Cruise
control

Remember, all this is for a 91, so your system or its
component locations might be a bit different.
If you supply me with information on differences for your model year,
I’ll include them in the write-up.
The cruise control system consists of an electronic control
module, a vacuum pump, a vacuum pot, cutout switches on the brake and clutch
pedals, and a few feet of vacuum hose. Most
problems are caused by leaks in the hoses, so are easy to fix.
The vacuum pump is driven by a small electric motor, and
also has an electrically operated valve that allows vacuum when energized, or
dumps vacuum when de-energized. It’s
located in the aquarium, on the passenger side (US).
The vacuum pot has a rubber diaphragm connected to a metal
rod. Vacuum pulls the diaphragm
back, which causes the rod to retract. A
metal bead chain connects the rod to the accelerator linkage.
The vacuum pot is about 3” away from the top of the accelerator pedal
(it’s not easy to see).
The control module is beneath the dash on the US driver's
side. It's attached to the front of the inverted white 8” x 8”plastic
box that serves as a general attachment and wire routing point (it’s secured
with a slide-on sheet metal clip). It’s very simple inside: A memory IC, a resistor (resembles
a resistor, anyway; might be a coil or a fuse, who knows?) and a couple of
relays. There’s not much in the
box to go wrong, and it usually doesn’t.
The cutout switches not only open the electrical circuit
when the pedals are pressed, they also dump vacuum. I broke my clutch switch when replacing the master cylinder.
I replaced the vacuum/electrical switch with a simple electrical switch
(I just plugged the vacuum line that went to the original switch).
It performs just the same as the original switch.
As far as I can tell, the vacuum-dumping switch function is just a
redundant safety feature. NOTE that
brake light switches close (make contact) when the brake pedal is pushed, to
turn on the brake lights. The
cruise control cutout switches open when the pedal is pushed, so standard brake
light switches won’t work as replacements.
I used a very generic momentary pushbutton switch from Radio Shack. While typical brake switches have long-throw plungers,
generic pushbuttons typically have buttons that only move an eighth of an inch
or so. I glued a small square of
¼” balsa wood to the clutch pedal where it contacts the switch.
The proper shim thickness will just allow the switch to make when the
pedal is released, without restricting the clutch pedal travel or putting too
much pressure on the switch. I
didn’t get an original replacement switch because the Saab switches appeared
to come only in a matched set (I couldn’t figure out how to replace only one)
and I figured that since it’s such a non-standard design, Saab probably wants
an arm and a leg for them.
Another NOTE: The brake and clutch cutout switches provide
a ground for the controller through the brake light filaments. I am
not sure if a single brake light failure will disable the cruise or not, but
it's a good idea to check the bulbs and the sockets to make sure the bulbs can
get a good ground. The filament monitor should alert you to any problems.

Troubleshooting
If the cruise doesn't operate at all:
It appears that the brake light bulbs must be operating
in order for the cruise to work. That's how I interpret what the manual
says, anyway. They're easy to check, so make sure the bulbs and grounds
are good first.
Check the fuse first. If it's OK, check the adjustment
and function of the switches. Bob
Davis says they are adjustable. He says: "Push the pedal in far
enough to release the switch, pull the switch plunger all the way out (there
should be clicking sounds), then slowly release the pedal back to the resting
position." He also says that it appears that on 95 and later cars,
the switches lack the vacuum function (do not know if these are
adjustable). If both switches and fuse are OK, look up under the dash
and make sure the bead chain isn’t broken. If that's OK, check for
vacuum leaks (see below).
If the cruise operates erratically:
Check for vacuum leaks.
There is a hose that runs a few feet, from the vacuum pump to the
vacuum pot. That hose also tees
off and is wyed to the two pedal switches (or just to the brake pedal switch
for a car equipped with automatic transmission). The simplest way to check for
leaks is to disconnect the hose from the pump, suck on it and see if it holds
vacuum. Remove the aquarium
cover. The pump is on the
passenger side (US). There are
two short hoses that run from the front of the pump to the back of the pump,
but don’t bother with them unless you can’t find anything else wrong.
Disconnect the main hose from the lower attachment tube that goes into
the front of the pump (the upper one is the air intake for the pump) and then
suck on the hose. If it doesn’t
hold vacuum, there’s a leak (likely). The
hose could be split at one of the attachment points, one of the switches could
be defective, the vacuum pot could be bad or something could have damaged a
hose (the long screw at the front center of my aquarium cover chewed a hole in
my hose). To eliminate switches
as the culprit, disconnect the hoses from the switches and plug the hoses,
then repeat the suck test
No leaks, good switches, good chain?
The pump gets power on pin 3 of its connector, by way of the cruise
control switches, and ground on pin 2 by way of the controller. The valve
gets power the same way and ground on pin 1, again by way of the
controller. The controller is permanently grounded by pin 8 of its
connector. It gets operational ground on pin 3 by way of the cutout
switches and the brake light bulbs. It gets permanent power on pin
1. Speed is sensed on pin 5. Pins 2 and 6 appear to supply power by
way of the cruise controls switches.
