigid construction employing safety beams in the doors and a reinforced roof. The in-line mounted engine is located over the gearbox or automatic transmission providing drive to the front wheels. Unlike the more conventional layout, the engine is positioned with the flywheel at

It is freely illustrated, especially in those parts where there is a detailed sequence of operations to be carried out. There are two forms of illustration: figures and photographs. The figures are numbered in sequence with decimal numbers, according to their position in the Chapter — eg Fig. 6.4 is the fourth drawing/illustration in Chapter 6. Photographs carry the same number (either individually or in related

groups) as the Section or sub-section to which they relate. There is an alphabetical index at the back of the manual as well as a contents list at the front. Each Chapter is also preceded by its own individual contents list. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver's seat facing forwards. Unless otherwise stated, nuts and bolts are removed by turning anti-clockwise, and tightened by turning clockwise. Vehicle manufacturers continually make changes to specifications and recommendations, and these, when notified, are incorporated into Our manuals at the earliest opportunity. Whilst every care is taken to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

900, 99 and 90 the front of the car, but this facilitates removal of the clutch without having to remove either the engine or gearbox. Being of an up market design, the car incorporates many extras to add to comfort and driveability. The Saab 90 replaced the 99 in the UK in 1984. Details of this vehicle are explained in the introduction to the supplementary chapter at the end of this manual.

Contents Page

Acknowledgements

2

About

2

this manual

Introduction to the Saab 900, 99 and 90

2

General dimensions, weights and capacities

6

Use of English

7

Buying spare parts and vehicle identification numbers

8

Tools and working facilities

12

General repair procedures

12

Jacking and towing

13

Recommended

14

lubricants and fluids

Safety first!

15

Routine maintenance (a/so see Chapter 73)

16

Fault diagnosis

22

Chapter 1

26

Chapter

Engine (a/so see Chapter 73)

2. Cooling system (a/so see Chapter 73)

55

Chapter 3

Fuel, exhaust and emission control systems (a/so see Chapter 13)

66

Chapter 4

Ignition system (a/so see Chapter 73)

94

Chapter 5

Clutch

Chapter 6 Manual gearbox

Chapter

7

:

108

and final drive

116

Automatic transmission and final drive

131

Chapter 8

Driveshafts (a/so see Chapter 73)

137

Chapter 9

Braking system (a/so see Chapter 73)

143

Chapter 10 Electrical system (a/so see Chapter 713)

156

Chapter 11

208

Suspension and steering (a/so see Chapter 713)

Chapter 12 Bodywork and fittings (a/so see Chapter 73) Chapter 13 Supplement:

Revisions and information

227 on later models

248

Conversion factors

307

Index

30 ie)

RARER Aen Behe

PROG

Es

eErgas

i

5-door Turbo 900 Saab

Gees66 15

400p-Z

General Dimensions

dimensions, weights and capacities

in (mm)

Overall length — 99 models: Saloon — Gary’ 19:7Qiskec Seecattscteusreterteressrastntes-tavc)useuskacieastensersarce ceaStanrs Saloon — late 19.79 Omer tietencsccesesstoriant assataneenestaste cnseus teaentctersett cede COMbI COUPE) ssssisscisccsccreversaeaneavescesestnas tatesverceessarcansas tsatteee: aemmcemecents aemecaes Overall length — 900 models: Saloon’ and’ Combi Coupe ii....-ecctmpere-ctherceaseacsisuttiseeeenetseteetaeeentaserars Overall width: All MOEIS .:.cciscssseasssosessacevsatessteveuasececastantevenieattesutcutcdrety orebecsestaants meartateces

174.01

in (4420 mm)

176.26

in (4477

mm)

178.35 in (4530 mm) 186.57

in (4739 mm)

66.54 in (1690 mm)

Overall height (at curb weight): QO MOde|IS sinsccdiscssccceusoasecedebersusacenereanotanen teedancer nesseeeee tens Pun Tae eeetasse Asan GOO MOde|IS sescscsiennccssacsavectetgcanereantten oeeeeretncees aserase ee eee aece eect antes Track — 99 models:

Non=Turbo. preé=1982 ...cisc.cccsstesnameotetmeresdteccter eorerecerceet meas Turbo and 1982 on models Tack — GOO models iiicsscccscscocescsecvsocovencameeuteenccartecaes arsores seeearte meen sessetcenetesss Wheelbase — Pre=1982 1.982. ON Wheelbase — Pre=1982 T9882 on

