Cooling System: Other Saab 9-5 I

To Fit

Note. Make sure that the hose clip on the lower radiator hose is situated as high up as possible, close to the coolant pump connection, when fitting the radiator.

Spray all connectors with Kontakt 61 contact cleaner, part No. 30 04 520.

1. Fit in reverse order.
2. Switch off the A/C or ACC. Fill with coolant to the MAX level. Do not forget to close the drain plug on the radiator first. Refer to «Coolant, 4-cyl.»(ref-212216-S32274313142005122200000) . Close the lid.
3. Start the engine and run unloaded at varying engine speeds until warm and the radiator fan starts.
4. Turn off the engine and top up to the MAX level.
5. Check the oil level in the automatic gearbox and top up as necessary.
6. Switch off the engine.
7. Raise the car.
8. Check for any leakage.
9. Fit the lower front cover.

Note. Check the roundness of the O-rings and change them as necessary.

1. Fit the O-rings. Coat them with Gleitmo 805, part. No. 30 06 442.
2. Fit the oil cooler in reverse order. Fill the it with the recommended motor oil. Tightening torques: Oil cooler pipe, nut: 10 Nm (7.4 lbf ft)
3. When the oil cooler is fitted, start the engine and check for any oil leaks.
4. Switch off the engine and check the oil level after about 5 minutes.

Scheme 29

Scheme 30

Scheme 31

1. Remove the radiator, 4-cyl.
2. Raise the car.
3. Remove the charge air cooler's bracket from the oil cooler.
4. Suspend the oil cooler from the charge air cooler's bracket by means of cable ties.
5. Lower the car to the floor.
6. Undo the hose clips on the charge air cooler's inlet and outlet connections. Remove the hoses. Remove the fasteners securing the charge air cooler to the body.
7. Remove the front grille.
8. Remove the headlamps and direction indicators and set aside.
9. Suspend the capacitor with a cable tie, part No. 83 95 212.
10. Remove the charge air cooler's bracket from the condenser.
11. Lift out the charge air cooler.

Note. Spray the connector with Kontakt 61 contact cleaner, part No. 30 04 520.

Fit in the reverse order. See the tightening torques specified below for direction indicators without screw slots. Check the headlamp alignment.

Tightening torques

Charge air cooler/condenser 8 Nm (6 lbf ft)

Screw for direction indicator, hole fitting 1.5 Nm (1 lbf ft)

Scheme 32

Scheme 33

1. Remove the radiator, V6
2. Undo the hose clips on the charge air cooler's inlet and outlet connections. Remove the hoses.
3. Remove the fasteners securing the charge air cooler to the body.
4. Remove the front grille.
5. Remove the headlamps and direction indicators and set aside.
6. Suspend the capacitor with a cable tie, part No. 83 95 212.
7. Remove the charge air cooler's bracket from the condenser.
8. Lift out the charge air cooler.

Scheme 34

Scheme 35

1. Lift the charge air cooler into position.
2. Attach the charge air cooler's bracket to the condenser. Remove the cable tie holding up the condenser. Tightening torque: 8 Nm (5.9 lbf ft)
3. Fit the headlamps and direction indicators. Check headlamp alignment. Tighten direction indicators without slots carefully. Tightening torque, screw for direction indicator, hole fitting 1.5 Nm (1 lbf ft)
4. Refit the front grille.
5. Fit the fasteners securing the charge air cooler to the body.
6. Connect the charge air cooler's inlet and outlet hoses.
7. Fit the radiator. See «To fit»(ref-212216-S35704662282005122200000) .

Thermostat, 4-cyl.

Scheme 36

Scheme 37

Scheme 38

Scheme 39

1. Open the cap on the expansion tank and release the pressure.
2. Raise the car.
3. Remove the lower front cover.
4. Drain off the coolant.
5. Lower the car to the floor.
6. Loosen the hose clamp on the upper radiator hose mounting at the thermostat housing.
7. Move the hose to one side.
8. Undo the ground connection and bracket for the coolant pipe by the thermostat housing.
9. Slacken the upper bolt for the thermostat housing and remove the lower bolt.
10. Remove the thermostat housing and thermostat.

