Page 31
High fuel consumption
1. Check the CO-value (warm engine).
$ 5202 CHECKING THE INJECTION VALVES
CHECKING THE CO-VALUE F y
4. Check that the cold start valve is not leaking.
2. Check the control pressure with the engine warm. In-
sufficient contro! pressure implies a fuel-to-air ratio
which is too rich.
$5212
CHECKING THE COLD START VALVE
5. Check that there is no external leakage of fuel.
CHECKING THE CONTROL PRESSURE
“ w
3. Check that the injection valves atomize the fuel. De-
posits on the spark plugs can give an indication of
poor fuel atomization.
—38
240 SAAB
—
Page 32
eee * o
ds
EXHAUST EMISSION CONTROL SYSTEM
In order to meet the exhaust emission standards which
apply in the USA, Saab engines have been equipped with
the following:
CI-SYSTEM
See section 240,
Canada ___| USA
| Model 1975-76 Model | Model Model Model Turbo
Model Model | Federal | California 1977 | 1977-79) 1978-79) 1980
1979 1980 [iy [a ses pon
fi catalyst | Catalyst | catalyst Catalyst
Deceleration device Xx
Deceleration device,
vacuum x xX |X x x x x
Deceleration device,
dashpot x Xx
Delay valve x Xx x x
EGR on-off x 12) Xx
EGR proportional xX x
EGR two port x3) yx) x
Air injection x
Pulse air Xx X
Catalyst and Lambda x x x
Compression 7.2:1 x
Compression 8.7:1 X |X x x
Compression 9.25:1 x x x x x
ELCD-system x |X x x x Xx Xx x
|) 1) Only cars with automatic transmission
2) Up to and incl. model 1977
3) As from model 1978
SAS 254-1
Page 33
EGR service
1. Remove the throttle valve housing, EGR crosspipe
and EGR vaive.
CLEANING THE HOLE IN THE EXHAUST MANIFOLD
3. Clean the EGR crosspipe by flushing with a suitable
solvent {2.g. trichloroethylene}. Pipes with thicker
deposits of soot should be cleaned by means of a
wire.and then blown clean.
4. Clean the inlet and outlet of the EGR valve by
means of a rotary wire brush, Take care not to
damage the valve stem during cleaning of the out-
let.
REMOVING THE EGR VALVE
2. Clean the calibrated hole at the exhaust manifold by
means of a drill.
EGR on-off: ¢ 0.16 in. (@ 4 mm)
EGR proportional: @ 0.39 in. (¢ 10 mm)
EGR two port, manual transmission: 0.0.20 in. (@ 5 mni)
EGR two-port, automatic transmission: 4 0.39 in;
{9 10 mm),
|
WIL Niet
|
pet! |
Ra THT
Hl Le
CLEANING THE OUTLET OF THE EGR VALVE
Flush out the valve with trichtorethylene, By means
of a vacuum tester, create a Vacuum in the vacuum
connection to open the valve. At the same time,
blow compressed air through the valve,
254-10 SAAB
Page 34
ital
i Min 10. Reset the EGR counter to zero as follows:
a. Remove the left-hand screen below the instru- {
merit panel. |
b: Remove the cover of the counter and press the tip
button,
iW
sill
es
a
==
inl
pel ert
——s
—
-
_
—s
=>
==
BLOWING THROUGH THE EGR VALVE
=
===
Check the opening and closing of the valve by
means of the vacuum tester.
5. Clean:the hole in the inlet manifold wall by means
of a 0:39"' (10 mm) dia. drilland remove any soot
deposite which may have formed inside the mani-
fold.
PRESSING IN THE BUTTON
CLEANING THE HOLE IN THE INLET MANIFOLO WALL
@
w c. Replace the-cover. i
d. Fit the screen below the instrument panel. |
6. Fit the EGR valve with a new gasket. Connect the
hose from the PVS valve. /
7. Fit the EGR crosspipe to the exhaust manifold and
the EGR vaive. Clamp: the pipe at the throttle valve
housing.