99 models: MoOdEIS ic..cocosscessecesccucacataceunant eeteemtece acess attssga anaes tara cteesns MOIS iicicccsscecsscks ossronesepteteeccnetense ccoeaeenaseestneoeasareasicereecantanans 900 models: model viiccccicssscossecesscueereeeectertaereueeneetten ia:deeeserer tensa eee eeeee Model sisiissccsdscctlecuetatecttorsedeessntettes covets nsateweedrieeemeaccr eens

Turninggcircle — 99: models: .....

iS

w

5

107a SV 2.5

ae ag)eee 123 IF !

a

|

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3

rs a seis el

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HIT9OS

Fig. 10.23 (continued) Wiring diagram for 1980 (UK) 900 Turbo

196

Key to Fig. 10.24

Battery (B2) Alternator (B2) WN

Ground

tab, instrument

console

(C9,

126 Motor, electrically operated rear view

mirror Left (F6)

48

Starter (B2) Ignition coil (B5) Distributor (A5) Ground tab (D2, F3) Light relay (D7) Light switch (E8) High beam (B1, E1) Low beam (B1, E1) Parking light (A1, F1)

49 50 51 52

Clock (D10) Dome light, interior centre (B10) Dome light, interior front (B10) Ignition lock light (B9)

129 130 134 140

53 54

Switch, interior light (B10) Door contact, interior light (B7, B10,

142 Solenoid valve, idle speed raise (F4)

55 56

Trunk light (BQ) Trunk light contact (B9)

Rail light (A13, A14, B14, F13)

57

3-pole

EOE

iPee

Zao

EO:

B12)

58

Light, instruments (C10) Light, glove box (D11) Ignition lock (B8) Ignition lock relay (D5) Fuse box (C3, C4, D4) Flasher relay (F11)

59

60

Direction indicator switch (E10) Warning flasher switch (E11) Direction indicator lamps, Left (A13, A14)

Direction indicator lamps, Right (A13, A14)

Brake light contact (E12) Brake

light lamps

(A13,

B14,

E14,

61 62 63 64

65 66 68 69

F13)

34 35 36 37 39 40 41 42 43 Aa 45 46 47

Hand brake control lamp (C10)

F12)

Dil2

Licence plate light (C13, C14) Instrument light rheostat (C10)

33

Reserve (C10)

N Reserve (C11) OChoke control lamp (C9) Cigarette lighter (F11)

Cif

Sit 32

mirror Right (F12)

K

M_

Back-up light contact (D8)

Back-up light lamps (A13, A14, E14, F13) Rear fog light (A13, B14, E14, F13) (certain markets only) Choke control switch (C12) Fan switch, cabin (C12) Fan motor, cabin (C12)

Cooling fan motor (D1) Thermo contact, cooling fan (D2) Signal horn (E1)

Signal contact (E8) Brake warning contact (C3) Hand brake contact (B12) Oil pressure warning contact (A6) Temperature transmitter (A6) Fuel transmitter (B12) Combination instrument (C10): Fuel gauge (D10) Fuel warning light (D10)

indicator

lamp

Electrically

heated

control lamp (C9)

rear

149 Main switch, fan (C12)

(B3, B7, BY,

B13,

150 Switch, AC (D12) 152 29-pole connector (A7-F7)

2-pole connector (B11, C11, D11, E8,

153 Light, cigarette lighter (E9)

E12) 2-pole connector (A8, A10, A12, B6, BiseGl Dip ine Dil2es, ESury. FQ) 1-pole connector (B6, B8, B10, B11, C7 1D3, E4 ESE ISR E14) Switch, wiper system (E9) 2-speed windshield wiper (F5) Washer motor (B1) Electrical pad with thermostat (A9) Earth point, handbrake (B8) Headlight wiper motor (B1, D1)

154 Light, heating control

Horn relay (B4) Seat belt warning light switch, passenger (B1) Seat belt contact, driver (B11) Seat belt contact, passenger (B11) Lamp seat belt warning (B12) Socket for ignition control (C7) _ Resistance, cabin fan, low speed (C12) Contact, idle speed raise (B8)

155 AC cooling fan relay (B5) 156 Cooling fan relay (D5) 157 Spark plugs (A4, A5) 158 Distribution plinth — (C5) 159 Distribution plinth + 15” (C6) 160 Switch,

162 Electrical 163 Electrical 165 Left-hand

166 167 168 169 170

Right

window

regulator

switch

window

regulator

switch

electrical window

regulator

motor (F7) Cooling fan pressure switch (E4) Throttle contract (F4) Coolant thermo-contact (F3) Pressure switch (B8) Compressor (F4)