Scheme 40

Scheme 41

Scheme 42

1. Check and clean the sealing surfaces. Grease the rubber seal lightly with non-acidic vaseline.
2. When fitting the thermostat, ensure that the vent hole is at the top (thermostat marking "TOP").
3. Fit the thermostat housing. Tightening torque: 22 Nm (16.2 lbf ft).
4. Fit the ground cable and the coolant pipe bracket. Apply acid-free vaseline to both sides of the ground connection.
5. Position the upper radiator hose and fit the hose clip on it. Connect the radiator hose.
6. Fill with coolant. Do not forget to close the drain plug on the radiator first. Refer to «Coolant»(ref-212216-S06303401752005122200000) for mixtures. Close the cap.
7. Check for coolant leakage. Start the engine, set the heat to max. and run the engine until warm.
8. Switch off the engine.
9. Check the coolant level.
10. Raise the car.
11. Fit the lower front cover.

Thermostat, V6

Scheme 43

Scheme 44

Scheme 45

Scheme 46

Scheme 47

1. Open the cap on the expansion tank and release the pressure.
2. Raise the car.
3. Remove the lower front cover.
4. Drain the coolant from the radiator.
5. Lower the car to the floor.
6. Remove the upper engine cover.
7. Remove the upper intake manifold.
8. Remove the middle intake manifold.
9. Remove the lower intake manifold.
10. Remove the mass air flow sensor and hose.
11. Detach the turbo's intake pipe and move it towards the charge air cooler. Also detach the turbo bypass pipe and the connection to the crankcase breather pipe.
12. Remove the dipstick and the pipe going to the thermostat.
13. Remove the thermostat and thermostat housing.

Scheme 48

Scheme 49

Scheme 50

Scheme 51

Scheme 52

1. Check and clean the sealing surfaces.
2. Fit a new O-ring to the thermostat and its connecting pipe. Coat the O-ring with a little non-acidic vaseline to facilitate assembly.
3. Fit the thermostat and its connecting pipe. Tightening torques: Thermostat: 20 Nm (14.7 lbf ft)
4. Fit the dipstick.
5. Fit the turbo intake pipe. Also fit the turbo bypass pipe and the crankcase breather pipe connection. Tightening torques: Turbo/intake pipe, V-clamp: 3 Nm (2.2 lbf ft) Bypass pipe/intake pipe, bolt: 8 Nm (5.9 lbf ft) Bypass pipe, hose clip: 8 Nm (5.9 lbf ft) Crankcase breather pipe: 24 Nm (17.7 lbf ft)
6. Fit the mass air flow sensor and hose.
7. Fit the lower intake manifold. Check the O-ring and coat it with non-acidic vaseline. Tightening torque: 20 Nm (14.7 lbf ft).
8. Fit the middle intake manifold. Tightening torque: 20 Nm (14.7 lbf ft).
9. Fit the upper intake manifold, using a new gasket. Tightening torque: 20 Nm (14.7 lbf ft).
10. Fill with coolant. Do not forget to close the drain plug on the radiator first. Refer to «Coolant»(ref-212216-S06303401752005122200000) for mixtures.
11. Vent the cooling system as follows: Fill the system to the MAX level, close the expansion tank filler cap, start the engine and warm it up at varying speeds until the radiator fan starts. Open the expansion tank filler cap and fill up again to the MAX level. Close the cap and run the engine at varying throttle openings until the radiator fan has started three more times. Switch off the engine and top up as necessary to the MAX level. NOTE: The A/C should be OFF.
12. Raise the car.
13. Check for any leakage.
14. Fit the lower front cover.
15. Lower the car to the floor.
16. Fit the upper engine cover.

Coolant, 4-cyl.

Scheme 53

Scheme 54

1. Open the cap on the expansion tank and release the pressure.
2. Raise the car.
3. Remove the lower front cover.
4. Open the drain cock on the radiator and drain off the coolant.
5. Close the cock.
6. Lower the car to the floor.
7. Switch off the A/C or ACC. Fill with coolant to the MAX level. Do not forget to close the drain plug on the radiator first. Refer to «Coolant»(ref-212216-S06303401752005122200000) for mixtures. Close the lid.
8. Start the engine and run unloaded until warm at varying engine speeds until the radiator fan starts.
9. Turn off the engine and top up to the MAX level.
10. Fit the lower front cover.

