SAAB WIS ONLINE

(TA232-0338) Air leak testing, intake system, B207

TECHNICAL ADVICE - Quick information for your help
Bulletin Nbr: TA232-0338
Date: ........... July 2003
Market: All
Air leak testing, intake system, B207

VEHICLES CONCERNED

Saab 9-3 with petrol engine alternative B207 E/L/R, M03-

BACKGROUND

The car may have certain fault symptoms without a diagnostic trouble code being generated. This can be due to an air leak in the intake system.

The following fault diagnosis covers air leak testing of the intake system . If a diagnostic trouble code arises then relevant fault diagnosis must first be used . The following method is supplementary if the fault cannot be located by normal fault diagnosis .

CONDITIONS

The car may have one or more of the following symptoms:


• Poor driveability

• Reduced performance

• Engine has uneven/low idling speed

• Surge or hesitation upon acceleration


Tools and Materials

83 95 659 Plug set with pressure regulator

83 94 595 Plug

83 93 514 Measuring equipment for charge pressure

30 07 739 Pliers for hose clip

M12 bolt or equivalent plug for the crankcase ventilation hose

Leakage (detection) spray or soap solution

Tech 2

ACTION


1. Copy the Checklist in this document in 2 copies. Enter the values from Tech 2 into one of the copies before any action is taken.

2. Remove the upper engine cover in order to uncover the intake system and the throttle.


3. Connect the measuring equipment for charge pressure 83 93 514 via a T-pipe to the hose between the fuel pressure regulator and the intake manifold.


4. Undo the crankcase ventilation hose clamp by the camshaft cover using pliers 30 07 739 and block it with an M12 bolt or other suitable plug.

Caution

Do not plug the hole in the camshaft cover. It must be possible to evacuate the air that leaks past the pistons down in the crankcase during test pressurising out through this hole.


5. Replace the existing plug in kit 83 95 659 with plug 83 94 595. If necessary a new hose clamp must be used in order to keep the hose tight on plug 8394595.


6. Undo the intake hose by the air filter can. Fit plug 83 94 595 in the hose and then connect the pressure regulator to an external compressed air outlet.

Caution

Close the pressure regulator before connecting it to the air pressure outlet.

7. Pressurise the intake system by carefully turning the pressure regulator until the maximum 0.6 bar overpressure is reached. Read the pressure on charge pressure meter 83 93 514.

8. In this way the entire intake system is pressurised and leaks can be located by using leakage (detection) spray or soap solution which will bubble and foam around the leak . Inspect all components, hoses and connections and rectify any audible or visible leaks .

Caution

Only large leaks are of any significance for the functioning of the engine management system. When leakage (detection) spray or soap solution is used small leaks will also be discovered. Several small leaks together can equate to a large leak. Individual very small leaks do not need to be rectified .


9. Remove plug 83 94 595 from the intake hose. Connect the hose to the air filter can.

10. Remove the plug from the crankcase ventilation hose. Connect the hose to the camshaft cover.

11. Remove the charge pressure meter. Connect the hose to the fuel pressure regulator.

12. Fit the upper engine cover.

13. Read out the control module software version (Software Module Identifier #1) in Tech 2. If there is a later software version in TIS2000 then this must be programmed into the control module.

NOTE: If new software is not programmed into the control module then the fuel adaptation must be reset to zero before step 12 is carried out.

14. Perform the fuel adaptation and check it using Tech 2 as follows:

14.A. Switch off the A/C or ACC

14.B. The engine temperature must exceed 80°C and the engine must have been running for at least 3.5 minutes in order that fuel adaptation can be performed.

14.C. Drive on a level road within the engine speed range 1500 - 2750 rpm in 5th, or 4th gear, preferably with the accelerator pedal completely still for approx . 3 minutes.

14.D. Stop the car and allow the engine to run at idling speed for approx . 3 minutes.

14.E. Read "Multiplicative adaptation " on Tech 2.

14.F. Read off "Additive adaptation" on Tech 2.

If the adaptations did not change from 0, switch off and start the engine again and repeat step 14c - 14f.

15. Fill out the second copy of the checklist.

16. Disconnect Tech 2

17. If the problems have not been solved, contact the importer's technical support. Have the checklists that were filled out ready.


Checklist

1 Describe the fault symptom ...................................................................... ...................................................................... ......................................................................
2 Connect Tech 2.
3 Switch off the A/C or ACC and let the engine idle. Coolant temperature must be over 80°C
Note

Diagnostic trouble codes may not be erased.


4 Read and note any diagnostic trouble codes: ...................................................................... ......................................................................
5 Select "Engine" - "Engine management system" - "Read values" in Tech 2. Read and note the following values:
Unit Ignition On Idle Desired value
Engine speed rpm ............ 650 - 900
Air mass/Combustion mg/c ............ 70 - 150
Requested air mass/combustion mg/c ............ 70 - 150
Coolant temperature °C 80 - 100
Intake air temperature °C 20 - 60
Atmospheric absolute pressure kPa 90 - 115
Charge air absolute pressure kPa 90 - 115
Intake manifold absolute pressure kPa 25 - 60
Additive adaptation mg/c ± 1.5
Multiplicative adaptation % ± 10




Number of knockings Number of misfires
Cylinder 1
Cylinder 2
Cylinder 3
Cylinder 4


Under "All" - "ECU Information / System information" - "ECM" there is information on Vehicle Identification Number and software version for Trionic 8.

Chassis number (compulsory)
Software Module Identifier #1 or Software Version (compulsory)
Programming date (compulsory)