171 Cycle contact (B8) 174 175 177 178 179 180 181 182

115 Electrically heated rear window (A112) 116 Switch, electrically heated rear window (E12)

183

118 Cornering light (A1, F1)

184

119 Side back-up light (A1, F1) Seat contact, electrical pad (A10)

185 AQ,

window

Right-hand (F9)

relay

A8,

light

Left (F8)

110 Tachometer (CQ)

(A7,

compartment

173 Diode (F4)

103 Fuel pump (A11) rear window

glove

(D12) 161 Rear fog light switch (E12)

172 Cooling fan (C1)

Switch, starting ratchet (B8) Wiper/washer interval relay (E10) Gear position light (B8)

122 8-pile connector 123 4-pole connector

rear view

148 Ashtray lamp (D12)

Temperature time switch (A2) Starter valve (A4) 95 Make-up air valve (A2) 96 Pilot pressure valve (A2) 102 Fuel pump relay (B6)

121

electrically operated

144 Pressure switch (D8) 146 Control unit, electronic ignition (A6)

(D6)

(D10) ce

Motor,

mirror Right (F11) Buzzer, coolant (E8) Coolant thermocontact (E9) Magnet valve (D2) Fuel lock magnet valve (B5)

C13, F5)

113 Electrically heated

Temperature gauge (C10) Oil pressure warning light (C10) Charging control lamp (C9) Brake warning light (C10) High beam control lamp (C10) Direction indicator lamp Left (D9) Oo >[EA amo Direction w

70 71 72 73 74 76 77 83 91 92 94

connector

127

F7,

Fat2) 124 Switch, electrically operated rear view mirror Left (F8) 125 Switch, electrically operated rear view

186

188

Thermo switch, coolant (E3) Fuel cut-off relay (C7) Electronic unit, APC (F6) Sensor (F4) Solenoid valve (F4) Pressure transmitter (F4) Switch, electrically operated sunroof (FQ) Motor, electrically operated sunroof (F10) Control unit, central lock, Left, LHD (A7) Motor, central lock, Left, RHD (A7) Control unit, central lock, Right, RHD (A8) Motor, central lock, Right, LHD (A8) Motor right, central lock, rear door (A8) Motor left, central lock, rear door (A9) Motor, central lock, tail gate (B9)

,

197

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Fig. 13.24 Insert screwdriver as shown to release the timing chain tension for camshaft sprocket removal — H type engine from 1984 (Sec 4)

Fig. 13.25 Chain tensioner adjustment — H type engine from 1984 (Sec 4)

Cooling system

Cooling system — draining 1 When draining the engie coolant from the cylinder block on the B201 type engine produced from 1985 on, remove the lower plug shown in Fig. 13.27. The upper plug is an access point for an immersion heater if fitted.

Fig. 13.27 The B201

Fig. 13.26 Chain tensioner transit lock removal — H type engine from 1984 (Sec 4)

7 2

engine cylinder block and drain plug — from 1985 (Sec 5)

Cap Coolant drain plug

3

Immersion heater plug

260

Chapter 13 Supplement

——_—COCOCO—

nnn

Cooling system circuit — B202 engine 2 The main cooling system components and B202 type engine are shown in Fig. 13.28. 3 The operation of the thermostat differs on type shown in Chapter 2 in that when fully through the radiator, but also allows a greatly through the heater unit.

6

Fuel system — carburettor

/dle shut-off valve — single carburettor (Zenith/Solex) the system circuit for the this engine to the earlier open, it forces coolant reduced flow of coolant

models

Roll-over valve 1 Models produced from 1984 on are fitted with a roll-over valve, which in the event of an accident prevents fuel from escaping. The valve is located in the right-hand side of the luggage compartment in the rear wing panel. It is connected to the fuel tank vent hose. 2 Access to the roll-over valve is gained after removing the trim panel on the right-hand side of the luggage compartment. To remove the valve, undo the retaining screws, disconnect the hose and withdraw the valve. 3 Refitting is a reversal of the removal procedure, but note that the valve must be fitted with its long outlet uppermost, and the lugs on the

face of the valve must face towards the body panel screw holes.

Carburettor modifications — from 1985 4 A disc valve is now fitted to the carburettor throttle butterfly, its purpose being to assist in regulating the fuel/air mixture on the overrun. This valve replaces the deceleration valve fitted to some earlier models.