Coolant, V6

Scheme 55

Scheme 56

1. Open the cap on the expansion tank and release the pressure.
2. Raise the car.
3. Remove the front lower cover.
4. Open the drain cock on the radiator and drain off the coolant.
5. Close the cock.
6. Lower the car to the floor.
7. Fill with coolant. Do not forget to shut the drain valve on the radiator first. Refer to «Coolant»(ref-212216-S06303401752005122200000) for mixtures.
8. Vent the cooling system as follows: Fill the system to the MAX level and close the lid of the expansion tank. Start the engine and run unloaded until warm at varying engine speeds until the radiator fan starts. Open the lid of the expansion tank and top up to the MAX level. Close the expansion tank lid and let the engine run at varying engine speeds until the radiator fan has started three more times. Switch off the engine and top up as necessary to the MAX level. NOTE: The A/C should be OFF.
9. Raise the car.
10. Fit the lower front cover.
11. Lower the car to the floor.

Expansion tank, 4-cyl.

Scheme 57

Scheme 58

Scheme 59

1. Open the cap on the expansion tank and release the pressure. Close the cap.
2. Remove the cover.
3. Remove the battery cover, undo the minus and plus cable terminals and remove them from the battery.
4. Remove the battery.
5. Remove the expansion tank bracket on the suspension strut.
6. Move the tank forwards. Unplug the connector on the expansion tank's level sensor.
7. Undo the clip securing the relay box's wiring harness at the battery holder.
8. Lift the expansion tank. Pull out the lower hose between the wiring harness and battery holder.
9. Clamp the hoses connected to the expansion tank using pinch-off pliers, part No. 30 07 739.
10. Move the expansion tank forwards and drain its contents into a suitable receptacle.
11. Undo the hose clips on each hose. Remove the hoses.
12. Lift out the expansion tank.

Note. Spray the connector with Kontakt 61 contact cleaner, part No. 30 04 520.

1. Fit in reverse order.
2. Fill with coolant. Refer to «Coolant»(ref-212216-S06303401752005122200000) for mixtures. Close the cap.
3. Start the engine and run until warm with the heater control at maximum.
4. Check the coolant level. Top up as necessary.
5. Reset the clock and radio, if fitted.

Expansion tank, V6

Scheme 60

Scheme 61

Scheme 62

1. Open the cap on the expansion tank and release the pressure. Close the cap.
2. Remove the expansion tank cover.
3. Remove the battery cover, undo the minus and plus cable terminals and remove them from the battery.
4. Remove the battery.
5. Remove the expansion tank bracket on the suspension strut.
6. Move the tank forwards. Unplug the connector on the expansion tank's level sensor.
7. Undo the clip securing the relay box's wiring harness at the battery holder.
8. Lift the expansion tank. Pull out the lower hose between the wiring harness and battery holder.
9. Clamp the hoses connected to the expansion tank using pinch-off pliers.
10. Move the expansion tank forwards and drain its contents into a suitable receptacle.
11. Undo the hose clips on each hose. Remove the hoses.
12. Lift out the expansion tank.

Scheme 63

Note. Spray the connector with Kontakt 61 contact cleaner, part No. 30 04 520.

Scheme 64

Scheme 65

1. Lift the expansion tank into position.
2. Fit the hose clips on their respective hoses. Remove any clips from connecting hoses.
3. Run the lower hose between the wiring harness and battery holder.
4. Fit the clip securing the relay box's wiring harness at the battery holder.
5. Move the tank forwards and plug in the connector for the expansion tank's level sensor.
6. Fit the expansion tank bracket on the suspension strut.
7. Fit the battery.
8. Connect the minus and plus cable terminals to the battery and fit the battery cover.
9. Fit the expansion tank cover.
10. Fill with coolant. Refer to «Coolant»(ref-212216-S06303401752005122200000) for mixtures. Close the cap.
11. Start the engine and run until warm with the heater control at maximum.
12. Check the coolant level. Top up with coolant as necessary.
13. Reset the clock and radio, if fitted.

Radiator fan, 4-cyl

Scheme 66

Scheme 67

1. Remove the bypass pipe and valve. NOTE: There is an O-ring at the bypass pipe's attachment to the turbo intake pipe.
2. Unplug the radiator fan's connectors.
3. Loosen the clip holding the cooling system vent hose. On cars with automatic transmission, also remove the pipes mounted on the fan cowling.
4. Undo the radiator fan retaining bolts.
5. Unhook the radiator fan's lower hooks and raise the fan slightly.
6. Move the fan slightly to one side and twist the corner up.

Note. Spray the connectors with Kontakt 61, part no. 30 04 520.

Fit in reverse order.

Tightening torques

Bypass pipe/intake pipe, bolt: 8 Nm (5.9 lbf ft)

Bypass pipe, hose clip: 8 Nm (5.9 lbf ft)

Radiator fan: 8 Nm (5.9 lbf ft).

