(248-2547 utg. 2) New engine variant for E85 fuel
| TECHNICAL SERVICE BULLETIN | |
| Bulletin Nbr: | 248-2547 utg. 2 |
| Date: ........... | Juli 2006 |
| Market: | enl separat lista |
| New engine variant for E85 fuel |
This bulletin advises of a new engine variant and comes into immediate effect. WIS will contain this information.
| Cars affected |
Saab 9-5 M06- with engine variant B205L and B235E (Flex-fuel) with manual and automatic transmission.
| Background |
Saab 9-5 is available with a new engine variant adapted for driving on E85 type fuel which is a mixture of ethanol and petrol. Ethanol is an environmentally friendly fuel, as it adds no new carbon dioxide to the cycle during combustion. The engine variants are the B205L/B235E with Trionic T7 engine management system. The car is available with both manual and automatic transmission.
Workshop information will be integrated into the next WIS disc for the 9-5.
For M06- information on BioPower is integrated into the normal Owner's Manual.
This bulletin is being sent out to more markets than those where Saab has decided to sell BioPower cars. If your market is not one of the allocated markets, please regard this bulletin as purely technical information on Saab BioPower.
| Theory |
E85 is a mixture of 15% petrol and 85% ethanol. Ethanol has the formula C2H5OH and accordingly differs from petrol as it is one substance and not a mixture of several.
E85 has the following properties that distinguish it from pure petrol:
| • |
Lambda 1 is 9.8:1 instead of 14.7:1.
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| • |
Worse evaporation at low temperature.
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| • |
Higher octane rating (104 RON).
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| • |
Faster combustion.
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| • |
Colder exhaust due to greater fuel mass with Lambda 1.
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| • |
Better fuel-air mixture cooling during evaporation.
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| • |
More aggressive against certain metals and plastic/rubber.
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| Adaptation |
Lambda 1 is 9.8:1 instead of 14.7:1
The engine can be run on all fuel mixtures from pure petrol to pure E85. This means that T7 must learn the mixture to be able to calculate the correct injection quantity. The adaptation is conducted by examining the lambda control. If the vehicle is run on pure petrol and then refuelled full with E85, then the lambda control factor is increased because oxygen sensor 1 shows lean with the new leaner fuel. During E85 adaptation the lambda control factor is seen to increase, so we decrease the recalculation factor from 14.7 to a lower value, (minimum 9.8 with pure E85) and increase the injection times in this way until the lambda control works at around 0% again.The E85 adaptation can be seen as a variant of the traditional multiplicative adaptation. The E85 adaptation does not take place continuously but only if refuelling has been detected.
It is therefore very important that the engine is run until it is warm (however at least 5 minutes) following refuelling with another fuel, so that an adaptation is completed. Driving should be calm (lambda controlled). If consideration is not made of this a subsequent cold start could be difficult due to incorrect adaptation.
Hard driving (not lambda controlled) directly after refuelling with another fuel could lead to engine damage as T7 would then adapt fuel quantity and ignition timing according to the incorrect fuel.
Adaptation takes place when one of the following as occurred:
| • |
When refuelling has been detected in one of the following ways:
- The level in the tank is higher than when the ignition was last turned off. - The level in the tank rises when the car has been stationary for more than 1½ minute with ignition turned on. |
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| • |
The level in the tank is below 8 litres and lambda control is outside +/- 10%.
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| • |
If the previous adaptation was discontinued before it was complete due to the ignition being turned off.
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| • |
Following loss off power supply +30 to T7
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| • |
Following clearing of certain diagnostic trouble codes.
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| • |
On command from Tech2.
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The adaptation value is saved in the flash memory for 15 minutes after the ignition has been turned off. This means that refuelling with another fuel followed directly by battery replacement within 15 minutes leads to incorrect adaptation values being used at the next start, which could lead to starting problems. However, after the engine has started running, an adaptation will take place as the +30 power supply has been lost.