=

5 The idle shut-off valve is located on the underside of the carburettor and is screwed into the throttle body. The purpose of the valve is to prevent the engine from running on when the engine is switched off. It achieves this by closing off the idle fuel mixture through the throttle bypass port, the valve being electrically activated by the ignition switch. 6 To check the idle shut-off valve, connect up a tachometer and run the engine at its normal idle speed. Detach the lead from the shut-off valve and check that the engine speed drops by a minimim of 200 rpm. Reconnect the lead to the valve. If the valve is defective it must be renewed. 7 Running-on can be caused by any one or more of the following:

(a) (b) (c) (d)

Incorrect ignition timing (too for advanced) Incorrect fuel grade used (higher octane rating required) Carburettor idle speed set too high, or mixture setting too weak Heavy carbon build-up in combustion chambers caused by use of excessive choke and engine running too coo/

/dle shut-off valve — twin carburettors 8 The idle shut-off valve on twin carburettor engine variants is located on a bracket beneath the air cleaner unit. 9 The shut-off valve is electrically operated and regulates the communication between the area of the float chamber above the fuel level and the constant pressure chamber. As the engine is switched off, a timed relay shuts a circuit, the solenoid valve opens a connection to the float chamber, and the depression above the fuel rises. This does away with the difference in pressure required to draw fuel through the carburettor needle valve and the engine stops. The relay is de-

energised after a period of 6 seconds.

Hot water Cold

water

Fig. 13.28 Cooling system circuit 7

Radiator

2

Water pump

3

Thermostat

4 5 6

Preheater housing Heater valve — open Heater valve — closed

— B202 engine (Sec 5) 7 8

Heat exchanger (heater matrix) Expansion tank

261

Fig. 13.30 Fuel system roll-over valve location (1) (Sec 6)

Fig. 13.29 Coolant flow through the thermostat B202 engine (Sec 5)

7 2

To radiator From engine

3 4

on the

To heater Bypass port

Fig. 13.32 DDC valve location in the throttle butterfly showing the air/fuel inlet direction (arrowed) — 1985 on models (Sec 6)

Fig. 13.33 Idle shut-off valve location — single carburettor (Sec 6)

Fig. 13.34 Idle shut-off valve location - twin carburettor (Sec 6)

262

Chapter 13 Supplement

10 To check the idle shut-off valve, detach the communication hoses from the valve, then blow through the connections to the float chamber vent valves. Initially blow through within six seconds of turning off the ignition. In this instance, the float chamber to suction chamber passage should be open. 11 Make a similar check, but this time with the ignition switched on, or six seconds or more after the ignition has been turned off. The float chamber vent valve should be open, allowing the entry of air. 12 If the idle shut-off valve is proved to be defective it must be renewed. 13 Other possible causes of running-on are listed in paragraph 7.

Solex 175 CD carburettor(s) 14 In some instances, Solex 175 CD carburettor(s) may be fitted in place of the Zenith 175 CD dealt with in Chapter 3. Both carburettor types are identical in detail, and the information detailed in Chapter 3 for the Zenith type can therefore be applied to the Solex type also.

Pierburg 175 CDUS carburettor — description 15 Carburettor engine models produced from 1987 are fitted with a Pierburg 175 CDUS carburettor. Although differing in appearance to the Zenith 175 CD carburettor used on earlier models and dealt with in Chapter 3, the basic operating principles and design features are much the same, being a horizontal constant-pressure carburettor, with a variable jet and air controlled vacuum piston. A manual choke is used for cold starting. The main jet is temperature-compensated by means of bi-metal washers which regulate the axial setting of the jet in accordance with any changes in temperature.

Fig. 13.35 Idle shut-off valve check — twin carburettor (Sec 6)

Fig. 13.36 Pierburg carburettor and connections

(Sec 6)

263

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Carburettor body Float chamber cover Carburettor cover Choke disc Cover, Damper piston cap (and oil filler plug) 12 Piston (damper)

1 2 3 4 5 8

Piston (vacuum) Spring (damper piston) Throttle spindle Throttle Throttle lever Choke /ever Adjustment screw (fast idle) Modulator valve

22 23 24 25 26 27 28 29

Fig. 13.38 General external views of the Pierburg carburettor

1 2 3 4 5

Carburettor body Float chamber cover Carburettor cover Choke disc Cover

8 15 16 17 78

Damper piston cap Throttle spindle Throttle Throttle lever Choke lever

6

Oil filler plug

20

Choke cable holder

Deceleration valve CO adjustment screw Lock plug Damper oil Idle speed adjuster valve plug (air conditioned models) 35 Vacuum connection (ignition advance/retard)

30 31 32 33 34

Float Float valve Jet Jet holder Needle Bi-metal washers Springs Idle bypass duct

30 Deceleration valve 31 CO adjuster screw 34 Idle speed adjuster valve plug (air conditioned models)

(Sec 6)