Radiator fan, V6

Scheme 68

Scheme 69

Scheme 70

Scheme 71

1. Remove the upper engine cover.
2. Remove the bypass pipe and valve. Undo the vacuum hose on the turbo bypass valve. NOTE: There is an O-ring at the bypass pipe's attachment to the turbo intake pipe.
3. Unplug the connector from the temperature/pressure sensor on the charge air pipe.
4. Undo the charge air pipe from the throttle body, raise the car.
5. Detach the charge air pipe from the charge air cooler leaving the clip to hang on the cooler.
6. Lower the car and remove the charge air pipe.
7. Remove the heat shield over the front exhaust manifold.
8. Undo the air connection to the SAI valve by pressing together the clip and pulling it back. .
9. Remove the SAI pipe from the front exhaust manifold.
10. Remove the mass air flow sensor and hose.
11. Remove the turbo intake pipe.
12. Unplug the fan motor connectors.
13. Remove the radiator fan.

Note. Spray the connectors with Kontakt 61, part no. 30 04 520, before connecting.

Scheme 72

Scheme 73

Scheme 74

Scheme 75

1. Fit the radiator fan. Tightening torque: 8 Nm (5.9 lbf ft)
2. Plug in the fan motor connectors.
3. Fit the SAI pipe with new gaskets to the front exhaust manifold.
4. Fit the hose connection to the valve, check the connection.
5. Fit the heat shield over the front exhaust manifold.
6. Fit the charge air pipe.
7. Raise the car.
8. Fit the charge air pipe to the charge air cooler with the clip.
9. Lower the car to the floor.
10. Fit the charge air pipe to the throttle body.
11. Plug in the connector for the temperature/pressure sensor on the charge air pipe.
12. Fit the turbo intake pipe. Tightening torques: Turbo/intake pipe, V-clamp: 3 Nm (2.2 lbf ft) Crankcase breather pipe: 24 Nm (17.7 lbf ft)
13. Fit the mass air flow sensor and hose.
14. Fit the bypass pipe with valve using a new O-ring for the connection to the turbocharger inlet pipe.
15. Fit the upper engine cover.

Scheme 76

Scheme 77

1. Remove the radiator fan; see «RADIATOR FAN, 4-CYL»(ref-212216-S20653718602005122200000) or «RADIATOR FAN, V6»(ref-212216-S15912938322005122200000)
2. Undo the fan cowl fasteners (snap up).
3. Release the connector from the clip using a screwdriver.
4. Undo the screws holding the fan motor.
5. Lift out the motor and fan blades.

Note. Spray the connectors with Kontakt 61, part no. 30 04 520, before connecting.

Fit in reverse order.

For refitting the fan, see RADIATOR FAN, 4-CYL or RADIATOR FAN, V6

Coolant pump, 4-cyl.

Scheme 78

Scheme 79

Scheme 80

Scheme 81

Scheme 82

Scheme 83

Scheme 84

1. Open the cap on the expansion tank and release the pressure.
2. Raise the car.
3. Remove the lower front cover.
4. Drain off the coolant.
5. Lower the car to the floor.
6. Unplug the mass air flow sensor connector.
7. Remove the air hose and mass air flow sensor.
8. Off-load the multigroove V-belt using the pull bar, part no. 83 95 254.
9. Remove the belt from the power steering pump and water pump.
10. Remove the crankcase breather pipe, fastened to the turbo intake pipe, and the camshaft cover.
11. Unplug the boost pressure control valve connector.
12. Remove the engine lifting eyelet.
13. Loosen the hoses to the turbo's wastegate valve.
14. Remove the bypass pipe with valve. NOTE: There is an O-ring at the bypass pipe's attachment to the turbo intake pipe.
15. Remove the exhaust manifold heat shield. The heat shield is attached with a nut and two clips on the underside.
16. Undo the quick-release coupling on the vent hose, using tool 83 95 261.
17. Remove the turbo intake pipe.
18. Remove the intake pipe.
19. Plug the turbo inlet using a plastic plug or the like.
20. Undo the power steering pump.
21. Move the power steering pump aside.
22. Remove the hose clips and hoses on the coolant pump inlet.
23. Detach the two longitudinal coolant pipes from the engine block.
24. Detach the two longitudinal coolant pipes from the coolant pump.
25. Slacken the bolt (by the turbo) securing the coolant pipe from the coolant pump.
26. Remove the coolant pipe from the coolant pump.
27. Undo the coolant pump retaining bolts.
28. Carefully work the pump free from the bracket and from the pump's connecting piece on the engine block.
29. Remove the connecting piece from the engine block and inspect its seals, Change the seals as necessary. IMPORTANT: It is normal for a very small amount of coolant to pass via the coolant pump shaft seal in order to lubricate it.

