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Help please... Aero just died, need advice Posted by Chadwick [Email]  (#569) [Profile/Gallery]
(more from Chadwick) on Thu, 28 Feb 2008 20:49:42
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Hey everyone,
I have a stage 5 9k Aero, 232k miles, 5spd.
Volvo green injectors, walbro 255lph fuel pump
Car just suddenly died on me after an evening of skiing. Started it up, ran fine, went to the gas station and filled up with gas, and went off on my way. I did about 3 miles and the car just died, engine cut out.
All electrics were fine. Cranked, no start. Car would hit and start for about 5 seconds then die again. Checked fuel pump fuse, was fine. Physically got out removed floor and listened to fuel pump run, ran fine. Swapped DI over with my spare I keep, still did not start. Pulled fuel rail to verify injectors were firing, they were but perhaps seemed to not be firing very much (I do not know the exact idle flow rate, but it is typically not much). Dropped fuse box to get access to relays and double checked electrics. Battery died at this point from so much cranking, nice motorist stopped and offered jump, had the gf sit in the car and crank while I inspected anything else I could find (mind led to me crank sensor, but if that was the case I would not have fuel pump and the spark I was getting). I'm clueless here, sounds almost electrical, like ECU related? Have a JSP stage 5 ECU, great product, I do not think it would just randomly malfunction. Only ground I checked was the one that mounts to back of the head and under dogbone arm. It was 10 degrees out, a foot of snow, and nighttime so I was pretty frustrated and decided to accept the nice offer of a ride home from the motorist.
Going back to the car in the AM to tinker, any thoughts at this point? Here is the service history I keep on the car, a lot of unrelated to engine junk in there but has whats important.
Thanks for your time,
-Chad
1994 Saab 9000 Aero Service History, 5sp, non TCS
April 06- Purchased from Patrick Walsh, Blacksburg VA. , 185,000 miles
Apr 06 -
1. Replace alternator
2. change oil
3. added sony x-plod 4 way rear component speakers, infinity speakers in font
May 06 -
1. Replace tail pipe
2. Replace fog light bulbs
3. Replace PCV valve
4. Change spark plugs, NGKBP7’s
June 06 –
1. Replace fog light switches
2. Clean sunroof drains
3. Clean aquarium drains
4. Flush coolant
5. Cleaned leather
July 06 –
1. Airbox mod completed
2. Replace ACC unit
3. Added boost gauge
4. Replace headlight relay
5. Refinished headliner, A pillar covers
6. Oxygen sensor replaced, Bosch 3 wire
October 06 -
1. Change oil
2. Change small coolant overflow hose (radiator to reservoir)
3. Changed all vacuum hoses
4. New exhaust hangers
January 07 –
1. Replaced serpentine belt
2. Replaced idler pulley
3. Replaced Tensioner pulley
4. Replaced Front brake rotors
5. Replaced reverse threaded tensioner bolt and tensioner bracket
6. Cleaned leather
7. Added Greddy style blow off valve
8. Custom intake pipe fabricated (IC to Turbo)
9. Replaced headlight switch
March 07 –
1. Changed transmission fluid (10w40 Dyno)
2. Changed oil
3. Adjust AC clutch gap (still intermittently cuts out, compressor will be replaced)
4. Added center gauge holder
5. New front wipers, Bosch Icon
April 07 –
1. Front windshield and seal replaced with OEM, no rust found
2. Used McGuire’s clay bar on exterior, then waxed and sealed
May 07 –
1. Change head gasket
2. Added JT 3 Inch downpipe
3. Heater core hoses (inlet and outlet)
4. R&R turbocharger
a. New td04-15T purchased from Justin Duthie, new seal rings
5. Replaced crankcase vent hose
6. Replaced turbo water send to PCV hose
7. Flush coolant
8. Change spark plugs, NGKBP7’s
9. Change oil
a. Fully converted to Synthetic motor oil, Mobil 1 10w30 used
10. State inspection
11. ABS light cleared
June 07 –
1. Encountered pass side rear shock tower rust
a. Ground out, por 15’d. Made metal brackets and welded in
2. Replaced blown rear speakers with new Sony Xplod
3. Flushed brake fluid (clutch)
July 07 –
1. Added rocky black arm rest (purchased from Justin Duthie)
2. R&R Drivers side seat cover with like new used
3. Added 2x12 subwoofers and amplifier + wiring (Rockford Fostgate subs & wiring, alpine amp)
4. R&R Blow off valve connection boot
5. R&R rear brake pads and rotors (bled rear calipers)
6. Worked on pass rear seat recline issue, completed sheath repair, seat still does not recline properly. Sheath will need replaced