Vacuum connection (ignition advance/retard) 36 Idle speed adjustment screw

35

264

Chapter 13 Supplement

Fig. 13.39 Detach the lead from the warm start valve — Pierburg carburettor (Sec 6)

Fig. 13.41

Removing

Fig. 13.40 Remove the intake hose flange — Pierburg carburettor (Sec 6)

the carburettor — Pierburg carburettor

(Sec 6) 16 An electromagnetic shut-off valve is fitted to prevent running-on when the engine is switched off, and is located on the underside of the inlet manifold. 17 On models with air conditioning an idle speed adjustment valve is fitted which becomes operational when the air conditioning system is switched on. The purpose of this valve is to increase the mixture supply to the engine and stabilise the engine idle speed accordingly. 18 The main components of the carburettor are shown in Figs. 13.37 and 13.38.

Pierburg 175 CDUS carburettor — removal and refitting 19 Disconnect the battery earth lead. 20 Disconnect the following items. (a)

Vacuum advance/retard hose and the EGR hose (if fitted)

(b)

Warm start valve, float chamber vent shut-off valve and idle speed adjustment valve (as applicable) (c) The accelerator and choke cables (d) The air intake hose from the carburettor flange 21 Detach and remove the intake hose flange and gasket from the carburettor.

22 Detach

the

fuel

hose

from

the

carburettor.

Move

the

hose,

complete with the vapour trap and clamp, out of the way. 23 Undo the retaining nuts and withdraw the carburettor from the inlet manifold. 24 Refitting is a reversal of the removal procedure. Fit new gaskets where applicable. Ensure that the hose and wiring connections are

secure. When fitted, top up the damper cylinder with oil to the depth indicated in Fig. 13.42. On restarting the engine run it up to its normal Operating temperature then check and adjust the carburettor as necessary.

Fig. 13.42 Damper cylinder oil level must be 10 mm (0.4 in) at point indicated. Check ventilation hole (arrowed) in damper piston is clear — Pierburg carburettor (Sec 6)

265 Float level

Oil level in damper cylinder

Position of fuel jet

Needle shoulder flush

of vacuum piston Basic dimensions 2.5mm under the face of the jet mounting boss

see

Konic. 2) 4

Position of float valve Fig. 13.43 Pierburg carburettor showing

setting requirements

(Sec 6)

with bottom

266 Pierburg

Chapter 13 Supplement 175

CDUS carburettor — overhaul

25 The dismantling, inspection and reassembly procedures of this carburettor closely follow those described for the Zenith 175 CD carburettor in Chapter 3. When cleaning the diaphragm, only use paraffin. 26 Check that the axial play of the damper piston is 0.02 to 0.06 in (0.5 to 1.5 mm). Ensure that the ventilation port in the damper piston is not blocked. 27 When fitting the fuel metering needle into position, align the flat section of the needle shoulder with the locking screw and set the needle so that the base of its shoulder is level with the base of the piston. 28 When fitting the float, ensure that its adjustment tongue is located under the locking needle of the float valve, fit the plastic retaining bracket, then check the float level. 29 To check the float level, press the plastic bracket down so that the float is correctly fitted, then tilt the carburettor to the point where the float arm is just in contact with the needle valve ball, but with no pressure applied to the ball. In this position measure the distance between the float and the gasket face. If required, adjust the float height by bendng the tongue at the needle valve to suit. 30 The jet spring, jet and float chamber cover can now be fitted and the jet adjusted for basic setting as follows. 31 Turn the adjuster screw in the float chamber cover to set the jet 0.098 in (2.5 mm) under the face of the jet mounting boss. 32 When fitting the piston and diaphragm into the carburettor, ensure that the diaphragm guide locates in its recess in the carburettor body. The carburettor cover alignment marks must correspond as it is fitted. 33 The remainder of the assembly procedures are a reversal of the dismantling procedures.

Fig. 13.44 CO content (mixture) setting screw Pierburg carburettor (Sec 6)

(arrowed) =

Pierburg 175 CDUS carburettor — adjustments 34 Before checking the carburettor for correct adjustments, it is important that the engine is known to be in good condition, the ignition timing correctly set and the associate items of the fuel system known to be in good condition and working order. 35 The engine should be at its normal operating temperature, the cooling fan having cut in at least once, and the choke be fully disengaged. 36 Connect up a tachometer to the engine in accordance with the manufacturer's instructions, then check that the idle speed is as specified. Adjust if necessary via the idle speed adjustment screw.

