Starting System: Other Saab 9-5 I рестайлинг 2

Refitting

Note. Ensure that the guide sleeve is in place in the middle bolt hole of the starter motor.

Scheme 8

Scheme 9

1. Lift the starter motor into place and fit the lower bolt. Tightening torque: 24 Nm (18 lbf ft)
2. Fit the lower engine cover.
3. Lower the car.
4. Fit the starter motor connecting cables.
5. Fit the coolant pipe bracket and the positive cable clamp, fit the nuts.
6. Fit the upper starter motor bolts. Tightening torque: 24 Nm (18 lbf ft)
7. Tighten the bracket nuts.
8. Fit the sound insulation and the upper engine cover.
9. Fit the negative battery cable.
10. Reset the car.

Scheme 10

1. Remove the cover on the battery and the shield on the intake manifold.
2. Disconnect the negative battery cable.
3. Remove the starter motor's upper retaining bolt (18mm).
4. Disconnect the starter motor connecting cables.
5. Raise the car.
6. Cut the strap around the solenoid.
7. Unscrew the starter motor's lower retaining nut.
8. Lower the starter motor and lift it out.

Scheme 11

1. Clean the starter motor mounting surfaces and electrical contacts and apply Vaseline.
2. Screw on the starter motor's retaining nut.
3. Fit a new strap.
4. Lower the car.
5. Clean the starter motor connecting cables, apply Vaseline and reconnect them.
6. Screw on the starter motor's upper retaining bolt.
7. Reconnect the negative cable to the battery.
8. Fit the cover and shield.

Scheme 12

Scheme 13

1. Remove lower panel from driver's side.
2. Unplug the connector from the contact.
3. Cut the cable tie.
4. Press in the catch and pull down the contact.

Scheme 14

Scheme 15

1. Replace the contact.
2. Fit a new cable tie.
3. Plug in the connector.
4. Replace the lower panel on the driver's side.

Scheme 16

1. Starter motor (4)
2. Ignition switch (20)
3. TWICE control module (632)
4. Gear selector, automatic (239/77)
5. Starting relay (517)
6. Immobilizer (463)

Scheme 17

Starter motor

The starter motor is fitted on to the engine block. A solenoid engages a pinion with the ring gear on the engine 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 is activated when the ignition switch is in the 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 sends the "Key correct" message to 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.

Starting interlock contact, clutch pedal

Some cars with manual gearboxes made for the US/CA market are equipped with a contact for the clutch pedal that does not allow the car to be started unless the pedal is in the depressed position.

Scheme 18

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 two sub-circuits

1. the working circuit, and
2. the operating circuit.

Scheme 19

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

Starter motor (4)

4-cyl. petrol

Scheme 20

4-cyl diesel

Scheme 21

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Scheme 24

Main unit, audio system (353)

K14

Scheme 25

K16

Scheme 26

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Scheme 30

Scheme 31

Connector H24-1

4-cyl petrol

Scheme 32

4-cyl diesel

Scheme 33

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Scheme 42

Location: Left-hand structural member behind headlamp (battery ground).

Connected components

BATTERY CHART

Scheme 43

Scheme 44

Location: On seat member under RH seat.

A. Components always connected

WIRING HARNESS COMPONENTS CHART

B. Additional components for LHD car

ADDITIONAL COMPONENTS FOR LHD CAR REFERENCE

C. Additional components for RHD car

ADDITIONAL COMPONENTS FOR LHD CAR REFERENCE

Scheme 45

Scheme 46

Location: On the gearbox.

BATTERY REFERENCE

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

Scheme 47

STARTER MOTOR REFERENCE CHART

Test values

TEST VALUES REFERENCE

Scheme 48

STARTER MOTOR REFERENCE

Test values

TEST VALUES

Scheme 49

See TECH2

Group: Test equipment

SPECIAL TOOL REFERENCE

Scheme 50

Used with ISAT. For measuring large currents, e.g. starter motor current consumption or generator charge current.

