SAAB WIS ONLINE

(321-2663) Battery care

Symptom: The battery is discharged. The battery does not respond to recharging. The battery analyser advises "Charge & test" or "Replace battery".

TECHNICAL SERVICE BULLETIN
Bulletin Nbr: 321-2663
Date: ........... April 2007
Market: ej US/CA
Battery care

This bulletin provides information on battery care and takes effect immediately.

WIS edition 2007-2 will contain this information.

Note

The accompanying methods have also been reported for purposes other than battery care.


Cars affected

Saab 9-5

Background

If a battery is left without maintenance for long periods, its degree of charge will gradually decrease. The rate at which the degree of charge decreases depends mainly on how much current is being used by the car's electrical system. There is a certain amount of self-discharge even when the battery has been disconnected. This increases with rising temperatures.

If a battery is left with a degree of charge that is too low for a longer period then a chemical process starts where the battery acid is gradually converted into water and the battery plates start to corrode (sulphate). This corrosion process starts to become critical if the battery is left for approx. 2 weeks with a degree of charge below 65-75 % (equivalent to an unloaded battery voltage of less than approx. 12.4 volts).

The damage that is then caused is permanent and cannot be remedied with normal battery recharging. As a result, the capacity and service life of the battery will be permanently impaired.

The purpose of this TSB is to prevent this type of damage to the battery arising, and so to enable an increase in the service life of the battery, and above all, to be able to ensure that the customer has a satisfactory battery.

To enable this, the following methods have been changed/added:


1. Pre-delivery inspection

2. Storage care

3. Delivery service

4. Battery check

5. Transport mode/customer mode of car's electrical system


Symptom description

The battery is discharged.

The battery does not respond to recharging.

The battery analyser advises "Charge & test" or "Replace battery".



Parts required

Not affected.

Procedure

Carry out/update handling as per the following instructions.

Underlined text symbolises links to other instructions found in this bulletin or in WIS. WIS instructions not attached are not affected by this bulletin.

1. Pre-delivery inspection

Pre-delivery inspection of a new car is mandatory for all Saab cars.

Carry out the checks and confirm the inspection by signing the Pre-delivery inspection form .

A new car is to be inspected immediately after reception. The receiver is responsible for ensuring that faults and deviations are reported as described in applicable routines.


1. Check that the car's specification matches the order form. This also applies to optional equipment.

2. Check the underbody for transport damage.

3. Check that the car's spare wheel/repair kit and tools are present.

4. Check that accompanying material is present.

5. Carry out a battery check .

6. Clean the car for paintwork and damage inspection. If you clean away dust and dirt with a strongly alkaline cleaning agent, it could affect the paintwork. Keep chemical usage to the bare minimum for this cleaning.

Cars with paint protection plastic: If there has been damage to the paint protection, remove it to examine the damage. Then store the car, preferably under a roof.

7. Check the car for damage both inside and out.

8. Note and report any damage and other observations.


Action if the car will be stored




1. Check and if necessary adjust tyre pressure to 3.5 bar (50 psi).

2. If the car is stored in an ambient temperature greater than +20°C (69°F), fuel should be filled to min 2/3 tank. Otherwise, there is a risk of fuel pump malfunction due to oxidation.

3. Open the bonnet.


Additional action if the car will be stored outdoors




1. Check the coolant level and anti-freeze content. The coolant should handle at least -30°C (-22°F). It then also provides maximum corrosion protection. For certain climates, the mixture must handle lower temperatures. Top up as necessary following the specification.

2. If the car's paint protection plastic has been removed, the car must be stored under a roof.

3. Drive the car to the parking area. While doing so, brake repeatedly very briefly so that the brake discs become clean and dry.

4. Make sure:

• The parking brake lever is released to its home position.

• Manual gearbox: Reverse gear engaged.

• Automatic transmission: Gear selector in P.

• All windows, doors and the boot lid/tailgate are properly closed.

5. Check the protective plastic on the seats and correct as necessary.

6. Lock the car.


2. Storage care

Storage care is mandatory for all Saab cars with intervals of no more than 60 days until the car is sold.

The check intervals for the battery are no more than 30 days. Check the battery card to see when the last battery check was performed. Follow the procedure under Battery check .

If the car is locked and the car's electrical system is in transport mode, only the left front door can be unlocked using the metal key.