Ensure that no electric cables or hoses can come
Into contact with the EGR crosspipe. gh,
8. Mount the throttle valve housing together with a :
new gasket and connect the rubber bellows, the :
vacuum Hoses and throttle cable,
9. Start the engine and check that there are no leaks
in the system.
ee
| SAAB | 254-11
Page 35
Fault tracing
Faults in the EGR system — general
The following simple test can be carried out to ascertain
whether any faults occurring arise from the EGR system:
Disconnect one of the hoses to the PVS valve and check
whether the fault remains. (This does not apply if the
EGR valve should stick.) If the fault remains, it is prab-
ably not connected with the EGR system,
EGR valve
a. Checking valve movement:
Remove the hose between the PVS valve and the EGR
valve at the connection of the former. Suck the end of
the hose to create a vacuum of at least 100 mm Hg
(4 inches Hg} at the EGR valve and then release the
pressure suddenly. The valve should now be heard to
close quite clearly, [f the valve cannot be readily heard
to close, it should be removed for inspection. Faulty
valves should be replaced.
b. Checking the opening pressure:
Connect a vacuum pump and gauge to the EGR valve
| as above. Check the reading at which the valve starts
! to open. The valve ster is visible in the opening be-
tween the diaphragm housing and the valve body. The
opening pressure should be 60 t 5 mm Hg (2.44 0.2
inches Hg).
HECKING THE OPENING PRESSURE
It
| = (The valve stem is visible at the arrow}
->
Checking the PVS valve
Check the valve by first disconnecting It and then blowing
through it. When the engine is cold the valve should re-
main closed. When the engine is warm, the valve should
open, Faulty valyes should be replaced.
CHECKING THE PVS VALVE
Checking the cut-in speed. (on—off and two port system)
1. Warm-up the engine and connect a revolution counter,
2. Rev the engine and check the opening of the EGR
valve. The valve should open at fast-idling speed (see
below). The valve stem is visible between the valve
body and the vacuum control unit,
Engine speed (fast idling) at
une which the valve should open
EGR on-off Approx. 1900 rev/min
EGR two port,
Manual transmission 2 600-3 200 rev/min
EGR two port,
automatic transmission 2 300—2 900 rev/min
EGR VALVE STEM
Checking the vacuum signal switch {proportional system)
a. Check to be carried out when the engine runs poorly
at idling speed:
Disconnect the hose from the blue connection on the
vacuum signal switch and allow the engine to idle at
normal running temperature.
254-12 SAAS
Page 36
a
THE HOSE AT THE BLUE CONNECTION IS DISCONNECTED
If the engine now runs properly, reconnect the hose
ly w to the -blue connection and remove the hose from the
white one.
Connect.a vacuum pump and gauge to the white con-
nection and apply @ vacuum of at least 300 mm Ho
i (12 inches Hg).
VACUUM PUMP AND GAUGE CONNECTED TO THE WHITE
CONNECTION
If the engine now runs properly, the fault will be
found in the hose between the vacuum signal switch
and the throttie vaive housing or in the throttie valve
housing outlet. A vacuum of 350=450 min Ha (14—18
inches Hg) at the outlet should be read off at an idling
speed of 875 rev/min.
If the-engine still runs unsatisfactorily when a vacuum
of 300 mm Hg (12 inches Hg) is applied at the white
outlet, the vacuum signal switeh should be replaced.
b, Measuring the signal from the vacuum signal switch:
Disconnect the vacuum hose from the distributor and
Measure the vacuum at the blue outlet on the Vacuum
Signal switch. Up to 2.500 + 500 rev/min., the reading
should be 0. {During the running-in of the engine, the
cut-in speed can be somewhat lower.) For engine
speeds in excess of this the readings should be:
Manual transmission approx. 30 mm Hg (1.2 in. Hg)
Automatic transmission approx. 50 mm Hg (2 in. Hg}
MEASURING THE SIGNAL FROM THE VACUUM SIGNAL
SWITCH
Checking the amplifier (proportional system)
a. Residual pressure, engine idling:
Disconnect the hose from the ted outlet on the vacu-
um signal switch-and connect a vacuum tester to the
hose. The readings at idling speed should be:
manual transmission 23—38 mm Hg (0.9—1.5 inches Hy)
automatic transmission 41—56 mm Ha (1,6—2.2 inches Hg)
In the case of deviating values, the venturi tap, venturi
and hoses should be checked and cleaned if necessary,
Checking the holding vaive (two-port system)
1. Rev the engine to open the EGR valve completely
(approx. 3 000—3 500 rev/min},
2. Clamp together the hose between the release valve-and
the three-way nipple in the line to the EGR valve,
CHECKING THE HOLDING VALVE
3. Let the engine drop to idling speed and check that the
EGR valve remains open for an additional 6 seconds.
