Starting System: Other Saab 9-3 I

Starter Motor

The starter motor is fitted to the engine block. A solenoid engages a pinion with the ring gear on the engine's flywheel.

When the engine is started and the engine speed exceeds the starter motor rpm, the pinion is disengaged from its shaft via a free wheel. This prevents the starter motor from overrevving.

Ignition Switch

The starter motor operates when the ignition switch is in start position.

TWICE Control Module

The control module grounds the starting relay actuating coil when it has received the ready signal from the immobilizer unit.

The TWICE control module outputs "Key correct" on the bus when the correct key is being used.

Gear Selector, Automatic

The gear selector on cars with automatic transmission allows start only when the selector lever is in position P or N.

Identifying Starter Motor. Scheme 21

The starter motor has permanent magnets to reduce strain on the battery.

A planetary gear increases the starting torque.

The starter motor circuit consists of tow sub -circuits

1. working circuit
2. operating circuit

Identifying Working Circuit Chart. Scheme 22

The working circuit goes from the battery's positive terminal to terminal 30 on the starter motor.

Operating Current Circuit Diagram (Automatic Transmission). Scheme 23

The operating circuit goes from the battery's positive terminal to the ignition switch and on to the starting relay, and via the starting relay to terminal 50 on the starter motor, which is the operating current connection on the solenoid.

On cars with automatic transmission, the gear selector lever must be in position P or N if the start relay coil is to receive a current.

The starting relay actuating coil is grounded via the TWICE control module when it has received the ready signal from the immobilizer unit.

Operating Current Circuit Diagram (Manual Gearbox). Scheme 24

The operating circuit goes from the battery's positive terminal to the ignition switch and on to the starting relay, and via the starting relay to terminal 50 on the starter motor, which is the operating current connection on the solenoid.

The starting relay actuating coil is grounded via the TWICE control module when it has received the ready signal from the immobilizer unit.

Control module

When the control module is supplied with current, the processor in it is tripped. The processor then reads the instructions stored in the control module's memory.

The control module is programmed to read the inputs and activate the outputs. If the control module program is faulty, the diagnostic trouble code "Internal Control Module Fault" will be generated.

The control module must be supplied with current before the system will function. The control module is supplied with current and the processor tripped when the control module can be contacted by the diagnostics instrument.

Outputs

The purpose of the system is to control a number of functions by means of various actuators, such as an injector or lamp. For the system to be capable of performing its functions, it must be possible to activate the actuators. For this reason the actuators must be connected to the control module and have a proper power supply or ground connection.

Inputs

A condition for the control module's capability of controlling its actuators is that the system's sensors supply it with correct values.

Sensor performance can be checked with the diagnostics instrument.

Tech 2 menu structure

TECH 2 MENU STRUCTURE

Identifying Diagnostic Tools. Scheme 25

It is our experience that the majority of control modules returned to us for repair or replacement under warranty are in perfect working order. In these cases, fitting a new control module has obviously not cured the fault. Therefore, go through all the following points carefully before changing the control module

Scheme 26

1. Check the latest edition of TIS2000 to see whether the problem can be solved with a control module software update (for control modules that can be reprogrammed). IMPORTANT: Avoid SPS programming unless it is absolutely necessary. It is extremely important to follow the instructions for SPS programming to avoid damaging the control module.
2. Check all grounding points and the power supply to the control module.
3. Check with a diagnostic tool that all the readings are plausible (several readings can affect one function).
4. Check with the diagnostics tool that all activations function normally. (Malfunction in one output circuit can affect another output circuit).
5. If the fault persists, the control module must be changed. Fill in the "Checklist for changing turbocharger and engine control module" before changing the control module and attach it when the control module is returned. (Scheme 26): Checking Control Module
6. Control modules are sensitive to electrostatic discharges. Great care must be taken to follow the following procedure to avoid damaging internal components in the control module: Keep the control module in its packaging for as long as possible. Never touch the pins of a control module with your hands or clothing. Ground yourself by touching part of the car's body/engine. Unplug the connector from the car's control module. Place the exchanged control module in its return packaging without touching the pins. Ground yourself by touching part of the car's body/engine. Plug in the connector to the car's control module.