Scheme 85

Note. Spray the connectors with Kontakt 61 contact cleaner, part No. 30 04 520.

Scheme 86

Scheme 87

Scheme 88

Scheme 89

Scheme 90

1. Fit the connecting piece to the engine block. Coat seals with Gleitmo 805, part. No. 30 06 442.
2. Fit the coolant pump. Tightening torque: 22 Nm (16.2 lbf ft)
3. Fit and tighten the coolant pipe to the coolant pump and by the turbo. Tightening torques: Banjo bolt, turbo: 25 Nm (18.4 lbf ft)
4. Fit the two longitudinal coolant pipes to the coolant pump. Tightening torque: 10 Nm (7.4 lbf ft)
5. Fit the two longitudinal coolant pipes to the engine block.
6. Fit the hose clips and hoses to the coolant pump inlet.
7. Fit the power steering pump. Tightening torque: 24 Nm (17.7 lbf ft)
8. Extract the plug from the turbo inlet and then fit the intake pipe. Tightening torques: V-clamp: 3 Nm (2 lbf ft)
9. Reconnect the vent hose.
10. Fit the exhaust manifold heat shield. Tightening torque: 20 Nm (15 lbf ft)
11. Fit the bypass pipe and valve. Tightening torques: Bypass pipe/intake pipe, bolt 8 Nm (6 lbf ft) Bypass pipe, hose clip 8 Nm (6 lbf ft) NOTE: Fit a new O-ring at the bypass pipe mounting to the turbo intake pipe.
12. Fit the hoses to the turbo's wastegate valve.
13. Fit the engine lifting eye.
14. Plug in the boost pressure control valve connector.
15. Fit the crankcase breather pipe, fastened to the turbo intake pipe, and the camshaft cover. Tightening torques: Crankcase breather pipe 24 Nm (18 lbf ft)
16. Fit the multigroove V-belt and tension it with the belt tensioner. Use the pull bar part no. 83 95 254.
17. Fit the air hose and mass air flow sensor.
18. Plug in the mass air flow sensor connector.
19. Switch off the A/C or ACC. Fill with coolant to the MAX level. Refer to «Coolant»(ref-212216-S06303401752005122200000) for mixtures. Do not forget to close the drain plug on the radiator first. Close the expansion tank lid.
20. Start the engine and run unloaded until warm at varying engine speeds until the radiator fan starts.
21. Turn off the engine and top up to the MAX level.
22. Inspect the system for possible leaks.
23. Raise the car.
24. Fit the lower front cover.
25. Lower the car to the floor.

Coolant pump, V6

Scheme 91

Scheme 92

Scheme 93

Scheme 94

1. Open the cap on the expansion tank and release the pressure.
2. Raise the car.
3. Remove the lower front cover.
4. Drain the coolant from the radiator.
5. Lower the car to the floor.
6. Lift the engine using a jack, for example, until the right-hand engine mounting is offloaded. IMPORTANT: Be sure to use spacers between the jack and oil sump when lifting the engine. The spacers distribute the pressure on the sump
7. Remove the mass air flow sensor and hose.
8. Remove the power steering hose from the holder.
9. Remove the right-hand engine mounting with the bracket and mounting.
10. Undo the coolant pump pulley bolts and the power steering pump pulley bolts.
11. Slacken the multigroove belt.
12. Remove the coolant pump pulley and power steering pump pulley.
13. Remove the belt tensioner.
14. Remove the timing cover.
15. Remove the coolant pump.

Scheme 95

Note. Spray the connectors with Kontakt 61, part no. 30 04 520, before connecting.