37 Idle mixture adjustment should only be carried out if the requirements outlined in paragraphs 34 and 35 are complied with. Detach the crankcase ventilation hose nipple from the valve cover and plug the hose. Connect up a temporary fume extraction hose to the valve cover and direct it to atmosphere (downstream of the CO meter). 38 ACO extraction hose with an open-type coupling must be used to prevent a vacuum build-up in the exhaust system. 39 Detach the EGR vacuum hose and plug the hose to the EGR valve (when so equipped). Detach the vacuum hose from the distributor and plug it. Switch on the driving lights. 40 Start the engine and run it at a steady 2000 rpm. When the radiator cooling fan cuts in, check the CO content reading. If the CO content is

Fig. 13.45 Checking the modulator valve — Pierburg carburettor (Sec 6)

not within the specified amount, adjustment is necessary. : 41 Prise free the seal plug on the float chamber cover then, using an 8mm socket, turn the adjuster as necessary. Turning clockwise will reduce the CO content. If a swivel type spanner is used to make the adjustment, take care not to short it onto the starter motor or alternator

connections. 42 |f a CO adjustment was made the fast idle speed should be checked as follows. 43 With the engine at its normal operating temperature, detach the distributor advance hose and pull out the choke control so that the line on the lever aligns with the fast idle screw. Check the engine speed and compare it with the fast idle speed specified. If adjustment is required, turn the screw in the required direction. 44 Pull out the choke control knob and ensure that the lever at the carburettor fully deflects. Now push the control knob fully in and check that the lever moves back to the lowest travel limit and that the fast idle screw is not in contact with it. Adjust if necessary. 45 To check the modulator valve, disconnect its hose and plug it with the engine idling. The CO level should rise and the idle speed may fall slightly. If not, the valve is faulty or the hose is leaking. 46 When all checks and adjustments are complete, disconnect the test gear and remake the original connections.

Fig. 13.46 APC system control unit location from 1986 on (Sec 7)

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268

Chapter 13 Supplement

47 Fit a new seal plug to the CO adjuster screw when required. In some EEC countries (though not yet in the UK) this is required by law. 7

Fuel system - fuel injection models

Control unit

— APC system

1 On 1986 on models, the APC system control unit is located in the engine compartment on the left-hand inner wheel arch. 2 This is a later type control unit, and has the additional function of reducing the charging pressure to its basic setting on the overrun.

Fuel injection system (Turbo 16V) — description and operation 3 Saab 900 models powered by the Turbo 16V engine are equipped with a turbocharger with intercooler and Bosch LH-Jetronic micro processor-controlled fuel injection system. This new system incorporates the best features of previous systems with the capability to measure air mass and hence the density of the induction air rather than just its volume as in previous fuel injection systems. In addition the LH-Jetronic system utilizes a microprocessor which receives information from various sensors to accurately determine fuel injector opening duration. 4 The component parts of the system and their operation are as follows. Fuel pump: The fuel pump is an electrically driven rotary unit located in and totally surrounded by fuel in the fuel tank. On 1985 and later models the pump is located inside a container within the fuel tank. The container is pressurised by an additional feed pump enabling the main pump to draw pressurised fuel, thus eliminating the formation of vapour bubbles. The pump is fitted with a non-return valve in the pressure line to prevent the fuel pressure dropping after the pump stops running. Fuel filter: The filter consists of a nylon filter and paper element located in an aluminium housing. This assembly is connected in the pressure line between fuel pump and fuel pressure regulator. Originally mounted on the left-hand inner wheel arch, on 1986 models onwards it is located underneath the car, forward of the fuel tank on the right-hand side. Fuel pressure regulator: The fuel pressure regulator is mounted on a bracket attached to the cylinder head and inlet manifold, immediately adjacent to the fuel injection manifold. The regulator maintains fuel pressure in the pressure line at a set value above the pressure in the inlet manifold. Excess fuel is returned to the fuel tank via the fuel return line. Fuel injection valves: The fuel injection valves are operated by solenoids according to impulses received from the microprocessor in the electronic control unit. The valves open and close simultaneously, once for each engine revolution during normal running and twice when cold starting. Fuel injection manifold: Each of the fuel injection valves is connected to the fuel injection manifold which supplies fuel to each valve from the fuel pressure line, controlled by the fuel pressure regulator. Inlet manifold: The inlet manifold houses the fuel injection valves and the NTC temperature transmitter and is bolted to the left-hand side of the cylinder head.