Carry out the checks and confirm the inspection by signing the Storage care form .

See workshop information and routines for the remedying of faults.

Check and action points


1. Check that the paint protection plastic is intact. If there has been damage to the paint protection plastic, remove it to examine the damage. Then store the car under a roof.

2. Unlock the car.

Note

Since the car's electrical system is in transport mode, the car can only be unlocked manually. The left front door is unlocked with the metal key.


3. Carry out a battery check .

4. Fill the fuel up to min 2/3 tank to prevent dry running of the fuel pump.

5. Check the engine oil. If the oil is thick or contains clumps, the oil and oil filter must be replaced.

6. Check and if necessary adjust tyre pressure to 3.5 bar (50 psi).

7. Check the coolant level.

8. Drive the car at least 200 metres. While doing so, brake repeatedly very briefly so that the brake discs become clean and dry.

9. Park the car facing the opposite direction to distribute the effects of the sun.

10. Open the bonnet to enable the engine to cool more quickly.

11. Check the protective plastic on the seats and correct as necessary.

12. Make sure:

• The parking brake lever is released to its home position.

• Manual gearbox: Reverse gear engaged.

• Automatic transmission: Gear selector in P.

• All windows, doors and the boot lid/tailgate are properly closed.

13. Lock the car.

14. Check the engine bay for the start of corrosion, particularly on the aluminium.

Treat as necessary with 30 15 914 Protective wax . Apply a covering wax film without excess.

15. Close the bonnet.


3. Delivery service

The material needed for delivery service if packed in the car's glove box and luggage compartment.


1. Unlock the car.

Note

Since the car's electrical system is in transport mode, the car can only be unlocked manually. The left front door is unlocked with the metal key.


2. Cars with sports chassis: Remove the transport supports from the suspension.

3. Remove the transport guards from the brake discs (certain markets).

4. Retighten screwed joints .

5. Carry out a battery check .

6. Adjust tyre pressure (including spare tyre).

7. Cars with steel rims: Fit hubcaps.

8. Check the level and top up the following fluids:

• Washer fluid

• Engine oil, gearbox oil and power steering fluid

• Coolant, brake fluid and clutch fluid

9. Remove the protection from the following in the interior :

• Seats

• Rear seat

• Gear lever/gear selector

• Steering wheel

• Floor

• Door trim on driver's side

• Front sills

• Bottom part of dashboard

• Cars with navigation system: Navigation unit display.

10. Not US/CA: Put extra mats in place.

11. Remove the VIN label from the rear door window.

12. Take the accompanying items from the glove box.

• Not US/CA: Fit cover washers to the driver's door and boot lid/tailgate lock.

• Not US/CA: Affix anti-theft alarm labels .

• SE and FI: Affix child seat label .

• EU: Put the Certificate of Conformity in the Owner's Manual folder.

• Cars with navigation system: Put the map disc in the navigation unit's DVD player.

• Fit the wheel bolt caps .

• Not US, CA and PA: Fit spacer rings and number plate.

13. Activate customer mode (TWICE control module) - see Transport mode/customer mode of car's electrical system .

Note

The transport fuse is packed in the glove box.


14. Carry out Procedures after disconnecting the battery and program SID.

15. Check the functionality of the washer and wiper system .

16. Clear the diagnostic trouble codes in all systems.

17. Test drive the car.

18. SE, US and CA: Check that no diagnostic trouble codes have been detected in the control system for the engine and automatic transmission.

Disconnect the diagnostic tool and refit the cover over the data link connector.

19. Remove the towing eye, close the cover, remove the spare wheel and stow the towing eye in the tool compartment. Refit the spare wheel.

20. Carry out Final removal and finishing measures .


4. Battery check


1. Remove the battery cover.

2. Check the battery electrolyte level. The battery cannot be topped up with electrolyte. It must be replaced if the level is too low.

Note

The electrolyte level is checked through an indicator window on the battery that appears white if the level is too low. If the electrolyte level is sufficiently high, the indicator window appears black.


3. Remove the cover from the fuse box and remove maxi fuse 4.

4. Switch off all current consumers and remove the ignition key from the ignition switch. Wait at least 20 seconds before connecting the battery analyser.

