Car not starting Codes P0638 and P1523

Tiny
MICHAEL LYNCH2
  • MEMBER
  • 2003 SAAB 9-3
  • 2.0L
  • 4 CYL
  • TURBO
  • 2WD
  • AUTOMATIC
  • 120,000 MILES
Hi, I recently acquired this car which had broken a timing chain tension-er. Now all reassembled, the head was rebuilt (machined including valves seats and new valve seals etc). Have put back together and have all the required things for it to run. There is fuel pressure in fuel rail and the injectors are all working, spark on all plugs and compression across all cylinders approximately 165 PSI average. I have double checked the timing and certain its correct.
What I am getting is a starter that cranks the engine sounds like the engine is going to start then the starter disengages but the car does not run. So have to turn off the key and run through the procedure again. No joy. Pulled the codes and I am getting P0638 and P1523. So I am led to think its a throttle body issue. But I have taken the throttle body off and cleaned it. Not particularly dirty. The throttle body actuator is sealed so you cannot access it. Interestingly there is no movement on the butterfly because the actuator holds it firmly in place in the closed position and I am not going to force anything. I am not sure if this is correct and it would open when the car starts to idle?
I have also checked and cleaned the connector to the actuator. Any suggestions would be really appreciated. I am starting to run out of ideas.
Wednesday, October 18th, 2017 AT 2:26 AM

7 Replies

Tiny
KEN L
  • MASTER CERTIFIED MECHANIC
  • 47,722 POSTS
I would try to hold the throttle open a little to see if it starts. Sometimes the system just needs to run and learn itself. If it does run I would replace or check the connector at the throttle body it sounds like a open connection could be the issue. Also, check for corrosion.

Here is guide and some engine wiring diagrams (Below) so you can do some testing:

https://www.2carpros.com/articles/how-to-check-wiring

Let us know what happens and please upload pictures or videos of the problem.

Cheers, Ken
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Wednesday, October 18th, 2017 AT 12:43 PM
Tiny
MICHAEL LYNCH2
  • MEMBER
  • 23 POSTS
Hi Ken
Thank you. I have tried starting it with the accelerator pushed down at various levels. With no joy. (Once again it its very close to starting.) The butterfly in the throttle body does not move and remains shut. The only time I have the butterfly move is when I first turn the key to on and the butterfly gives a very small flutter back and forward as the ECU goes through its check.
The information you have provided is great. However, are you able to have another look for me to see if you can locate the wiring schematics for the particular model I have? It is a 2003 2.0 liter turbo four door. The Engine is a B207 Vin number is YS3FD49S631029231.
The ones you have provided would be awesome, but they are not for the model I have and are not really usable. For example the throttle body actuator on the car has 8 pins. The schematic on your email shows it as having 10 pins. The wiring color coding is completely different.
I do not have to have them but it will make what is going to be a tedious job tracing the wires back to the ECU just a little bit easier.
Would really appreciate anything you can come up with.
At this stage I can see that I have three of the eight wires that are hot going to the actuator. Running approximately five volts.

Cheers
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Wednesday, October 18th, 2017 AT 11:38 PM
Tiny
KEN L
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Okay, I think I found the right engine wiring diagram for you (below).

Please let us know what happens.

Cheers, Ken
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Thursday, October 19th, 2017 AT 11:31 AM
Tiny
MICHAEL LYNCH2
  • MEMBER
  • 23 POSTS
Thanks Ken
Those schematics match the car. I do have the problem in that I see no way that the ECU plugs will split apart to reveal the connections within the plug. I can trace the wires by using a probe in the pin holes of the plug. But if I find I have a bad connection and there is no physical damage to the length of the wire (The wires all look like they are in good condition now I have unwrapped the insulating tape) I still have no way of re-soldering or repairing the joint that is within the plug. There must be a way as to have to replace that section of wiring harness for the sake of a loose or damaged plug connection seems an extreme measure.

Cheers Michael
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Thursday, October 19th, 2017 AT 3:39 PM
Tiny
KEN L
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We can cross that bridge when we get there nine times out of ten a wiring problem is because it has rubbed through or there is correction somewhere. Do your inspection and tests to make sure the wiring is sound.

Please let us know what you find. I am interested to see what it is.

Cheers, Ken
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Friday, October 20th, 2017 AT 12:13 PM
Tiny
MICHAEL LYNCH2
  • MEMBER
  • 23 POSTS
Hi Ken
I've managed to sort the throttle body out. The motor that drives the spindle shaft that turns the butterfly was jammed shut for some reason. After spending a few hours chasing the wiring to from the throttle body motor back to the computer I determined the wires all had continuity and were connected to the ECU. I pulled out the throttle body and tested the connections to the motor. I could identify the pins because of the wiring diagram you sent. I then connected 5V to them and could only get a very slight movement on the butterfly.
But just to make sure this was the problem that was causing the engine not to run and I hadn't screwed the timing up when I put the engine back together (You start to doubt yourself when looking at the problem too long and the cams and cam gears have no timing marks on this engine so not easy to get right without the cam lock tools which I didn't have). As the throttle body was removed I made a plate to swivel over the throttle body opening on the inlet manifold and gave it a small opening so the engine could breathe and turned it over on the starter. It fired up and ran straight away although it was idling all over the place because the throttle body intake and and intake sensor could not be connected across the plate I had made. Anyway whilst I was doing all this I had the throttle body plugged into its plug and it was sitting on the valve cover.
After switching off the engine the throttle body butterfly had somehow done a reset and was working properly. Crazy. Bolted it back on and now it is working perfectly.
Next problem I have is the alternator is not charging the battery. Has a message come up on the dash. Put a volt meter on it and it definitely isn't charging checked all the plugs on the alternator and they are OK so I will have to pull it out and have a look. It might be the regulator diodes? Or I might need another one.

Cheers
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Tuesday, October 31st, 2017 AT 2:24 AM
Tiny
KEN L
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That is great the problem sorted itself out, nice work chasing it. For your new problem please start a new question

Please post your question here

https://www.2carpros.com/questions/new

Cheers, Ken
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Tuesday, October 31st, 2017 AT 11:01 AM

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