Examples that lead to incorrect adaptation value:
| • |
Driving too briefly following refuelling with another fuel (cold engine or less than 5 minutes with warm)
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| • |
Driving too hard following refuelling with another fuel (not lambda controlled)
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| • |
Replacement of tank contents (draining 20 litres of E85 and filling 20 litres petrol, e.g. in connection with pump or tank replacement)
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| • |
Fault in component, e.g. fuel level sensor, oxygen sensor 1 (before catalytic converter), mass air flow sensor or fuel pump
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| • |
Air leakage in the induction system
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| • |
Loss of +30 before adaptation or writing to flash memory has taken place
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| • |
SPS programming (overwriting flash memory) without re-entering the original value following programming
|
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Worse evaporation at low temperature
Starting characteristics in cold are limited by the E85 content in the fuel. Almost no ethanol is evaporated at temperatures below 40°C. Starting at lower temperatures is made possible by means of the proportion of petrol in E85 (15 %). When driving on pure E85 the car starts to become difficult to start at approx. -10°C. Any restarts are normally without problem as ethanol does not form soot on, or acidicly degrade spark plugs as petrol does. At temperatures lower than -12°C an engine block heater should be used when the car is parked for a longer period. A greater proportion of petrol in the tank is recommended during extreme cold and uncertainty over access to engine block heater sockets. A fuel driven engine block heater must not be installed in E85 cars. The starting fuel quantity and post-start enrichment is considerably greater with high adapted ethanol content. This means that engine oil dilution is greater than during operation on pure petrol. This is one of the reasons why the service interval is shorter for BioPower.Due to ethanol's poor evaporation in the cold, misfiring may occur with a high engine load and cold engine. For this reason, an engine temperature dependent torque limitation has been added. The limitation is active at 50-85% ethanol in the fuel and an engine temperature lower than 50°C.
Higher octane rating (104 RON)
Ethanol's favourable effect on the octane rating facilitates higher torque and output. In T7 torque limitation is stepless depending on adapted ethanol content, from 240 Nm/150 hp at 0% to 280 Nm/180 hp at 85% (pure E85).This means that the car may seem sluggish after driving on E85 for a while and then changing over to petrol.
Faster combustion
Ethanol provides faster burn-through of the fuel-air mixture after the spark plug has ignited. This means later ignition is selected when the ethanol content is great. Similarly for torque limitation, the ignition timing depends on adapted ethanol content and is changed steplessly from the best angle at 0% ethanol to the best angle at 85% (pure E85).Colder exhaust due to greater fuel quantity with Lambda 1
The effect of the greater fuel quantity is that the exhaust gases are colder. In turn, this means that the engine can be run on a high load without greater full load enrichment. In this way the same nozzle size and fuel pressure can be maintained despite longer nozzle times at lambda 1.Better fuel-air mixture cooling during evaporation
This property of ethanol means that the fuel-air mixture is cooled efficiently during the injection which results in improved cylinder filling without needing higher boost pressure.More aggressive against certain metals and plastic/rubber
Ethanol can mix with water and acts more aggressively against certain metals, including copper and brass. The choice of plastic and rubber must be adapted. Ethanol diffuses more easily through certain types of plastic than petrol. For this reason the car has been equipped with a petrol tank normally used in the US market where normal petrol can have a greater proportion of ethanol than normal petrol does in the Swedish market (more than 5%).The US tank has ORVR (Onboard Refuelling Vapour Recovery system). During refuelling an ejector effect is obtained in the filler pipe and a smaller quantity of air is drawn down into the tank with the fuel and is then vented clean, out through the evaporative (EVAP) emission canister. The filler pipe is only approx. 25 mm in diameter in order to obtain the correct function, and in a few cases this can lead to premature closing of the pump nozzle during refuelling.
All brass parts have been replaced with stainless steel. Gaskets are produced in Viton. Electrical leads in the tank now have Teflon insulation in order to withstand the fuel, and the seals in the pump module's electrical connection have been improved. The parts in the tank exposed to flowing fuel have been grounded to prevent sparks from static electricity.
The fuel pump now has stainless steel housing and carbon commutator. The fuel pressure regulator's diaphragm is in new ethanol resistant material. The bleeder hose to the intake manifold is also in different material. The MIU has been changed so that the tank sensor is pulsed. Continuous measuring would mean the tank sensor having considerably reduced service life due to corrosion.
Engine
The engine has electric engine block heater as standard. The intake valves are in new material. All valve seats are also in new material. The reason for this is that the wear is considerably greater when running on ethanol. Spark plugs are harder, NGK 7 instead of 6, Type NGK BCPR7ES-11. Platinum pins must not be used as the ionisation measuring is disrupted in combination with the ethanol fuel.| Miscellaneous |
Fuel consumption
Consumption increases the higher the proportion of ethanol there is in the fuel. This is a natural consequence of more ethanol being required than petrol for a certain air quantity in order to obtain lambda 1 as well as that ethanol is not so rich in energy. An increase of 40% can be expected when running on pure E85. The software in the MIU and SID has been adapted to new fuel consumption calculation and new service intervals.Service
The service interval is 15 000 km (see service interval below). Oil and filter changes are the main items during this service. The shorter interval is due to increased engine oil dilution that is due to increased start fuel quantities. E85 in Sweden contains a red colouring substance that means that all engine parts that come into contact with the fuel have a red coating. The engine oil is also redder due to the colouring substance. Spark plug change interval is 30 000 km. The spark plugs face harder wear when running on fuel containing ethanol.Tech2
When contact has been established with T7, Tech2 will identify the car as BioPower. A special menu entitled BioPower E85 can then be accessed.After which, the following procedures are possible:
| • |
Read adapted ethanol content.