Group: Test equipment

SPECIAL TOOL REFERENCE

Scheme 51

Voltage range 8-16V

Group: Test equipment

SPECIAL TOOL REFERENCE

Scheme 52

1. The customer's description of the problem constitutes a basis for the fault diagnosis strategy. If necessary, the customer must demonstrate the trouble on the car to avoid misunderstandings.
2. In certain cases, the function may be correct. 2.a. Good product knowledge is required to decide this. 2.b. If the function is correct, this must be explained to the customer.
3. If the function is judged to be faulty, the car should be repaired. Saab's fault diagnosis strategy assumes that the technician is familiar with the customer's description of the problem. So note the customer's complaint and any other observations on the job sheet.
4. The technician obtains a readout of the diagnostic trouble codes from all systems. A malfunction in one system can often be caused by a fault in another system.
5. The car may contain diagnostic trouble codes which are secondary faults or which have been incorrectly generated. 5.a. Compare the customer complaint with the symptom description for the various diagnostic trouble codes. WIS has a quick search function for this purpose. 5.b. If the symptom description for a diagnostic trouble code matches the customer's complaint, this diagnostic trouble code is probably caused by the primary fault. Repair as per instructions.
6. If there is no match with diagnostic trouble codes or symptoms, the technician must diagnose the fault himself. 6.a. Search in WIS under fault diagnosis for symptoms in the system where the fault exists. Also check whether there is a TSB/MI in force. 6.b. If the symptom description in the current system matches the complaint, the right fault diagnosis description has probably been found. Repair as per instructions.
7. Certain fault symptoms can be remedied by reprogramming the control module. 7.a. Does the customer complaint stem from a known software problem in a programmable control module? 7.b. Reprogram the control module following the instructions in SPS.
8. If there is no match with diagnostic trouble codes or symptoms, the technician must diagnose the fault himself. Good technical product knowledge is required to solve this type of problem.
9. A final check must be carried out after the repair.
10. The car is ready.

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.

The performance of the majority of the actuators can be checked with the diagnostics instrument.

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.

Scheme 53

Scheme 54

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 55

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.
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 56

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 57

Scheme 58

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 59

Scheme 60

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 61

Scheme 62

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.

Scheme 63

Conditions

None.

To check

Check that

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

Scheme 64

Note. See STARTING/CHARGING in SYSTEM WIRING DIAGRAMS (2006) or SYSTEM WIRING DIAGRAMS (2007) and ELECTRICAL COMPONENT LOCATOR (2006) or ELECTRICAL COMPONENT LOCATOR (2007) article.

List of components

COMPONENTS LIST No. Name Location Illustration Components 1 Battery in engine bay - 4 Starter motor on rear long side of engine (left) 20 Ignition switch in floor console between front seats 22a Fuse box, dashboard on the short edge of the instrument panel by the driver's door - 77 Switch, starter motor interlock, automatic gearbox (in 239) in transmission range switch 2 on gearbox 239 Transmission range switch 2, automatic transmission (31,77), on the automatic gearbox in the engine bay 353 Main unit, audio system in centre of dashboard 411 Switch, clutch, starter motor interlock on bulkhead partition by clutch pedal 463 Antenna unit, immobilizer by ignition switch 501 Main fuse box, maxi fuses behind the battery - 517 Relay, starter relay on the main relay board in the dashboard 632 Control module, TWICE under left-hand seat 16-pin connector H16-7 Under maxi-fuse box closest to the engine 24 pin connector H24-1 Grey connector in middle of bulkhead partition (engine compartment side) 80-pin connector H80-1 In the connector console under the A-pillar Crimp connectors J19 Approx. 175 mm from the H24-1 and H24-2 branching point towards the Trionic control module J55 LHD: Approx. 125 mm from branching DICE control module towards the main relay board RHD: Approx. 430 mm from grounding point G42 branching point towards DICE control module J56 LHD: Approx. 20 mm from the branching point of the DICE control module towards the engine bay grommet RHD: Approx. 310 mm from rear of DICE control module connector towards the engine bay J117 Approx. 230 mm from branching point of floor console switch panel towards right seat J235 Approx. 115 mm from branching of wiper motor toward cabin J236 LHD: Approx. 40 mm from branching DICE control module towards the main relay board RHD: Approx. 180 mm from grounding point G42 branching point towards DICE control module Grounding points G2 On the left-hand structural member behind the headlamp (battery ground). - G24 Behind seat member under RH seat - G25 On gearbox (battery ground)

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