Battery Maintenance Program (311-2009)

BATTERY MAINTENANCE PROGRAM

TECHNICAL SERVICE BULLETIN

BATTERY MAINTENANCE PROGRAM

Model(s): 1999-on Saab 9-3, 9-5

Section: 3 - Electrical

Bulletin No.: 311-2009

Date: March, 1999

CARS AFFECTED

9-3, 9-3CV and 9-5 from M1999 inclusive.

BACKGROUND

This SI replaces all previously published information pertaining to battery maintenance.

If a battery is not maintained over a long period of time, its level of charge will gradually drop. The rate at which the level of charge drops depends mainly on how much current is being used by the car's electrical system. There is a certain amount of self-discharge even when the battery has been disconnected. This will increase with temperature.

If the battery is left with too low a level of charge for long periods, a chemical process will commence in which the battery acid gradually changes to water, corroding the battery plates. This corrosion process starts to be critical if the battery is left for about 2 weeks at a charge level below 65-75% (corresponding to an unloaded battery voltage lower than approx. 12.4 volts). A battery with a low charge level can freeze even at 32°F (0°C), which will also damage the battery plates.

The damage that is then caused is permanent and cannot be corrected with normal battery recharging. As a result, the capacity and service life of the battery will be permanently impaired.

The objective of this maintenance program is to prevent this type of damage to the battery from ever occurring and thereby increasing the service life of the battery and, above all, to ensure the customer receives a battery that is in perfect condition.

MATERIALS

Saab Battery Tester 311 (Fig. Fig 1 ), P/N 86 12 525 $203.00

This tester will be issued as an essential special tool by Kent-Moore/SPx Corporation during March, 1999. You will be billed against your April parts statement.

Additional testers can be ordered directly from Kent-Moore at 1-800-345-2233 at this essential tool price while supplies last. When supplies are depleted, the price will be raised to $810.00 (non-essential price).

PARTS REQUIRED

Saab Battery tester 311.

The tester is available in two language versions:

1. 86 12 525 English (US), French (CA), Spanish, Portuguese, Italian, German
2. 86 12 533 Swedish, Finnish, German, Dutch, French, English (UK)

BRIEF SUMMARY OF THE BATTERY MAINTENANCE PROGRAM

This program is a procedure for documenting the condition of the battery from the factory to the final customer.

Each car is provided with a battery card at the factory. After being approved for delivery, the battery is tested and the results entered on the battery card. The battery is tested using a new type of battery tester that can measure and assess its current capacity as well as its voltage.

A similar tester (Battery tester 311) will be delivered to all dealers as an essential tool and is to be used at every link in the distribution chain. This tester provides a read-out of the test results as well as a test code containing all the test values.

The battery should be tested once a month during the distribution phase from the factory to the dealer as well as when the car is in storage at the dealer. The test code results are to be entered on the battery card, along with odometer reading and date.

Demonstration cars (e.g. in showrooms, etc.) should be tested once a week.

If the battery requires charging, Battery tester 311 will indicate this. The battery should be charged as soon as possible and then the battery card should be updated with new test values.

When the car is delivered to the final customer at the Dedicated Delivery, the battery status should be registered in the customer's Warranties and Service Record Booklet in the form of a code together with the odometer reading and date.

BATTERY TESTER 311

Battery tester 311 is manufactured by Midtronics Inc. in the USA and uses a patented method of conductance measurement with the ability of measuring not only the battery voltage but also the current capacity of the battery. Saab Automobile AB has judged this tester to be the most suitable test instrument available on the market for this type of maintenance program. By using this tester, a uniform battery test method can be achieved on Saab markets all over the world.

Battery tester 311 is available in two language versions (see PARTS REQUIRED  ), each with six languages to facilitate handling.

Handling is simple as only four keys are used:

• two arrow keys for menu selections
• the return key to confirm selections
• an "i"-key to read the test code

See Fig 2 .

Through a specially adapted Saab measuring program, the tester presents the test results in the form of a test code consisting of 8 characters.

The tester requires no power source of its own but is supplied by the battery it is connected to while testing.

Only 12 V starting batteries can be tested. The tester can also be used to test batteries in the Saab 900 and 9000.

Saab warrantees the tester for a period of one year. During this warranty period, a defective instrument can be sent to Kent-Moore/SPx Corporation following normal tool warranty rules.