Fig. 13.50 Fuel injector valve (Sec 7)

Fig. 13.48 Fuel pumps

71 2

Main pump Container

Fig. 13.51

used on 1985 and later models (Sec 7) 3

Fuel injection manifold

Feed pump

(Sec 7)

\

Chapter 13 Supplement

Fig. 13.52 NTC temperature transmitter

NTC temperature

transmitter:

(Sec 7)

The Negative Temperature Coeffi-

cient temperature transmitter is located in the inlet manifold and provides the microprocessor in the electronic control unit with information on engine temperature. The resistance of the NTC resistor within the unit alters according to temperature and this is interpreted by the microprocessor which responds with longer injection valve

duration (cold engine — richer mixture) or shorter injection valve duration (warm engine — weaker mixture) accordingly. Throttle switch: The throttle switch is attached to the throttle housing which is in turn bolted to the inlet manifold. The switch is connected to the throttle butterfly spindle and consists internally of a cam plate and two sets of switch contacts. When the throttle is open the cam plate actuates the full throttle contacts, a signal is sent to the microprocessor and the engine is provided with full throttle enrichment. With the throttle closed the idling contacts are actuated and the engine is provided with fuel for the idle mode. Auxiliary air valve: On models up to 1985, an auxiliary air valve, located on the thermostat housing, is used to allow air to bypass the throttle butterfly during cold starting. The unit contains a heating coil and bi-metal strip connected to a valve disc. During cold starting the heating coil is energised, causing the bi-metal strip to deform thus opening the valve. Air now bypasses the throttle butterfly by passing through the valve via hoses connected to the throttle housing. After starting the heating coil is de-energised and the valve slowly shuts. AIC actuator: On 1986 and later models an Automatic Idling Control actuator is used to provide a stabilised idling speed under all

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wl

es]

fc}

“o} ia

al

alS

Os}

SEE

=|

ol]

a)

(ee

A

ls] eel) i

fas(02 ar

8LS} sek} Se eRe eg cel —eeele} sh wile

Sik}

8} Slo]

oes]

Seer]

a) &

SIE)

a|

Fla eal

a aaes

al

lols

SBE] SPR)iS S| ~hLiole|o allSab} SeeBE] ia aie

Oyeala] ol -

Saal (aa)

iS) -” Gleol-isjo

NIM [loin

Hele) lela)

MINN] -]

=

oO

||) sine DI

—|n]—

rel

2c} oal

©

al a m a] -|

sz] a]




oltle

“Io cali

al>|

>|z2

o|>

sto) wo

ololo

Slo

SE}

=|”

sis

C

Sh

SER

H/o rlolo

a\< S\6

iva) (Va) (tay

wi)

U VID

RHD

HI7413—

Fig. 13.73 (continued) Wiring diagram for 1985 (UK) 16-valve 900 — part 3

282

449 GR/VT 1.5 (05, 448 RO/VT 15 (D6

467F BR/VT 0.75 (D5)

WY

180

VA

: 508A GN/VT1.0 (08 501A_SV_1.0 (C6

jo}

509A GL 1.0 (D8

A

| SALES

489 BR

192

UAE

RES

7

450 RO 1.5 (05)

9S

3

S|

bese

[skanm 230

(581_BR25(C7) 591A BR 15 GEN

w

54

1

&=

467 BR/VT 0.75 (C8) 467A BRIVT 0.75

163

\

191

4560 SV15

i)

fa) genet

17g

189

me

‘

5 P60)

Z|

a:

a

ZeIC BRIVT-O eine

patie)

:

670 BR/VT 0.75 (D5

wl

467F_ BR/VT

es

67E _BR/VI_0.75(A7;

192

,

—“d

| Ss! PF

laa

S| a 2

a3]

a SC 4

8 ra be

2) ao] 2]

[2500 RD 15.(D5)

4)

ee

5

ral

sales

S|

2)

2

el

8]

ol

&

oy 3

a sa

S| 0ts a] =

algsiasil sl sl & =) LS}S| sl SL} Sl Ss} SS BolSlealo]

ele

S}

fale

‘| 43

|

=

So

&

a a) a SS esl si SS

192

S Zl 5

8} 3gi Ss)&| 5] 4 82

656 SV 0.75 (C7.

2

adn StMTEAEE

=

5

|

rs

167 SV 0.75 (D7

6a]

h

y

ra

as

2

507 BR/VT_1.0(F7

rz! 5

| |!

H

:

'

GALLER

1

,

:

&

I

160 S|

F

4

3

503 VL_1.0 (08

oo

3

502A BR/VT

(A7

oe jo-e) =

(CO.

