SAAB WIS ONLINE

(254-2640 utg.2) Enhanced fault diagnosis, Z19

Symptom: Low performance, powerless Abnormally high engine noise, diesel knock/metallic noise with light load Engine runs on 3 cylinders, misfires Regeneration does not work Grinding noise with light load (sounds like poor front wheel bearing) (applies to 9-3) Too high or low fuel pressure The following diagnostic trouble codes may arise: P0090 P1109 9-3: P2279 11 or 12 P0400 5A or 5B P1901 75 or 0F 9-5: P2279 P0402 or P0403 P1909 P0091

TECHNICAL SERVICE BULLETIN
Bulletin Nbr: 254-2640 utg.2
Date: ........... Oktober 2006
Market: enl. separat lista
Enhanced fault diagnosis, Z19

Cars affected

Saab 9-3 M05- with engine alternative Z19

Saab 9-5 M06- with engine alternative Z19

Background

This bulletin contains fault diagnosis methods as a complement to WIS.

In the case of customer complaint the following fault diagnosis must be carried out.

Symptom description



Low performance, powerless

Abnormally high engine noise, diesel knock/metallic noise with light load

Engine runs on 3 cylinders, misfires

Regeneration does not work

Grinding noise with light load (sounds like poor front wheel bearing) (applies to 9-3)

Too high or low fuel pressure

The following diagnostic trouble codes may arise :

P0090

P1109

9-3 :

P2279 11 or 12

P0400 5A or 5B

P1901 75 or 0F

9-5:

P2279

P0402 or P0403

P1909

P0091



Parts required

As required, see EPC

Procedure



Low engine performance / does not start


1. The following diagnostic trouble codes may arise:

9-3 : P0400 5A or 5B, P2279 11 or 12

9-5 : P0402 or P0403, P2279

2. Check the function of the EGR valve as follows:

Remove the upper engine cover and insulation and check the function of the EGR valve by activating it with Tech2. When activating the valve, the sound of the engine changes, or the engine stalls.

If no reaction is achieved, remove the EGR valve and activate it when it is hanging loose. Check that it closes fully.

Fit an EGR valve from another car (that is not faulty) in the defective car in order to ascertain whether the fault remains.

3. 9-3 : Check the vacuum system in accordance with TSB 254-2601 edition 2 step 6.

9-5 : Check the vacuum system in accordance with TSB 254-2614 step 6.

4. Check/pressure test the charge air system:

9-3 : See TSB 254-2601 edition 2 steps 7-20.

9-5 : See TSB 254-2614 steps 7-26.


Abnormally high engine noise, diesel knock/metallic noise with light load


1. Check that the latest possible software for EDC 16 is installed.

9-3 with DPF -M06:

Z19DTH with automatic transmission: P/N 55565574

Z19DTH and DTH with manual gearbox: P/N 55564018

9-3 with DPF M07-:

Z19DTH with automatic transmission: P/N 55565574

Z19DTH and DTH with manual gearbox: P/N 55564452

9-3 without DPF: Z19: P/N 55559129

9-5 : EDC 16: P/N 55563310

2. Carry out adaptation in accordance with TSB 234-2599.

3. 9-3 from and including Vehicle Identification Number 61101134 : Check that the sound insulation is fitted under the engine cover and oil pan.


Engine runs on 3 cylinders, misfires


1. Check that the battery is OK, see WIS, Electrical system - Charging systems - Adjustment/Replacement - Battery check.

2. Locate the defective cylinder by unplugging the injectors' connectors one at a time.

3. Check the wiring harness' connection to the nozzle as well as any open circuit in the engine's wiring harness.

4. Check the compression and compare with other cylinders.

5. If no other fault is identified in accordance with the above, replace the injector on the deficient cylinder.

6. If new injectors have been fitted : Connect the diagnostic tool for programming. Select, Menu - Engine - Engine management system - Adjustment - Injector replaced.


Regeneration does not work

With diagnostic trouble code:

9-3 : P1901 symptom 75 or 0F

9-5 : P1909


1. Check that the correct software for the engine control module is installed:

9-3 with DPF -M06:

Z19DTH with automatic transmission: P/N 55565574

Z19DTH and DTH with manual gearbox: P/N 55564018

9-3 with DPF M07-:

Z19DTH with automatic transmission: P/N 55565574

Z19DTH and DTH with manual gearbox: P/N 55564452

9-3 without DPF: Z19: P/N 55559129

9-5 : EDC 16: P/N 55563310

2. 9-3 : Carry out fault diagnosis in accordance with TSB 254-2601 edition 2

9-5 : Carry out fault diagnosis in accordance with TSB 254-2614.


Diagnostic trouble code P1109


1. Remove the engine cover. Check that the swirl throttles move between end positions during activation with Tech2.

2. Check that the swirl throttles do not jam by removing the lever to the actuator for combustion circulation (403). Move the swirl throttles manually from end position to end position. If the swirl throttles do not jam, replace the actuator. If the swirl throttles jam, replace the intake manifold.

In the event of significant soot build-up, check the function of the EGR valve as well.

Following the above action to the actuator/intake manifold, carry out manual regeneration.


Grinding noise with light load (9-3)

Noise similar to a poor front wheel bearing.

Note

Note that the drive shaft universal joint gaiter is not to be removed. Only the splined joint shall be lubricated.



1. Raise the car and remove the wheel.

CV : Remove the chassis reinforcement, front subframe, CV.

Remove the lower engine cover

2. Remove the steering swivel member bolt, fold down the suspension arm and fit a 83 95 238 Wedge between the suspension arm and the anti-roll bar.

3. Undo the brake hose from the clip as well as the ABS cable's holder. Angle the wheel diagonally for better access.

4. Tap the drive shaft out from the intermediate shaft using a brass drift and mallet.

5. Lubricate the shaft's splines using Mobil XHP 222 (blue water-resistant) for example.

6. Fit the drive shaft in the intermediate shaft's splines. Make sure that the seal to the intermediate shaft is fitted.

7. Remove the wedge and connect the ball joint to the steering swivel member. Fit the bolt and nut. Torque tighten the nut.

Tightening torque 50 Nm (37 lbf ft)

8. Fit the brake hose in the clip as well as the ABS cable in the holder.

9. Fit the wheel. See Wheels in accordance with WIS - 9-3 - Suspension, wheels - Wheels and tyres - Adjustment/Replacement.

10. Lower the car.

11. Fit the lower engine cover.

12. CV : Fit the chassis reinforcement, front subframe, CV.


Too high or low fuel pressure

With diagnostic trouble code P0090 or P0091


1. Check the pressure from the feed pump. The pressure should be 3.8 - 5 bar.

2. Check that the back pressure in the return line is not too high. The pressure may be a maximum of 1 bar.

Note

9-5 : from and including Vehicle Identification Number 63516890 the pump has a larger ejector diameter which results in a lower back pressure.



Warranty/Time Information

In the case of customer complaint and if the car is within the warranty period , use appropriate codes from STM.