BATTERY CARD

The objective of the battery card is to enable the condition of the battery to be documented from the factory to the final customer. The card is identified with the VIN (Vehicle Identification Number) and is placed in the glove compartment when the car leaves the assembly line. The first test is registered on the battery card after the car has been approved for delivery from the factory and then it accompanies the car until it reaches the final dealer. On delivery to the final customer, the card should be retained by the dealer together with the other vehicle documents.

The battery card must be updated each time the battery is checked at each link in the distribution chain as described below. The number refers to the corresponding area on the battery card, see Fig 3 .

1. 1) Vehicle (Dealer Reference No.) For the dealer's use (Stock No., location, etc.).
2. 2) VIN The Vehicle Identification Number printed at the factory.

BATTERY CARD FILING SYSTEM

Besides the Battery tester 311 and the battery card, each dealer is required to have a system for keeping track of which cars require testing or charging respectively. We recommend a loose-leaf binder system with four sections marked as follows:

1. CHARGE

   For battery cards from cars requiring charging according to the test message obtained from the Battery tester 311.

2. SHOWROOM

   For battery cards from cars displayed in showrooms, etc. These cars have a noticeably higher current consumption and therefore require weekly testing.

3. UNEVEN MONTH
4. EVEN MONTH

   These files are used for cars in storage. When the car has arrived at the dealer, the battery is tested and the result entered on the battery card, which is placed in the file corresponding to the next battery test (within one month). It is important that every dealer has a functional system so that the car (and its respective key) containing the battery that is next in turn to test/charge can be found easily.

TEST PROCEDURE

Use the arrow keys to select the correct alternative in each menu.

Use the return key to enter or confirm a selection. Selections will be retained as menu defaults the next time the tester is activated.

1. Check the electrolyte level and top up if necessary (especially on warm climate markets). If the battery has been used for a while with a low electrolyte level, it should be topped up and recharged before the battery test is performed.
   NOTE: If the electrolyte level is too low for long periods, it will cause permanent damage and shorten the service life of the battery.
2. Clean the battery terminals.
3. Connect the red cable clip to the positive terminal (+). (Reversed polarity will not damage the tester. The display on the tester will be blank.)
4. Connect the black cable clip to the negative terminal (-). When both clips are connected, the tester will be activated automatically and a self-test will start. If the tester is defective, the message "INTERNAL ERROR SERVICE REQUIRED".
5. Make sure the cable clips are making good contact.
   NOTE: The battery can also be tested when it is connected to the car's electrical system. The ignition key must then be removed. If the tester registers any interference from the car's electrical system, the message "SYSTEM NOISE" will be displayed continuously until the source of interference has been removed. If the DICE/ICE control module (applies to 900, 9-3 and 9-5) is active, maxi fuse 2 in the maxi fuse box must be extracted. See also "Fault Diagnosis". On a 9000, remove fuse #23 before connecting the tester.
6. Under "SELECT TEST", there is the option of selecting whether the battery is connected to the car's electrical system ("IN-VEHICLE") or not ("OUT-OF-VEHICLE").
7. Under "BATTERY TYPE", select whether the battery is Saab factory-fitted or an Interstate battery ("SAAB BATTERY") or a replacement battery from another manufacturer ("NON-SAAB").
8. Confirm with "SELECT TEST BY SAE (A)" if the battery's cold starting current is specified according to CCA (SAE) standard. For batteries specified according to DIN, select and confirm with "SELECT TEST BY DIN (A)".
   NOTE: CCA (SAE) is always applicable for Saab's factory-fitted batteries and US Saab replacement batteries.

   The European DIN standard can be selected when the tester is used to test replacement batteries that are not specified according to CCA (SAE).

9. Enter the cold starting current for the battery in question (CCA). On Saab's factory-fitted batteries, this value can be found in large characters on the label on top of the battery from model year 1999 inclusive.

The table below indicates the CCA (SAE) values that have been applied to factory-fitted batteries since model year 1994 and should be used when using Battery tester 311 to test the respective battery.

Make	Part Number	Car Variant	Ah	CCA (SAE)
Varta	4231775	900/9000	60	520 A
Varta	4813804	900/9000	60	520 A
Varta	4947065	900/9000/9-5	60	520 A
Varta	4812921	900/9000/9-3/9-5	60	580 A
Jungfer	4354908	900/9000	60	520 A
Baren	4813812	900/9000	60	600 A
Baren	4231783	900 V6/9000	70	570 A
Baren FIAMM	4813820	900 V6/9000/9-5	70	650 A
FIAMM	5107354	900 V6/9000/9-5	70	650 A

The following chart lists cold cranking amp values for Saab Interstate batteries. When testing an Interstate battery, select it as a Saab battery to provide a warranty code needed for claiming purposes.