Identifying Multimeter. Scheme 27

A suitable instrument to use is a multimeter.

The ohmmeter must not be used to test components containing semi -conductors, e.g. control modules and relay with timing functions, etc.

When measuring resistance, the power supply to the system being tested must be disconnected as the measuring instrument generates a weak current in the circuit in question.

This is done to ensure that there is no current already in the tested circuit and that the correct reading is obtained.

Testing For Open Circuits By Measuring Voltage. Scheme 28

Setting Multimeter For Measuring Voltage & Connecting Negative Lead Of Voltmeter To Grounding Point. Scheme 29

1. Turn on the load.
2. Set the multimeter for measuring voltage and connect the negative lead of the voltmeter to a good grounding point.
3. Connect the positive lead of the voltmeter to the point where the voltage is to be read.
4. On the output side of switches/control modules, it is better to start checking from these and gradually work your way towards the load. When there is no longer a voltage reading, you will have gone past the break point.
5. On the input side of switches/control modules/consumers, it is better to start at the power source (normally a fuse) and then move gradually towards the switch/control module/consumer.

When there is no longer a voltage reading, you will have gone past the break point.

Testing For Open Circuits By Measuring Resistance. Scheme 30

Setting Multimeter For Measuring Ohms & Connecting Ohmmeter To Each End Of Components. Scheme 31

1. Make sure the component or lead to be tested is not under tension (e.g. by removing the relevant fuse).
2. Set the multimeter for measuring ohms and connect the ohmmeter to each end of the component/lead to be tested.
3. Jiggle the relevant wiring harness while observing the ohmmeter. Normally, the resistance of a wiring harness is less than 1 ohm. Specified values apply to components.

Testing For Short Circuits To Ground. Scheme 32

Setting Multimeter For Measuring Ohms. Scheme 33

1. Make sure the lead being tested is not under tension (e.g. remove the relevant fuse) and that any loads are disconnected.
2. Set the multimeter for measuring ohms.
3. Connect one test lead to a good ground and the other to the point to be tested.
4. Carefully jiggle the wiring harness and make sure the multimeter reading shows infinite resistance (OL) all the time.

Identifying Fault Symptoms (No Diagnostics Communication). Scheme 34

No contact with any bus system

Condition

No conditions

Check

Check that

1. The battery cables are firmly tightened on the terminals and are not oxidized.
2. The battery connections to the car are tight and that there is no oxide or corrosion causing bad contact.
3. The starter motor connections are tight and that there is no oxide or corrosion causing bad contact.

Removing Upper Retaining Bolt Of Starter Motor (Petrol Engine). Scheme 35

Note. If the car is fitted with a radio other than Saab's original, check that the customer has the radio code before you begin work.

1. Disconnect the negative battery cable.
2. Drape protective covers over the front wings.
3. Remove the upper retaining bolt of the starter motor.
4. Disconnect the starter motor connecting cables.
5. Raise the car.
6. Unscrew the starter motor's lower retaining nut.
7. Lower the starter motor and lift it out.

Fitting Starter Motor's Lower Retaining Bolt (Petrol Engine). Scheme 36

1. Clean the starter motor mounting surfaces and electrical contacts and apply vaseline.
2. Fit the starter motor's lower retaining bolt.
3. Lower the car.
4. Clean the starter motor connecting cables, apply vaseline and connect them.
5. Screw on the starter motor's upper retaining bolt.
6. Connect the negative lead to the battery.
7. Set the clock and program in the radio code if any.

Removing Cover Under Drive Assembly. Scheme 37

Note. If the car is fitted with a radio other than Saab's original, check that the customer has the radio code before you begin work.