Note

Some diagnostic trouble codes may be generated if the battery check is carried out with the key in the ignition switch.


5. Connect the battery analyser with the red clamp to the positive terminal (+) and the black clamp to the negative terminal (-). Incorrect polarity will not damage the analyser. Make sure that the clamps make as good contact as possible.

Follow the instructions on the analyser display.

Note

Once both clamps are connected, the analyser activates automatically. For a more detailed description on analyser use, see the analyser's user manual.


6. Under "SELECT TEST", you choose whether the battery is connected to the car's electrical system ("IN VEHICLE") or not ("OUTSIDE VEHICLE"). Select ("IN VEHICLE") since the battery is connected to the car.

7. Under "BATTERY TYPE", select whether the battery is factory-fitted ("SAAB BATTERY") or a replacement battery from another manufacturer ("NON-SAAB").

8. Confirm "SELECT TEST BY SAE (A)" if the battery's cold starting current is specified as per CCA (SAE or EN) standard. For batteries specified as per DIN standard, select and confirm "SELECT TEST BY DIN (A)".

Note

The DIN standard can be selected when the analyser is used to test replacement batteries that are not specified according to SAE or EN.


9. Enter the cold starting current for the battery in question (CCA).

For Saab's factory-fitted batteries, this value if found in large text on the label on the top of the battery.

60 Ah = 580 CCA

70 Ah = 700 CCA

85 Ah = 750 CCA

After selecting and confirming the value, battery measurement starts automatically.

Under certain voltage and conductance conditions, the analyser will require information on whether the test is being performed before or after the battery has been charged in order to assess it correctly.

Select "BEFORE CHARGE" or "AFTER CHARGE".

Follow the action suggested by the battery analyser:

• Good battery = Battery is good. No action.

• Good, recharge battery = Battery must be charged, but not replaced.

• Replace battery = Battery must be replaced.

10. Fill in the battery card (applies to pre-delivery inspection, storage care and delivery service).

11. Note the test code if the analyser has indicated that the battery must be replaced within the warranty period. The test code from this measurement must then accompany the warranty claim (for more information, see Warranty policy).

12. Fit maxi fuse 4 and the cover to the fuse box.

13. Fit the battery cover.


5. Transport mode/customer mode of car's electrical system

Because the car's electrical system requires current, there are two different adaptations - transport mode and customer mode.

Transport mode

Minimises the car's current consumption during transport from the factory to the customer. Many customer-oriented functions are then not available, such as central locking, interior lighting and the audio/navigation system. The car is to be removed from this mode only as an exception during the car's handling up until delivery service has been performed. An example of an exception is cars parked in a showroom. If the car is put in customer mode, battery condition must be checked more often.

Function description: Activate transport mode

When maxi fuse 1 (transport fuse) in fuse box 501 is removed, +30 supply is cut off for certain functions, such as central locking, interior lighting and the audio/navigation system.

Upon activation of transport mode with Tech2, the central locking and alarm system functions (which are controlled by TWICE) are disabled.

If the ignition switch is turned to the "Ignition ON" position while the car is in transport mode, certain functions in TWICE are awoken/activated so that the car can be moved safely. When the ignition switch is moved to the "Ignition OFF" position, TWICE automatically goes back to sleep/low energy mode to minimise current consumption.

Activate transport mode

1) Remove the transport fuse from pos 1 in fuse box 501.

2) Connect Tech2 and select Body/TWICE/Adjustments/Transport mode "ON"

Customer mode

All functions (as per car specification) are now available to the customer.

Function description: Activate customer mode

When maxi fuse 1 (transport fuse) is fitted in fuse box 501, current is supplied to all functions in the car.

Upon deactivation of transport mode with Tech2, the central locking and alarm system functions (which are controlled by TWICE) are enabled.

Activate customer mode

1) Fit the transport fuse to pos 1 of fuse box 501.

2) Connect Tech2 and select Body/TWICE/Adjustments/Transport mode "OFF"

Demo/showroom cars

Trickle charging is recommended to prevent battery discharge and damage. The amount of charging should be adapted to current consumption. Too high voltage/current from the charger could damage the battery due to overcharging.

If trickle charging is not possible, the battery must be checked often (depending on current consumption) - a minimum of once a week. Use the standard battery analyser to check battery status.

Warranty/Time Information