Part Number	Model	Application	CCA (SAE)
02 50 191	A26R	-93 900, -1994 CV	525
02 51 280	A26 (1)	-93 900, -94 CV	525
02 50 217	60 - 34R	9000, 94- 900	685
02 63 335	60 - 47 (2)	9-3, 94-98 900	590
02 63 343	60 - 91 (2)	9-5, 89-98 9000	700
(1) Most pre-1994 900 models were fitted with a reversed polarity battery such as 02 50 191 listed in the chart above. During the mid-1980's however, there were cars built on different production lines which may have straight polarity. For this reason, we offer the straight polarity battery 02 51 280. (2) Due to their European case size, these batteries must be used in cars equipped with the heat insulating Saab battery cover. Since these covers reduce the affect of underhood heat on the battery, they also help control water loss. It is recommended that these covers remain installed whenever possible. They can also help control water loss on M94-cars as long as a European size Group 47 or 91 battery is installed.

Model	Value
900, 9-3 (not diesel)	570 CCA (SAE)
9000 and 9-5 with A/C	640 CCA (SAE)
9000 and 9-5 without A/C	570 CCA (SAE)

After selecting and confirming a value, the actual battery test will start automatically. The tester may then request more information before presenting the results.

FAULT DIAGNOSIS

1. If the display does not light up:
   • Check the battery connections and polarity.
   • If the battery voltage is below 5.5 volts, the battery tester will not start. Charge the battery and then retest.
2. If the message "CHECK CONNECTION" is displayed: Make sure both halves of the respective connecting clip have good contact with the battery terminal. There are 4 test wires - two in each test lead: one to each half of each battery clamp.
3. If the test message "SYSTEM NOISE CHECK LOADS" is displayed:
4. This message can be displayed while testing in vehicle when the tester has detected some kind of interference signal from the car's electrical system that is affecting the test result.
5. This message is displayed for the 9-3/9-5 principally when the DICE control module is active.
6. The DICE control module has a run-on time of 20 minutes after the ignition has been switched off and is woke up when a door is opened.
7. The DICE control module is de-energized by extracting maxi fuse 2 in the maxi fuse box. Maxi fuse 2 is always the second fuse from the +30 connection screw. The maxi fuse holder in the 9-3 is located by the battery. The maxi fuse holder in the 9-5 is located behind the main fuse box in the engine bay.
8. Remove fuse #23 from 9000 models before testing the battery.
9. When TWICE is programmed for transport mode (9-3/9-5 only), a door can be opened without "waking up" DICE. If the message "SYSTEM NOISE" remains after several test attempts and you cannot wait for 25 minutes to be sure the "run on" time of electronic units has passed, disconnect the negative battery cable and perform a new test. In this case, the parasitic current draw should also be tested as the fault symptom indicates there is an electric consumer still active. If there is ever any doubt, disconnect the negative battery terminal and test again.
   NOTE: The same "SYSTEM NOISE" test message can be displayed when testing the battery in a Saab 900, especially when the ICE control module is active.

   The ICE control module has a run-on time of 20 minutes after the ignition has been switched off and is woke up when a door is opened. The ICE control module can be de-energized by extracting maxi fuse 2 in the maxi fuse box. See Fig 4 .

TEST CODE

Saab's battery test code can be displayed at any time while the test results are being read by pressing the "i" button.

The test code consists of 8 characters and contains all the information obtained from the battery test in encrypted form. The code is required for all warranty claims. The code can be interpreted for warranty and quality control purposes using special software.

This test code (together with the VIN and test date) will also be used to chart the condition of the battery from the factory to the final customer and how the distribution chain can be further optimized in the future.

Return to the test results by pressing the "i" button once again.

CHARGE CODE

The return button can be pressed at any time while reading the test results to obtain a charge code. This code is for future use and can then be entered into a special, intelligent battery charger for automatic and specially adapted charging of the battery.

BATTERY CHARGING

The battery must be charged if the battery tester displays any of the following test messages:

1. "GOOD - RECHARGE"
2. "CHARGE & RETEST"

Use a battery charger with a charging current approx. 10-20 % of the battery's rated capacity, i.e. 7-14 amps for a 70 Ah battery. Normal charge time is 4-12 hours, depending on the condition of the battery and the charging current.

Always check the level of electrolyte before and after charging and top up as necessary.

The battery need not be disconnected and the caps can remain closed when the charging rates recommended above are used.

Perform a new test after charging and enter the result on the battery card.