Scheme 96

Scheme 97

Scheme 98

1. Clean the sealing surfaces and fit the coolant pump with a new O-ring. Tightening torque: 25 Nm (18 lbf ft)
2. Fit the timing cover.
3. Fit the belt tensioner. Tightening torque: 40 Nm (30 lbf ft)
4. Fit the coolant pump pulley and power steering pump pulley. Do not tighten the bolts. Use Loctite, part No. 74 96 292.
5. Fit the multigroove belt.
6. Tighten the belt pulleys. Tightening torques: Belt pulley, coolant pump 8 Nm (6 lbf ft) Belt pulley, power steering pump 20 Nm (15 lbf ft)
7. Fit the right-hand engine mounting with bracket and mounting. Lower the engine and tighten the engine mounting on to the bracket.
8. Fit the power steering hose to the holder.
9. Fit the mass air flow sensor.
10. Fill with coolant. Do not forget to close the drain plug on the radiator first. Refer to «Coolant»(ref-212216-S06303401752005122200000) for mixtures.
11. Vent the cooling system as follows: Fill the system to the MAX level and close the lid of the expansion tank. Start the engine and run unloaded until warm at varying engine speeds until the radiator fan starts. Open the lid of the expansion tank and top up to the MAX level. Close the expansion tank lid and let the engine run at varying engine speeds until the radiator fan has started three more times. Switch off the engine and top up as necessary to the MAX level. NOTE: A/C or ACC must be switched OFF.
12. Raise the car.
13. Check for any leakage.
14. Fit the lower front cover.
15. Lower the car to the floor.

Scheme 99

Scheme 100

Scheme 101

Scheme 102

Scheme 103

Scheme 104

Scheme 105

Scheme 106

Scheme 107

Scheme 108

Scheme 109

Scheme 110

Scheme 111

Scheme 112

Scheme 113

Scheme 114

Scheme 115

Scheme 116

Scheme 117

Scheme 118

Scheme 119

Scheme 120

Scheme 121

Scheme 122

Scheme 123

Scheme 124

Scheme 125

Scheme 126

Scheme 127

Location: In the engine bay on the side panel in front of the left-hand wheel housing

Connected Components

CONNECTED COMPONENTS

Scheme 128

Scheme 129

Location: In passenger compartment on left-hand side of knee member.

A. Connected Components In LHD Car

LHD CAR CONNECTED COMPONENTS

B. Connected Components In RHD Car

RHD CAR CONNECTED COMPONENTS

Scheme 130

Scheme 131

Location: On right-hand side of knee member

LHD CAR CONNECTED COMPONENTS

RHD CAR CONNECTED COMPONENTS

Conditions

The control module output is monitored and a diagnostic trouble code generated for

1. Shorting to ground/open circuit.
2. Shorting to battery positive (B+).

The control module output is monitored and a diagnostic trouble code generated for

1. Shorting to ground/open circuit.
2. Shorting to battery positive (B+).

The control module output is monitored and a diagnostic trouble code generated for

1. Shorting to ground/open circuit.
2. Shorting to battery positive (B+).

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, DICE

For more information about DICE Tech 2 structure, see B1100 , B2195 , and DICE .

The DICE can be programmed for either one radiator fan or two radiator fans.

TECH 2 MENU STRUCTURE (DICE)

Scheme 132

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 133

1. Check 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.
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.

Scheme 134

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.

Scheme 135

Scheme 136

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.

Scheme 137

Scheme 138

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.

Scheme 139

Scheme 140

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.

Coolant

COOLANT TECHNICAL DATA

Temperature/pressure limits

TEMPERATURE/PRESSURE LIMITS

List of lubricants

LUBRICANTS LIST

Scheme 141

Components

1. Radiator
2. Coolant reservoir
3. Coolant pump
4. Engine
5. Thermostat housing
6. Heat exchanger, cabin
7. Throttle body
8. Turbocharger
9. Oil cooler (aut. only)
10. Engine temperature sensor
11. Shut-off valve
12. Radiator fan

Scheme 142

1. Coolant pump
2. Engine
3. Thermostat
4. Radiator
5. Heat exchanger, cabin
6. Expansion tank
7. Electric pump
8. Oil cooler
9. Throttle body
10. Shut-off valve
11. Turbo
12. Radiator fan

Scheme 143

Thermostat closed

From the coolant pump - via a passage into the engine block - up through the cylinder head - through the thermostat housing's lower outlet - through the hose to the heat exchanger - through the return hose from the heat exchanger - back to the pump.

With the thermostat normally open (1)

From the coolant pump - via a passage into the engine block - up through the cylinder head - through the thermostat housing's upper outlet (past the thermostat) - through the radiator - back to the pump.

A small quantity of coolant passes through the thermostat's lower outlet to the heat exchanger and back to the coolant pump.

With the thermostat fully open (2)

The thermostat closes the lower passage through the thermostat housing thus forcing the full flow of coolant through the radiator.

