Technical Highlights/Service Reminders
87saab01FILE IN S.I. Man VOL. I
SEC. A-0 PG. 24
Service Information
SUBJECT: TECHNICAL HIGHLIGHTS - 1988 ISSUE: 09/87-990
APPLICATION: SAAB 900 MODELS
This Service Information contains basic highlights and important service reminders for the 1988 900. This should be read and used in conjunction with Service Manual Section 0 "NEWS" and Section 1:1 PDI and 1000 Mile Break-In Service which will be distributed in late September. Plastic-coated PDI checklist cards will also be distributed.
TECHNICAL DATA - 0
Vehicle Identification Number - The Federally required 17 character VIN incorporates a new designator for model year 1988 - "J". 900 models are no longer built on assembly line 2 as this line has been reserved for 9000 models.
SERVICE - 1
LH Fuel Injection System - Two generations of the LH system are used from M88. LH 2.2 has been fitted to 16-valve engines from 1985 and is still used on the Turbo. LH 2.4 is the next generation of the Saab electronic fuel injection and is notable because of its increased self-diagnostic capabilities. LH 2.4 is fitted to 900S models. Bosch C.I.S. mechanical injection is still used for 8-valve engines.
Retorquing Cylinder Head - Do not retorque the cylinder head on any 1988 900 models at the 1000 Mile Break-In Service.
New cylinder head gaskets have been introduced that make retorquing unnecessary. The same gaskets are also available in the spare parts system and can be used on earlier cars. See also S.I. 09/87-994.
Engine Oil Change Intervals - The recommended oil change interval for all 900 models is now every 7,506 miles. The introduction of watercooling for the turbocharger makes this change possible.
SETTING IDLE SPEED:
Idle speed Adjustment - A new procedure for setting the idle speed on LH 2.2 fuel systems has been introduced. The new procedure uses an inductive tach/dwell meter or the LH System Tester to monitor the pulse ratio of the AIC. See the "NEWS" Book or the PDI and 1000 Mile Break-In Service Manual for full instructions. A handy plastic-coated card is also being produced and will be available at Saab Technical Training Centers. 900S models with LH 2.4 need no idle adjustment.
Warranties & Service Records Booklet - As with earlier years, all scheduled maintenance (including PDI & the Break-In Service) is accompanied by a handy checklist which canbe checked off and stored in the dealership file. A stub stays with the booklet and must be stamped with your dealer stamp for the customer's records. On the inside front cover there are new spaces to indicate extended service contract coverage and speedometer replacement, if applicable.
LH FUEL SYSTEM TESTER COMPONENTS:
LH Fuel System Tester - About December a hand-held LH Fuel System Tester will be distributed. This new microprocessorbased LH system tester is connected between the wiring harness of the car and the ECU for the fuel injection system. There are three ways in which the tester can be used to check the LH system; one gives direct information on coolant temperature and opening duration of injectors, another checks the function of the throttle switch, status of pin 29 and notifies the operator when the AC compressor cycles on, and the third runs it's own test cycle and displays a fault code if a problem is found.
This has been designated as a Saab required special tool. It will also be required that the tester be registered by your dealership to ensure inclusion in the Specification Update Program. This program will consist of periodic software updates as they become available.
CHARCOAL CANNISTER WITH ELECTRIC PURGE VALVE (SEE ARROW):
Evaporative Emission Control System electrically switched valve replaces the vacuum operated purge valve at the charcoal canister on 900S models (equipped with new LH 2.4 Fuel System). The switch and hoses are to be inspected at the same intervals that you would check the vacuum type valve (at 60,000 miles or 60 months).
Spark Plugs - Spark plugs may no longer be inspected at mileage intervals of 15,000 during the first 50,000 miles, according to EPA regulations. Inspection and replacement may only take place at 30,000 miles despite a vehicle possible severe usage. For this reason it becomes increasingly more important to interview your customer to ensure that the correct spark plug is being used in the car.
