Saab 9-3 with a running problem

SAAB 9-3 with a running problem
SAAB 9-3 with a running problem

This SAAB 9-3 came in with a severe running and hesitation fault.

Carbon deposits inside manifold
Carbon deposits inside manifold

We test drove the car but didn't experience what the customer was feeling. As there were no lights on the dashboard it wasn't easy to decipher what the problem was. We carried out a diagnostics test but no faults were logged. The customer decided to leave the car with us for a few days for further invesitigations.

On driving the car the next day the engine appeared to be very unresponsive and slow to rev up from idle. The technician made further engine checks and noticed that the EGR flow was higher than normal. On removal of the EGR valve some heavy deposits were noted inside the valve. He fitted a blanking plate to the EGR valve and re-checked the engine, it appeared to be responding much better. He then checked the inlet manifold flaps and found the flap rod worn and the spindles have wear. To solve the problem the SAAB required a replacement EGR valve and inlet manifold. We removed the cambelt and high pressure fuel pump to gain access to the inlet manifold. We replaced the manifold assembly, control motor, control rod, cambelt kit and water pump.

New manifold fitted
New manifold fitted

To complete the job the motorised throttle flap assembly had a good clean out. We cleared any fault codes remaining on the computer and test drove the car. Everything was at it should be.