Scheme 144

From the coolant pump - via a passage into the engine block - up through the cylinder heads - through the thermostat housing's lower outlet - through the hose to the heat exchanger - through the return hose from the heat exchanger - back to the pump.

From the coolant pump - via a passage into the engine block - up through the cylinder heads - via the bypass passage - back to the pump.

Scheme 145

With the thermostat normally open

From the coolant pump - via a passage into the engine block - up through the cylinder heads - through the thermostat housing's upper outlet (past the thermostat) - through the radiator - back to the pump.

A small quantity of coolant passes through the thermostat's lower outlet to the heat exchanger and back to the coolant pump.

With the thermostat fully open

The thermostat closes the lower passage through the thermostat housing thus forcing the full flow of coolant through the radiator.

Scheme 146

Scheme 147

Cars without A/C are fitted with one electric fan mounted behind the radiator. The fan has two speeds, high and low.

The fan is controlled by the DICE system through the following input signal

1. Coolant temperature (bus from TRIONIC)

The radiator fan is activated when the coolant temperature is the same as or higher than the preprogrammed value (low/high speed).

The DICE unit receives information on the coolant temperature via the bus.

Scheme 148

Scheme 149

Cars with A/C are fitted with two electric fans mounted behind the radiator. The fans have two speeds, high and low.

The fans are controlled by the DICE unit via the following input signals

1. Coolant temperature (bus from TRIONIC)
2. A/C pressure
3. Car speed (bus from MIU)
4. Outside temperature (bus from SID)

The radiator fans start in the following cases

Scheme 150

1. When coolant temperature reaches 100°C the fans start at low speed. If the temperature rises to 113°C they start running at high speed.
2. When the A/C compressor is activated, the fans start running at low speed in one of the following cases: Outside temperature higher than 22°C Vehicle speed below 38 km/h and A/C pressure between 9 and 18 bar.
3. When the A/C compressor is activated, the fans start running at high speed if A/C pressure exceeds 18 bar. The DICE receives information on the coolant temperature via the bus. The pressure in the A/C system is obtained via its own pressure sensor.

Scheme 151

The radiator fan can be run at two speeds, depending on the coolant temperature

1. Low speed
2. High speed

The radiator fan is controlled by the DICE system via two relays, (155) and (81).

Irrespective of the ignition switch position, power is supplied via fuse 15 to the low speed relay (155).

1. Low speed The DICE applies the value of the coolant temperature which meets the conditions for low speed. The relay (155) is then grounded via pin 35 of the control unit. Power is supplied to the radiator fan which starts running at low speed because the current is reduced by a series resistor (367).
2. High speed The DICE applies the value of the coolant temperature which meets the conditions for high speed. The relay (81) is then grounded via pin 53 of the control unit which means that the radiator fan is grounded directly. Relay (155) is still in the operated state. The radiator fan now runs at high speed.

Scheme 152

The radiator fans can be run at two speeds, depending on coolant temperature, A/C pressure, car speed and outside temperature

1. Low speed
2. High speed

The radiator fans are controlled by the DICE system via three relays: (155), (81) and (396).

Irrespective of the ignition switch position, power is supplied via fuse 15 to relay (155) and relay (81) for low speed running.

1. Low speed, only relay (155) operated The DICE applies the values which meet the conditions for low speed. The relay (155) is then grounded via pin 35 of the control unit. Power is supplied to both radiator fans via relays (155) and (81). The radiator fans start running at low speed because the current is reduced as a result of them being connected in series.
2. High speed, all relays operated The DICE applies the values which meet the conditions for high speed. The relay (81) is then grounded via pin 53 of the control module, which means that the left-hand radiator fan (37 LH) is grounded directly and relay (155) is still in the operated state. Power is then supplied direct to the left-hand radiator fan (37LH) which starts running at high speed. Relay (396) is grounded at the same time, which means that the right-hand radiator fan (37RH) is supplied with power separately and starts running at high speed. The radiator fans are thus connected in parallel.

Two Radiator Fans (Cars With A/C)

1. Coolant temperature (bus from TRIONIC)
2. A/C pressure
3. Car speed (bus from MIU)
4. Outside temperature (bus from SID)
5. A/C system status (active/inactive)

The information is used in the DICE to determine whether the radiator fan/fans should be started or stopped.