Scheme 38

Scheme 39

1. Disconnect the negative battery cable.
2. Raise the car.
3. Remove the cover under the drive assembly.
4. Remove the radiation guard. (Scheme 38): Removing Radiation Guard
5. Remove the starter motor's lower retaining bolt. (Scheme 39): Removing Starter Motor's Lower Retaining Bolt (Diesel Engine)
6. Remove the lower bolt of the rear strut and loosen the upper bolt.
7. Lower the car.
8. Drape protective covers over the front wings.
9. Undo the connecting cables of the starter motor and cut the cable tie around the cable bar.
10. Remove the upper retaining bolt of the starter motor.
11. Lift up the starter motor.

Fitting Starter Motor (Diesel Engine). Scheme 40

Scheme 41

Scheme 42

1. Clean the starter motor mounting surfaces and electrical contacts and apply vaseline.
2. Fit the starter motor.
3. Screw on the starter motor's upper retaining bolt.
4. Connect the cables to the starter motor and secure them with a cable tie around the cable bar.
5. Raise the car.
6. Fit the starter motor's lower retaining bolt.
7. Put the rear strut back into place.
8. Put the radiation guard back into place. (Scheme 41): Installing Radiation Guard
9. Put the cover under the drive assembly back into place. (Scheme 42): Installing Cover Under The Drive Assembly
10. Lower the car.
11. Connect the minus cable to the battery.
12. Set the clock and program in the radio code if any.

Identifying Starter Motor (Petrol Engine). Scheme 43

Identifying Starter Motor (Diesel Engine). Scheme 44

Fuse board 22a in the dashboard

On the end of the dashboard at the driver's door.

Upper sleeve socket is incoming voltage.

Identifying Fuse Board (1 Of 2). Scheme 45

Identifying Fuse Board (2 Of 2). Scheme 46

FUSES SPECIFICATION

Identifying Switch, Immobilizer, Automatic Connector. Scheme 47

Identifying Gear Lever Position Switch Connectors. Scheme 48

Identifying Antenna Unit Connectors (Immobilizer). Scheme 49

Fuse board 501 for maxi fuses in engine bay

beside battery

Identifying Fuse Board 501 For Maxi Fuses In Engine Bay. Scheme 50

FUSES SPECIFICATION

Relay, starter relay (517)

LHD

Identifying Starter Relay Connectors (LHD). Scheme 51

RHD

Identifying Starter Relay Connectors (RHD). Scheme 52

Identifying Control Module, TWICE Connector. Scheme 53

Identifying Connector H33-3. Scheme 54

Connector H33-4

LHD

Identifying Connector H33-4 (LHD). Scheme 55

RHD

Identifying Connector H33-4 (RHD). Scheme 56

Connector H33-5

LHD

Identifying Connector H33-5 (LHD). Scheme 57

RHD

Identifying Connector H33-5 (RHD). Scheme 58

Identifying Dashboard Harness (Crimp J57). Scheme 59

Identifying Rear Harness (Crimp J112). Scheme 60

Identifying Rear Harness (Crimp J113). Scheme 61

Identifying Grounding Point G2. Scheme 62

Grounding Point G2 Circuit Diagram. Scheme 63

Location: in engine bay on side plate in front of LH wheel housing

Components Connected

COMPONENTS CONNECTED TO GROUNDING POINT G2

The battery is also connected to the gearbox grounding point G25

Identifying Grounding Point G14. Scheme 64

Location: under LH seat on floor behind seat member

COMPONENTS CONNECTED TO GROUNDING POINT G14

Identifying Connected Components Circuit Diagram. Scheme 65

Identifying Grounding Point G24. Scheme 66

Location: under RH seat on floor behind seat member

COMPONENTS CONNECTED TO GROUNDING POINT G24

A. Incremental Components For Left -Hand-Drive Car

INCREMENTAL COMPONENTS FOR LEFT-HAND-DRIVE CAR

B. A. Incremental Components For Right -Hand-Drive Car

INCREMENTAL COMPONENTS FOR RIGHT-HAND-DRIVE CAR (VIA CRIMP J161)

Identifying Grounding Point G25. Scheme 67

Location: in engine bay on gearbox

COMPONENTS CONNECTED TO GROUNDING POINT G25

The redundancy ground from the front left wheel housing is also connected.

Identifying Battery Terminal Circuit Diagram. Scheme 68