Traction Control System RECALIBRATION - Outline (02/92-0185)

TRACTION CONTROL SYSTEM RECALIBRATION - OUTLINE

TECHNICAL SERVICE BULLETIN

REVISED TCS CALIBRATION PROCEDURE

APPLICATION

Model(s): 1992 Saab 9000 Models with TCS

Group: Engine

Bulletin No.: 02/92-0185

Section 2

Page 14

Code 200

SERVICE INFORMATION

Because of the integration of the Traction Control System (TCS) with other operating systems in the car, the calibration of the traction control system is very important. Outlined below are procedures for calibrating the TCS for cars equipped with an automatic or manual transmission.

Calibration must be performed at the following times:

• During the 5000 mile "1st Service."
• After replacing any major system components, such as the ETS ECU, ASR ECU, pedal potentiometer, throttle housing, TC/ABS ECU, KDW motor, etc.
• After any major engine or transmission work has been completed, including replacement of the Kickdown cable on automatic transmissions.

Failure to perform the calibration procedure at these points could result in diminished engine performance.

CALIBRATION PROCEDURE - AUTOMATIC TRANSMISSION

1. Before calibration is performed, remove the spring-metal clip (if fitted). Cut off the clear plastic tip from the kick down cable, if fitted, where it is attached to the KDW motor (the plastic tip should not be re-installed). See Fig 1 .
2. Inspect the kickdown cable for proper adjustment. There should not be any slack in the cable, and you should be able to move the lever completely to its stop. If there is slack, or you can not move the lever completely to the stop position, adjust the basic cable setting as follows:
   1. Loosen the nut for the clamp on the cable sheath. Leave the kickdown cable attached to the KDW-motor lever.
   2. Move the lever to the fully extended position (toward right side of car) against the mechanical stop. Hold the lever in this position until step D is complete.
   3. Pull the kickdown cable sheath past the kickdown position to the full throttle mechanical stop in the transmission.
   4. Tighten the kickdown cable sheath clamp while holding the full throttle position. Torque the nut to 6 +/- 1 Nm (4.5 +/- 0.75 ft.lbs.). Ensure that the cable bracket is not bent in any way during the adjustment and torquing of the cable sheath.
      Fig 1: Removing Clear Plastic Tip

      
3. Start the engine and bring it to normal operating temperature.
   NOTE: If the engine will not run correctly during the warmup cycle, establish ISAT communications and enter command code 974 in order to enter basic data and enable warm-up to be completed.
4. Switch off the engine. Connect ISAT and capacitor lead P/N 86 11 048 to the BLACK diagnostic connector under the right-hand front seat.
5. Turn the ignition switch to the "DRIVE" position, select DIAG, ONE system from the menu, and enter system #3. Check to see if any fault codes are stored in memory. If fault codes are present, carry out whatever diagnosis and repair work that needs to be done, and ERASE FAULT CODES before proceeding.
6. With the ignition on, but the engine not running, enter COMMAND CODE 971:
   1. On some vehicles, ISAT will display code 8A971.
   2. WAIT AT LEAST 30 SECONDS while ASR & ETS store the base line settings, but during this time check the operation of the KDW motor visually to ensure that the lever moves all the way to the end of its travel.
7. The kickdown wire is pushed back to a mechanical stop in the motor. The motor then pulls the wire out to the full-throttle point and, when this is sensed, on to the fully pulled out kick- down position (mechanical stop in the transmission or KDW motor), then back to the idle position. On some vehicle ISAT will display code 8D971 when storage of the base-line settings has been completed.
   NOTE: If fault codes 45245 or 43691 are set in connection with the calibration, this does not indicate a fault. These fault codes can therefore be ignored and erased.
8. Check that no other fault codes were set. If so, diagnose and repair as necessary and then start the calibration process over again.
9. Re-establish communications with ISAT. With the ignition on, but the engine not running, enter COMMAND CODE 973:
   1. Once the TCS CTRL light illuminates, start the engine, but DO NOT TOUCH THE PEDALS OR THE GEAR SELECTOR LEVER.
   2. Wait for the idle to stabilize at around 850 RPM.
   3. When the TCS CTRL light begins to flash, press in and hold the SET button on the cruise control stalk. The button must be pressed within 10 seconds of the light starting to flash and held until the calibration process is complete (when TCS CTRL light is switched off).
   4. The ECU will pull the KDW motor to its maximum position and idle position, and will also increase engine speed to appro- ximately 3000 RPM.
   5. If the light is not switched off within 1 minute of the engine speed returning to idle, the calibration has not been performed correctly (fault codes have been set.)
      NOTE: The calibration procedure will be discontinued if any one the following occur:
      • The SET button is not depressed within 10 seconds of the TCS CTRL light beginning to flash.
      • The SET button is depressed before the TCS CTRL light starts to flash.
      • The SET button is released before the calibration process is completed.
      • The SET button is inoperative.
      • A pedal is depressed.
      • The car starts to roll.
      • The gear selector position is changed.
        NOTE: If fault codes 45245 or 43691 are set in connection with the calibration, this does not indicate a fault. These fault codes can therefore be ignored and erased.
10. Terminate ISAT communications, shut off the engine, and re-check to see if any fault codes were stored during the calibration process. If so, diagnose and repair as necessary and repeat the calibration procedure from the beginning.