7. R&R right side rear caliper (lifetime warranty, advance)
8. R&R fan switch on radiator
9. R&R Coolant temp sensor on intake manifold
10. Wired in Autometer air/fuel ratio gauge
August 07-
1. Replaced blow off valve clamps with constant torque hose clamps
2. Added clear side blinkers
3. Had Jak Stoll reprogram the ECU to stage 4 at SOC 07.
September 07 – 223k miles
1. Installed Bilstein HD full suspension kit, front and rear
2. Installed polyurethane rear sway bar bushings
3. Installed polyurethane front drop link bushings
4. R&R Headlight switch
5. Replaced screw in handbrake cover
6. R&R license plate bracket
7. R&R Rear décor panel
8. Purchased Valentine1 radar detector
9. Replaced drivers side front lower bumper cover
10. Replaced crank pulley inspection cover on serpentine belt cover
11. Replaced coin tray/cigarette lighter unit in dash
12. Replaced rear shock bolts
13. Replaced rear sway bar bushings (on shock mounting bolts)
14. Registered vanity plate “THE STIG”
15. Added Valentine 1 radar detector hardwire kit
16. Pirelli P4 tires (2) on mounted and put on front of car, P3000’s switched to the rear
17. Lexol treated and armoalled interior
18. 9/18/07. 227k miles. Had front end aligned at Meineke Car Care Center. Morgantown, WV.
October 07 – 225k miles
1. Installed front mount intercooler kit
2. Installed 2.5” piping from turbo to throttle body with stainless T clamps and blue silicone boots
3. Replaced lower radiator hose
4. Replaced reservoir to water pump hose
5. Repaired front bumper lower lip spoiler crack
6. Replaced water pump and o rings
7. Changed spark plugs
8. Added Jak Stoll Stage 5 ECU
9. Installed Volvo “Green Giant” Injectors
10. Replaced coolant reservoir cap
11. Replaced headlights with better condition used
12. Added 2.5” blow off valve flange pipe
November 2007 – 226k Miles
1. Replaced fuel pump with Walbro 225 higher output pump
2. Replaced fuel pump send check valve
3. Replaced fuel pump return check valve
4. Replaced hose from throttle body to crankcase vent hose
5. Replaced hatch shocks (2)
6. Changed oil, 227k miles
December 2007
1. Performed full AC service (Freon removal, evacuation, and replacement
2. Fixed AC compressor rattle caused by broken bolt
3. Installed 9-3 fuel clip recall part
4. Washed and waxed with Klasse
5. Repaired passenger side lower spoiler crack
6. Replaced connector on IAT sensor wiring harness
7. Installed a helper spring on the wastegate
January 2008 – 231k miles
1. Changed cabin air filter
2. Replaced upper timing chain guide
3. Checked torque of head bolts since head gasket job, found two bolts out of torque spec and tightened to proper spec
4. Cleaned PCV check valve
5. Replaced oxygen sensor
6. Replaced passenger side right seat back cable
7. Replaced hood release cable
8. Replaced Fuel pressure regulator
9. Replaced PCV check valve with OEM Saab instead of Scantech
10. Replaced coolant level sensor
February 2008 – 233700 miles
1. Changed oil, Royal Purple 20w40 and Mann filter
2. Replaced serpentine belt (continental)
3. Replaced Idler pulley
4. Replaced Tensioner pulley
5. Replaced hood shocks
posted by 71.61.187...
, Thu, 28 Feb 2008 20:49:42 <-- Viewing This Message, Sat, 1 Mar 2008 13:27:54, Fri, 29 Feb 2008 22:58:59
, Sat, 1 Mar 2008 15:39:46, Fri, 29 Feb 2008 13:31:47
, Fri, 29 Feb 2008 11:06:02, Fri, 29 Feb 2008 11:22:31, Fri, 29 Feb 2008 04:49:44, Sun, 2 Mar 2008 15:36:51
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