Checking the release valve (two-port system) I
1, Rev the engine to.open the EGR valve completely.
2. Let the engine drop to idling speed and check that the
EGR valve closes immediately. |
254-13 |
Page 37
Fault tracing chart for EGR-system
|
Symipton
Probable fault
Fault tracing, remedy
1. Engine runs poorly or not
at all at idling speed
EGR valve stuck in open
position
See EGR valve (a) page
254-10
Proportional system:
Vacuurn signal switch
not functioning
See vacuum signal switch
(a) page 254—10
. Engine stalls when dropping
from high speed to idling
speed
Two-port system:
Release valve not working
See release valve page
254—11
, Engine runs unevenly at
constant speed or accele-
rates slowly
Proportional system:
Incorrect residual pres-
sure from amplifier
See amplifier (a) page
254—11
Proportional system:
EGR valve incorrectly
calibrated
See EGR valve (b) page
254-10
Proportional system
Check that the 12 holes
in the venturi tap are not
clogged
4. High emissions HC
EGR valve has. stuck
Proportional! system:
Vacuum signal switch
not functioning
See EGR valve (a) page
254—10
See vacuum signal switch
(b) page 254—11
Proportional system:
Incorrect residual pres-
sure from amplifier
See amplifier (a) page
254—11
Proportional system:
Incorrectly calibrated
EGR valve
See EGR valve {b) page
254—10
Too high a signal from
amplifier
Check that the 12 holes
in the venturi tap are not
clogged
5. Poor driveability with cold
engine
PVS valve constantly
actuated
See PVS valve page
254—10
254-14
es
Page 38
WATER PUMP, VERSION |
1, Pump cover 8. Ball bearing
Ey i 2, Gasket 9. Oil thrower ring
. & Impeller A 10. Bearing housing
4. Water pump seal 14 O-rings
5. Thrower 12. Seal ring
6. Seal ring 13. Pump shaft
7, Ball bearing lock ring
WATER PUMP, VERSION I
1. Pump cover 6. Ball bearing lock ring
2. Gasket 7. Ball bearing
3. Impeller 8. Bearing housing
4. Water pump seal 9, O-rings
5. Seal ring 10. Pump shaft
262-4
PRESSING THE BALL BEARING ONTO,
= i.
-s
WATER PUMP, VERSION III (AS FROM MODEL 1977)
1. Pump cover 6. Ball bearing lock ring ~—
2. Gasket 7. Ball bearing
3. Impeller 8. Pump shaft
4. Water pump seal
5. Sealing ring
ASSEMBLING
1. Fit the oil thrower ring (version |).
2. Press the ball bearing on to the pump shaft using tools
8390551 and:
Version | 8390569
Versions Il and til 8392524
HE SHAFT eae |
SANE ¢
Page 39
WATER PUMP
REMOVAL
Brain the coolant, including
that in the engine block.
Disconnect the positive cable
from the battery,
Remove the alternator.
Remove the intake manifold.
pe 7
$1 295
Stick a strip of tape across the
intake ports in the cylinder
head.
Page 40
262-2
Disconnect the water hose fran
the water pump oover, release
the alternator mounting and fold
it down to the side,
Remove the water pump cover. If
the cover proves difficult to
remove, heat the engine block
around the pump cover,
Remove all gasket remnants fron
the engine block joint face.
Withdraw the pump unit from the
block, using tool
63 92 649. Make sure that the
nut unit of the tool is threaded
fully onto the pump shaft and
that it does not jam the pump
Grive as the pump is withdrawn.
Clean the bearing sleeve and the
recess in the engine block in
which the impeller runs.