CHECKING THE BATTERY ELECTROLYTE LEVEL

Always check the level of the electrolyte in all the cells before and after recharging the battery by removing the battery caps with a suitable screwdriver. A flashlight can be used to see the electrolyte level more clearly. See Fig 5 .

Top up with distilled or deionized water to the maximum level mark. Each cell has its own maximum mark.

Normal tap water can contain salts and minerals that increase the rate of corrosion of the battery plates and greatly decrease the service life of the battery.

Fit the caps and tighten them securely when finished.

MEASURING PARASITIC CURRENT DRAW

If the capacity of the battery has severely deteriorated while the car has been parked for a few days, the cause may be that current consumption from the car's electrical system has been abnormally high while the car was turned off. If there is the slightest suspicion that this can be the cause of the inferior battery performance, the parasitic current draw must be measured.

1. IMPORTANT: To protect the ammeter (multimeter), connect a jumper lead between the instrument's negative and positive terminals before connecting it.
   
   Disconnect the positive battery cable and connect the ammeter between the positive cable and the positive battery terminal. Connect the positive instrument cable to the battery and its negative cable to the car's positive cable.
2. Turn the ignition key to the ON position but do not start the engine - the instrument will otherwise be damaged.
3. Turn the ignition key to the OFF position after 10 seconds, remove the key and close all the doors.
4. Wait for 25 minutes (due to the run-on time of certain electronic units), disconnect the jumper lead across the ammeter and read off the parasitic current draw. Normally, it should not exceed the following guideline values (provided no accessories have been fitted, e.g. a telephone):

Car Model	Transport Mode	Customer Mode
9-3/9-5	5 mA	16 mA
900	7 mA	20 mA
9000	10 mA	30 mA

Transport mode: Maxi fuse 1 in the maxi fuse box extracted and the TWICE control module programmed to transport mode.

If these guideline values are exceeded, the source must be localized by removing the fuses one by one.

As can be seen in the table, it is of great importance to the service life of the battery that the car is left in transport mode for as long as possible.

BATTERY MANUFACTURE DATE

A manufacturing code has been stamped on top of the negative battery terminal on all factory-fitted batteries. This code indicates the calendar week the battery was activated at the manufacturer. It specifies the year and week as follows:

1. 25 98 alternatively 8 25 = year 1998, week 25.

PRE-DELIVERY INSPECTION (PDI)

This SI replaces the directions for pre-delivery inspection pertaining to the battery in Service Manual 1 Service.

In connection with pre-delivery inspection (or at the stage in the distribution chain when the dealer takes over maintenance responsibility), the battery must be tested using the Battery tester 311 and the result entered into fields 9 - 11 in the section "Pre Delivery Inspection (PDI)" on the battery card.

Charge the battery if necessary. (See "BATTERY CHARGING  ").

STORAGE CARE

This SI replaces the directions for storage care pertaining to the battery in Service Manual 1 Service.

Each time the car is put in storage, the battery must be tested monthly with the Battery tester 311.

Also check the battery electrolyte level each month (see "CHECKING THE BATTERY ELECTROLYTE LEVEL  "). This is especially important on warm climate markets.

Charge the battery if necessary. (See "BATTERY CHARGING  ").

After reconnecting the battery, the time and language must be set in SID.

DELIVERY SERVICE

This SI replaces the directions for delivery service pertaining to the battery in Service Manual 1 Service.

Test the battery with Battery tester 311 as the first step in the delivery service before fitting the transport fuse and programming the TWICE control module to customer mode.

The battery card should be kept together with the other vehicle documents at the dealer, so that the test result is available in case the Warranties and Service Record Booklet is lost. The test code must also be registered in the dealer's computer system on markets where the "Saab Service" book does not accompany the car.

MAINTENANCE SERVICE (SAAB ORIGINAL SERVICE)

Test the condition of the battery with Battery tester 311 on each service occasion and enter the test code and date in the "Remarks box" in the Warranties and Service Record Booklet. From model year 2000, the Warranties and Service Record Booklet will have a special box with the heading "Battery Test Code". The battery electrolyte level must also be checked on each service occasion (see "Checking the battery electrolyte level").

WARRANTY INFORMATION

1. If a warranty claim is made during new car in stock or demo service, the test codes (including test dates) from the preceding fields on the battery card including the dates of the battery tests must be used on the claim.
2. If a warranty claim is made after delivery, the test code (including test date) that was entered into the customer's Warranties and Service Record Booklet in connection with the delivery must be used on the warranty claim.