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| • |
Enter new ethanol content.
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| • |
Perform self-adaptation of ethanol content.
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Read adapted ethanol content before SPS or control module replacement and re-enter afterwards. Conclude with a self-adaptation. Perform a self-adaptation following repair of the fuel or engine management system. An air leakage or component fault may have caused an incorrect adaptation.
| Summary |
| • |
Higher engine torque and output the greater the proportion of E85 in the tank.
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| • |
A greater proportion of E85 involves a greater need for an engine block heater in cold conditions.
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| • |
Torque limitation with cold engine and large proportion of E85.
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| • |
Shorter service intervals than the petrol variant.
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| • |
More frequent spark plug replacement and harder pins (not platinum pins).
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| • |
E85 must be handled with the same caution as petrol.
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The red colouring substance in E85 colours the engine oil.
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Spilled oil is treated normally.
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Use Tech2 in order to correct incorrect adaptations in connection with service action, e.g. SPS, before delivery to customer.
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Adaptation diagnostic trouble codes and misfiring diagnostic trouble codes could be the result of incorrect adaptation during unfavourable conditions.
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| • |
Do not mix up control modules, engine parts or fuel system components that are specially developed for BioPower with components for standard petrol engines or vice-versa.
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| • |
The MIU and SID are adapted to the new fuel consumption calculation and new service intervals.
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| Service intervals for cars with BioPower engine |
Character explanation
X = Check/adjustO = Replacement
∇ = Lubricate/polish
◊ = Carried out only in first service
15 = 15 000 km
30 = 30 000 km etc.
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Distance driven in kilometres
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15
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30
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45
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60
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75
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90
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105
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120
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135
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150
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Fit protection and covers to the wings, seats etc. 82 93 706 Wing cover, 82 93 755 Front guard, 82 93 763 Seat cover and 82 93 771 Carpet cover
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X
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X
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X
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X
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X
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X
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X
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X
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X
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X
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All bulbs, check/adjust.
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X
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X
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X
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X
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|
X
|
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Coolant level, check/adjust.
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X
|
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X
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X
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X
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X
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Coolant, check mixture and leakage.
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X
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X
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X
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X
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X
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Brake fluid level, boiling point check/adjust. See Brake fluid quality, check and Brake fluid level.
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X
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X
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X
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X
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X
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Power steering, fluid level check/adjust
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X
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X
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X
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X
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X
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Dampers and bushes, check/adjust
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X
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X
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X
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X
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X
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Engine oil and oil filter, change.
|
O
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O
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O
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O
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O
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O
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O
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O
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O
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O
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Automatic transmission fluid, change
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O
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Oil leakage, check.
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X
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X
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X
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X
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X
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Gaiters on inboard and outboard drive shaft universal joints, check and adjust sealing integrity.
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X
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X
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X
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X
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X
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Ball joints, bushes and boots on suspension and steering, check/adjust
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X
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X
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X
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X
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X
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Check date marking on tyre repair aerosol. Replace as necessary.
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X
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X
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X
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X
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X
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Tighten bolts to front and rear subframe.
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◊
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Exhaust system, check/adjust suspension, sealing integrity and damage.
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X
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X
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X
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X
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X
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Fuel system incl. tank, check and rectify sealing integrity and damage.
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X
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X
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X
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X
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X
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Inspect brake lines and hoses.
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X
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X
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X
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X
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X
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Detachable towbar, check/adjust/clean/lubricate.
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X
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X
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X
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X
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X
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Brake lining, check.
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X
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X
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X
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X
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X
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Handbrake, check/adjust.
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X
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X
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X
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X
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X
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Tyres, check/adjust tyre pressure and wear.
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X
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X
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X
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X
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X
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Spark plugs, replacement.
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O
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O
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O
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O
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O
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Air cleaner filter element, replacement.
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O
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O
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Cabin air filter, replacement.
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O
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O
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O
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O
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O
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Drain hose for bulkhead partition space, clean.
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X
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X
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X
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X
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X
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Battery, check condition.
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X
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X
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X
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X
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X
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Fuel system in engine bay, check.
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X
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X
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X
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X
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X
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Wash/wipe system, check/adjust.
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X
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X
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X
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X
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X
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Drive belt, replacement
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O
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Drive belt condition and tension incl. automatic tensioner, check/adjust. Replace as necessary.