To maintain idling speed constant, the DICE sends information on the estimated current consumption to the engine management system via the bus. The information is send 0.1 seconds before the DICE starts or stops the radiator fan/fans. The estimated maximum current consumption of the radiator fan/fans is

One radiator fan (cars without A/C)

1. 15 A, low speed
2. 23 A, high speed

Two radiator fans (cars with A/C)

1. 9 A, low speed
2. 37 A, high speed

When the conditions for high speed are fulfilled, low speed should be active for 2 seconds before high speed is activated. If high speed is active and the conditions for stopping both low speed and high speed are fulfilled, high speed is stopped immediately and low speed is stopped after 2 seconds.

Note. High speed cannot be activated until 15 seconds after the ignition has been turned on.

Radiator fan does not run when ignition is turned from ON to OFF

30 seconds after ignition OFF

1. The radiator fan starts and runs for 3 minutes if the coolant temperature is 107°C or above. After 3 minutes the fan stops.
2. The radiator fan starts and runs for 30 seconds if the coolant temperature is between 103°C and 107°C.

1 minute after ignition OFF (only if coolant temperature was between 103°C and 107°C 30 seconds after ignition OFF)

1. The radiator fan continues to run for 3 minutes if the coolant temperature is 107°C or above.
2. The radiator fan stops if the coolant temperature is below 107°C.

The radiator fan runs at low speed when ignition is turned from ON to OFF

1. The radiator fan continues to run for 30 seconds if the coolant temperature is 103°C or above.
2. The radiator fan stops if the coolant temperature is below 103°C.

30 seconds after ignition OFF

1. If the radiator fan did not stop when the ignition was turned OFF, it will continue to run for 3 minutes if the coolant temperature is 107°C or above. After 3 minutes the fan will stop. If the coolant temperature is below 107°C the fan will stop.
2. If the radiator fan stopped when the ignition was turned OFF, it will start and run for 3 minutes if the coolant temperature is 107°C or above. After 3 minutes the fan will stop. If the coolant temperature is between 103°C and 107°C, the fan will start and run for 30 seconds. If the coolant temperature is below 103°C the fan will stop.

1 minute after ignition OFF (only if coolant temperature was between 103°C and 107°C 30 seconds after ignition OFF)

1. The radiator fan continues to run for 3 minutes if the coolant temperature is 107°C or above.
2. The radiator fan stops if the coolant temperature is below 107°C.

The radiator fan runs at high speed when ignition is turned from ON to OFF

Immediately after ignition is turned OFF the radiator fan will start and run at low speed for 2 seconds. After these 2 seconds the same logic applies as when the fan runs at low speed when ignition is turned from ON to OFF

Scheme 153

Scheme 154

The radiator fans have two speeds, high and low.

The fans are controlled by the DICE unit via the following input signals

1. Coolant temperature (bus from TRIONIC)
2. A/C pressure
3. Car speed (bus from MIU)
4. Outside temperature (bus from SID)

The radiator fans start in the following cases

Scheme 155

1. When coolant temperature reaches 97°C the fans start at low speed. If the temperature rises to 107°C they start running at high speed.
2. When the A/C compressor is activated, the fans start running at low speed in one of the following cases: Outside temperature higher than 22°C Vehicle speed below 38 km/h and A/C pressure between 9 and 18 bar.
3. When the A/C compressor is activated, the fans start running at high speed if A/C pressure exceeds 18 bar.

The DICE receives information on the coolant temperature via the bus. The pressure in the A/C system is obtained via its own pressure sensor.

Scheme 156

The radiator fans can be run at two speeds, depending on coolant temperature, A/C pressure, car speed and outside temperature

1. Low speed
2. High speed

The radiator fans are controlled by the DICE system via three relays: (155), (81) and (396).

Irrespective of the ignition switch position, power is supplied via fuse 15 to relay (155) and relay (81) for low speed running.

1. Low speed, only relay (155) operated

The DICE applies the values which meet the conditions for low speed.

The relay (155) is then grounded via pin 35 of the control unit.

Power is supplied to both radiator fans via relays (155) and (81). The radiator fans start running at low speed because the current is reduced as a result of them being connected in series.

1. High speed, all relays operated

The DICE applies the values which meet the conditions for high speed.

The relay (81) is then grounded via pin 53 of the control module, which means that the left-hand radiator fan (37 LH) is grounded directly and relay (155) is still in the operated state.

Power is then supplied direct to the left-hand radiator fan (37LH) which starts running at high speed. Relay (396) is grounded at the same time, which means that the right-hand radiator fan (37RH) is supplied with power separately and starts running at high speed. The radiator fans are thus connected in parallel.