POOR SHIFT QUALITY, AUTOMATIC TRANSMISSION

If you receive customer complaints of poor shift quality after calibration of the TCS (ASQ) system, particularly when engaging Drive or Reverse, the following inspection and adjustments should be made:

1. With the engine switched off, turn the lever on the KDW motor to the full-throttle position.
   NOTE: The throttle position is felt immediately before the kick-down position.
2. Using a vernier caliper, reach down and measure the length of exposed wire between the metal end of the cable's sheath and the end of the clevis attached to the wire. See Fig 2 . Write down the "Full-Throttle" measurement.
3. Start the engine and let it idle. Carefully take a new measure- ment of the exposed wire length with the KDW motor at its idle position. Write down the "Idle" measurement.
4. To determine the amount of cable travel, subtract the IDLE measurement from the FULL THROTTLE measurement.

   Cable Travel = Full Throttle - Idle 

   X = xx.x,mm - xx.x mm 

5. If the amount of cable travel does not equal 39.0 mm +1.0/-0 mm, loosen the clamp securing the cable sheath and move the sheath to adjust the length of travwl. After adjustment, re-tighten the clamp nut. Torque = 6 +/- 1 Nm (4.5 +/- 0.75 ft.lbs.).
   NOTE: Ensure that the cable bracket is not bent in any way during adjustment or tightening of the cable sheath.
6. Check the amount of cable travel again, and repeat the above procedure as needed.

CALIBRATION PROCEDURE - MANUAL TRANSMISSION

1. Start the engine and bring it to normal operating temperature.
   NOTE: If the engine will not run correctly during the warmup cycle, establish ISAT communications and enter command code 974 in order to enter basic data and enable warm-up to be completed.
2. Switch off the engine. Connect ISAT and capacitor lead P/N 86 11 048 to the BLACK diagnostic connector.
3. Turn the ignition on, select DIAG, ONE system from the ISAT menu, and enter system #3. Check to see if any fault codes are stored on memory. If fault codes are present, carry out whatever diagnosis and repair work needs to be done and ERASE FAULT CODES before proceeding.
4. To enter the baseline setting enter COMMAND CODE 971. ISAT will display 8A971. After several seconds, the display will change to 80971, indicating that the basic setting has been made and the system is ready for calibration.
5. With the ignition still on, but the engine not running, enter COMMAND CODE 973:
   1. Once the TCS CTRL light illuminates, start the engine, but DO NOT TOUCH THE PEDALS.
   2. Wait for the idle to stabilize at around 850 RPM.
   3. The ECU will raise the engine speed to approx. 3000 RPM.
      NOTE: The calibration procedure will be discontinued if any of the following occurs:
      • A pedal is depressed.
      • The car starts to roll.
6. When the calibration process is complete, the TCS CTRL light will shut off. Terminate communications, shut off the engine, and re-check to see if any fault codes were stored during the calibration procedure.