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X
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X
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X
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X
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X
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Locks in doors, bonnet and boot lid/tailgate, and door keeps, check/adjust/clean/lubricate.
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∇
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∇
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∇
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∇
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∇
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Seatbelts, check function and for damage.
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X
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X
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X
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X
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X
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Airbags and warning lamp, check.
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X
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X
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|
X
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X
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X
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Service indicator, reset.
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X
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|
X
|
|
X
|
|
X
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X
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Headlamp alignment, check/adjust
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X
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X
|
X
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X
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|||||
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Road test.
|
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X
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|
X
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|
X
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|
X
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|
X
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Remove the protection and covers.
|
X
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X
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X
|
X
|
X
|
X
|
X
|
X
|
X
|
X
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Customer programming.
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◊
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|||||||||
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Brake fluid, change.
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Change at 4-year intervals, see service booklet.
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|||||||||
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Distance driven in kilometres
|
165
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180
|
195
|
210
|
225
|
240
|
|
Fit protection and covers to the wings, seats etc.
|
X
|
X
|
X
|
X
|
X
|
X
|
|
All bulbs, check/adjust.
|
|
X
|
|
X
|
|
X
|
|
Coolant level, check/adjust.
|
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X
|
|
X
|
|
X
|
|
Coolant, check mixture and leakage.
|
X
|
X
|
X
|
|||
|
Brake fluid level, boiling point check/adjust.
|
|
X
|
|
X
|
|
X
|
|
Power steering, fluid level, check/adjust.
|
X
|
X
|
X
|
|||
|
Dampers and bushes, check/adjust.
|
X
|
X
|
X
|
|||
|
Engine oil and oil filter, change.
|
O
|
O
|
O
|
O
|
O
|
O
|
|
Automatic transmission fluid, change
|
|
O
|
||||
|
Oil leakage, check.
|
|
X
|
|
X
|
|
X
|
|
Gaiters on inboard and outboard drive shaft universal joints, check and adjust sealing integrity.
|
X
|
X
|
X
|
|||
|
Ball joints, bushes and boots on suspension and steering, check/adjust
|
X
|
X
|
X
|
|||
|
Exhaust system, check/adjust suspension, sealing integrity and damage.
|
X
|
X
|
X
|
|||
|
Fuel system incl. tank, check and rectify sealing integrity and damage.
|
X
|
X
|
X
|
|||
|
Inspect brake lines and hoses.
|
X
|
X
|
X
|
|||
|
Brake lining, check.
|
|
X
|
|
X
|
|
X
|
|
Check date marking on tyre repair aerosol. Replace as necessary.
|
|
X
|
|
X
|
|
X
|
|
Handbrake, check/adjust.
|
|
X
|
|
X
|
|
X
|
|
Detachable towbar, check/adjust/clean/lubricate.
|
|
X
|
|
X
|
|
X
|
|
Tyres, check/adjust tyre pressure and wear.
|
|
X
|
|
X
|
|
X
|
|
Spark plugs, replacement.
|
O
|
O
|
O
|
|||
|
Air cleaner filter element, replacement.
|
O
|
O
|
||||
|
Cabin air filter, replacement.
|
O
|
O
|
O
|
|||
|
Drain hose for bulkhead partition space, clean.
|
|
X
|
|
X
|
|
X
|
|
Battery, check condition.
|
|
X
|
|
X
|
|
X
|
|
Fuel system in engine bay, check.
|
X
|
X
|
X
|
|||
|
Wash/wipe system check/adjust.
|
|
X
|
|
X
|
|
X
|
|
Drive belt, replacement.
|
O
|
|||||
|
Drive belt condition and tension incl. automatic tensioner, check/adjust. Replace as necessary.
|
|
X
|
|
X
|
|
X
|
|
Locks in doors, bonnet and boot lid/tailgate, and door keeps, check/adjust/clean/lubricate.
|
∇
|
∇
|
∇
|
|||
|
Seatbelts, check function and for damage.
|
|
X
|
|
X
|
|
X
|
|
Airbags and warning lamp, check.
|
|
X
|
|
X
|
|
X
|
|
Service indicator, reset.
|
|
X
|
|
X
|
|
X
|
|
Headlamp alignment, check/adjust
|
X
|
X
|
X
|
|||
|
Road test.
|
|
X
|
|
X
|
|
X
|
|
Remove the protection and covers.
|
X
|
X
|
X
|
X
|
X
|
X
|
|
Brake fluid, change.
|
Change at 4-year intervals, see service booklet.
|
|||||
| Warranty/Time Information |
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