Engine - Reduced Performance/Turbo DTC's Set
Bulletin Number: 219-2494Reduced performance and diagnostic trouble codes for the turbo control valve.
Cars Affected:
Saab 9-5 M98 -
Saab 9-3 (9400) M98-03
Saab 9-3 (9440) M03-
Background
Analyses of returned turbochargers have revealed that the source if the fault is often in other components rather than the turbo itself. Normally faults are in the by-pass diaphragm, the wastegate unit or in the control function for the turbo. This can give rise to low boost pressure, reduced performance and diagnostic trouble codes being generated. To avoid the turbo being replaced unnecessarily a more thorough analysis needs to be performed, in accordance with the following.
Symptom description
Low boost pressure, reduced performance
Procedure
Before a possible turbo replacement, the system must be checked in accordance with the following checklist. This list must be enclosed with the turbo in the event of any claim.
To perform the test measurements, Tech2, 30 14 883 Pressure/vacuum pump and 83 93 514 Boost pressure gauge are required.
1. Enter the information shown.
2. Connect Tech2 and answer the questions shown.
3. Copy the information shown from "System Information" in Tech2.
4. Only petrol engines: Connect the pressure/vacuum pump as well as a boost pressure gauge, in accordance with the illustration, to the wastegate unit and create an overpressure/vacuum in order to check that there is no leakage in the unit. In addition, check that the lever is moving.
In the event of leakage: replace the wastegate unit.
5. Only petrol engines: Connect the pressure/vacuum pump to the by-pass valve and create an overpressure/vacuum in order to check that there is no leakage in the membrane.
In the event of leakage: replace the by-pass valve or diaphragm.
6. Pressure test the charge air cooler with hoses in accordance with WIS - Car type - Engine - Turbocharger system - Adjustment/Replacement - Test pressurization of the charge air cooler and pressure pipes, 4-cyl. (or equivalent for diesel engines).
7. Engines with vacuum pump: Connect the boost pressure gauge to the vacuum circuit, start the engine and check that a vacuum of at least 0.7 bar is formed. If the vacuum is not achieved, check the hoses and the pump separately.
If there is no fault: check engine compression.
8. Engines without vacuum pump: Connect the boost pressure gauge to the vacuum circuit. Start the engine and make sure that a vacuum of at least 0.4 bar is formed. If the vacuum is not achieved, check the intake manifold and the vacuum connections.
If there is no fault: check engine compression.
9. Detach the pipe to the turbo's air intake and check whether there is an abnormally large oil leakage in the turbo. Check whether there is any play in the turbine shaft axially or radially. Small axial play (up/down approx. 1-2 mm) is common but there must not be any radial play (gives blue smoke). In addition, check with a mirror that the compressor wings are not damaged.
10. If no faults are detected in accordance with the above, replace the turbo in accordance with WIS - Car type - Engine - Turbocharger system - Adjustment/Replacement - Turbocharger. (or equivalent for diesel engines). Enclose this checklist with the exchanged turbo.
Warranty/Time Information
In the case of customer complaint and if the car is within the warranty period, use the information shown to fill out the claim.
Labor Operation (CA): J5891
Time: 0.3 hr.
Reported times do not include the 0 owing a our operations: Replacement of wastegate unit, replacement of by-pass valve or diaphragm, pressure testing the charge air cooler, checking compression and replacement of the turbo.
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