Owner advice has been expanded in the vehicle Owner's Manual concerning spark plug use in CITY DRIVING and NORMAL DRIVING. Turbos operated exclusively in-town may require the spark plug listed for CITY DRIVING. Be prepared to counsel your customers. Page 61 of the 1988 900 Owner's Manual (P/N 04-00-945) contains the following note:
NOTE
In conditions other than normal driving, Turbo models may require a different spark plug than is fitted as standard equipment. Extensive idling, stop-and-go driving and operation in cold climates over repeated short trips without sufficient engine warm-up may cause Turbos to require the spark plug listed for City Driving in the Specification section of this book. Discuss this with your dealer.
Heated Oxygen Sensor - A heated oxygen sensor is now installed in all 8-valve models. The replacement interval has been extended from 30,000 miles to 60,000 miles, the same as for 16-valve models.
ENGINE - 2
LH 2.4 Fuel System, 900S - LH 2.4 is the latest generation of the LH fuel system and is only installed in the 900S (and 9000S). The main difference between this version and the LH 2.2 used on the Turbo is the expanded memory in the electronic control unit, a new plastic air mass meter and a built-in fault diagnosis system. The idle control is of the adaptive type. This means that the idling speed and AIC setting are adjusted automatically and continuously to compensate for all normal variations. This type of system results in little or no need for idle adjustments. In fact the idle speed should not be adjusted in normal service.
Review the Service Manual Section 0 - "NEWS" for a listing of the fault codes and the instructions for retrieving the codes. Later sections of 2:3 will also contain this information.
Water-cooled Turbocharger - Beginning with the 1988 model Turbo, the turbocharger is water-cooled. Water-cooling lowers the peak hot shut-down temperature in the center housing by about 200~F. and reduces the likelihood of coking.
When the engine is running, engine coolant is taken from the cylinder head through the bearing housing and back to the cooling system by way of the large coolant hose, upstream of the radiator.
ELECTRICAL - 3
Wiring Harness - As with the 9000, many minor refinements have been made to the harness in the car. We suggest that you study the "NEWS" Book for the 900 to get the full benefit of these changes. The wiring diagrams for all circuits that have been changed are reproduced there.
Recirculation Solenoid - The solenoid that operates the air inlet door when the Recirculation Switch is depressed, has been moved inside the car, bolted to the heater housing. The lower dash panel must be lowered to make repairs at the solenoid. Before 1988 the solenoid was located on the right inner fender, just above the front wheelwell.
Headlight Relay - A new solid state relay is introduced for the 900. The relay fits in the main fuse panel as before but is not interchangeable with earlier years.
TRANSMISSION - 4
Clutch Pressure Plate - The Borg & Beck DST pressure plate is now standard models with the manual transmission. The plate was first introduced into the spare parts system during Spring 1987. Clutch Removal Bar 83-94-033 must be modified according to S.I. 03/87-952 before working with the new pressure plate. A new Removal Spacer 87-91-618 was also introduced to facilitate repairs.
BRAKES - 5 Calipers/Discs - New front and rear brake calipers and discs have been introduced for 1988. These are the same type calipers that have been installed on the 9000 and means that all 900 models have front ventilated discs, not just the 900S and Turbo.
Handbrake Adjustment - The handbrake now operates on the rear wheels on the This affects handbrake adjustment as follows; a) the handbrake cables do NOT cross as before and b) the piston adjustment is made at the rear calipers, just like the 9000.
Besides the cable adjustment in the center console, there is a brake piston adjustment screw located in each rear caliper. It is important that this screw be properly set when making a handbrake cable adjustment. Be sure that all technicians are aware of this and we suggest that you refer to the "NEWS" Book if there is any question concerning the procedure.
SUSPENSION AND WHEELS - 7
Wheel Bolts - With the introduction of the 9000 style brakes, a new wheel bolt is fited to the 900. The new bolt has been specialially treated so that it can be used with steel wheels without the risk of corrosion.
Wheels - While using the 9000 configuration, wheels for the 900 are 5-1/2" wide, not 6".
Wheel Tightening - Wheel tightening torque has been raised slightly from 65-80 lbs to 80-90 ft.lbs. As before do not use air powered impact wrenches for the final tightening. This can damage the wheel and can make it difficult to remove for your customers in the event of a flat. Use a torque wrench for final tightening.
BODY - 8
Please see the "NEWS" Book for information.