2m GL _2.5 (3D1)

N67E _SV_0.7XC7. 504 BR/VT 1.0 (F7

507A BR/VT 1.0 (D3 (3€1

Bau

gis

S|

1898 SV 0.75 (C5

wl i g me ro} 60 be a =

1.0

2

aa

z

5

190

502 BR/VT 1.0 (D8,

a5

163 GL_0.75 (D3 161 GL_0.75 (D8 167A SV_0.75 (B6)

a

456F SV 1.5

oa

167D GR0.75 (BS

roe aE 1408 657 GR/RO0. 0.75

= g

5

S|

: f » | do Li] ts}

162

so

Sis

5

sPA

a} =] 2 2 Bl o

167A SV _0.75(B5, 167C_SV_0.75(D7)

/VT 1.5

4S} 3

alc reaye

I
| | 8

OOO KX

@

12) \ A

65

450E RD _1.5(D6

Se 2S ieSles 4]Sleeol S|steelcl Aa >| S| o 3

es!

608

vy ob ldo Li] ts) — 456B SV 15

65

‘

-

450C RD 15. (06)

1 [3]60 ANTENNSTYRN

.

450 RD 1.5 (E7) ee 450B RD_1.5 (C5

S| 3] S| 3] 8

{84a 4 eee elesime|| ik RS) es pees

a] 123{213 204

Sis)

S

aa é al SO} E} in) co]¥} Sl 4] aSi

Aralal

S| Si

7g a

S

g acI

=| ele alecla

F8

=|

a

2 &

=

a

a] o S|o|) Sis SIs

= Q

Fr

al a

O}0,

[spl

Ss als) sl

192

qd wi

A 3)

m

COMBI

COUPE

BAGAGEDORR

|!

al2 70f}il |!

502A BR/VT 1.0 (B6 503A VL 1.0 (B6

467E BR/VT 0.75 (05;

re) 5

|

\

71 || }

' 1

186

1]44 GN 0.75 (3E1)

[aca GN0.75(03)

:2NA SV 15 (C3 | NG 301 1

A

[372 BL/RD 15 (244)

451 RD 1.5 (D6

!

447 GN/VT 1. 446 GN/RD 1.5 (C6

| | ) '

Fig. 13.73 Wiring diagram for 1985 (UK) 16-valve 900 — part 4

RD

rr

57

oe ea roan

a

|

283

[ 29. RO /VT 0.75 (2A7)

28

bs

|O}

5

44B GN 0.75 (B3

14

S| 2

137 VT_0.75 (B3) (B3 133 RD 0.75 (B3) (B3

a9

3

GN

30

372 BL1.5 (B3)

ARM 250

33,30 (ME,FE.AU)

189 SV 1.5 (B3)

4

in

1.0.75 (C8)

S y

(Te)

ees 0.755)

S

2}

VT_0.75 (C6

2

=

VT_0.75 (D6 ¥T_0.75 (05 T_0.75(A7)

a

46

182

» S| al a

ra re

(T_0.75(F7)

aS

T_0.75(06)

|

20202

fe

Sof]

P

5 (06

Sof

S7ES

=

Eee

= ee eee eee oe a

SOAS

Ho onus

55

Ente)

1,

79 RD/VT 1.0 (2A7)

ie (Z)

44A GN_0.75 (AS)

®)

ST

4

137 VT_0.75 (C3)

H+)

32

133 RD_0.75 (C3)

Plea

S

)

5 (C6,

i) ||30

189E SV 0.75 (C4)

5 (E7)

al aq &

ale]

oe}ss) alWRG §

gle fo}fo)

ages

|

i5,(D5)

S|

fi Sl)

co

wo}

oe 5.

08)

ital Ss

B} =

sz}

=

akk

Sle

SES

uw

ES |as

SSS) Sia

Se

ae]

Rlalg]

—Blala

Zils}

sl at ala -|

oles} Sai)

Pate)

—l_|~s

SE

|

a

si sey

Ae el = i

e

a

5

bel

ala)

=

Ln]

e6|

s

=|

°

Cele

~

GALLER

COMBI COUPE

2

al_tald 3|_I5| Oo} =o}

=[Selaise Hlalalalokn

widle|}

mH.

Sl

Gezl

rs (PD S © =

_____GOugié | | of el ‘Nf

,:“a

p° ;

:

i

i]

X:01 (9) zt

}

TE

NZ

ee pal

ce 02 (St

-

7 q

GY OE

Sz du

ot wa sro Liz &)

Sz zz Gund ee tyauAe SSae) zi

ST auras S'Z:

fe

Fl of

E—

GZ GY OE

BL 25

18s ==

O1 STINNOEZT . LANOMEZ

a

9108

2

LAOL aioe

1

ve

aie SLO LA/IND 092

es)Sl) el - 2 a | de for z

iB5 eq in