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 Post subject: Re: TTID Aero daily
PostPosted: Tue Oct 09, 2018 7:44 pm 
Steve 9000 wrote:
''Removed at users request'' wrote:
Tidy motor and the plate looks familiar.
If you have access to tech2, I'd be looking at the fuel pressure on cranking, should very rapidly hit >260bar, if its struggling to build pressure you may have an injector(s) starting to fail.
Though I'd go with starter or spill off rubber pipes firstly.
Starters are well known to go weak, when I did my TiD the starter pinion felt "gritty" when turned by hand, new one was as expected smooth.

When you do the timing belt kit, it might be worth swapping the timing belt crank pulley at the same time, as the corners can round off the key inside the pulley, allowing the pulley to move out of time.
Pulley cost me £20 from a Vaux dealer using the GM part number.



Cheers, all on the check list now

Funny you mention the starter feeling gritty, for the short time the starter spins after the engine has caught it sounds rather hideous and grindy if that makes any sense?


My new one did that, so I spacered it with washers, when I pulled it when I was having issues, I regreased the whole thing - planetary gearset, shaft, pinion and gave it a push with my hands, it then went click and went fully home
Refitted and had no issues with it since

Could be the pinion / starter dog isn't retracting fully fast enough and is hitting the ring gear as it spins around?


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 Post subject: Re: TTID Aero daily
PostPosted: Tue Oct 09, 2018 7:48 pm 
If you do have a failing injector I'd recommend British Turbo Parts / BTP on eBay, they did 2 injectors for me, arranged collection FOC, left me on a Thursday afternoon, they got them on the Friday, sent back out on the Monday, back with me Tuesday lunchtime.
Had no issues at all with them and price was exceedingly reasonable - £68.75 each, phoned a few other places and they wanted £115+VAT and upwards.
Albeit I dealt with a different reconditioner before BTP and they took 2 weeks to get 1 injector back to me, were evasive on calls and the impression I got was just utter chaos, annoying as they had quoted a week turnaround


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 Post subject: Re: TTID Aero daily
PostPosted: Sun Oct 14, 2018 9:11 pm 
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Saab Nut
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Joined: Thu May 05, 2011 11:09 am
Posts: 1439
Location: Aberdeen
Car Model: MY99 9-3 SE HOT
Starter done now and it starts a bit better, Still a bit smokey when cold which I'm still thinking EGR as it looks like someone has had a crack at taking it off and given up leaving some lovely rounded torx bits...plan is to drill heads off using right angled drill and replace with stronger bolts.

Tried to replace glow plugs today and got 3 done (1&2 are like new and are NGK items) 3 is stuck so is soaking in plus gas now (may have to defer that to one of those companies that do injector removal if it all goes wrong) and 4 looked pretty knackered.

Thanks for the tips ''Removed at users request'', hoping that isn't the case but handy to know. Planning to get Opcom as a lot of people say it works with the TTID and I have a Mk4 astra coupe in the fleet too so won't go to waste.


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 Post subject: Re: TTID Aero daily
PostPosted: Mon Nov 12, 2018 7:47 pm 
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Saab Nut
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Joined: Thu May 05, 2011 11:09 am
Posts: 1439
Location: Aberdeen
Car Model: MY99 9-3 SE HOT
Small update on this

Done a couple k now and all seems good apart from a drop link making itself heard, so will be replacing both sides with HD items. Got the glow plug out by taking the car for a roasting and soaking liberally in plus gas a few times...Starts nearly perfectly unless it's a freezing morning in which case a couple heats makes life easier.

Cleaned the EGR valve which someone had done...but they had ignored the seat of the valve so it was sitting slightly open with all the crud stuck on the seat. As a result the car now feels much better and starting after it's been sat for a couple hours (i.e when it doesn't use the glow plugs) is almost instant, before it used to wind for a good 10 seconds before catching.

During EGR cleaning I noticed there wasn't an o ring on the EGR valve and the gasket on the housing was leaking coolant...I can't seem to find this gasket anywhere or if there should be an o ring on the EGR

I'm hoping to get round to the Timing belt and water pump this weekend coming, I would like to take off the inlet at the same time to clean it...same again I can't seem to find gaskets for the inlet. I'm wondering if I can just order insignia 2.0 CDTI gaskets for an A20DTX as I understand the inlet fits on these.

I've also started using BP ultimate diesel as it was sounding like an unserviced transit banana engine on Tescos finest, seems to pull better as well, much to the disappointment of a MK3 focus ST trying to show off :lol:


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 Post subject: Re: TTID Aero daily
PostPosted: Tue Nov 13, 2018 9:52 am 
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Joined: Wed May 12, 2004 9:46 pm
Posts: 14797
Location: Mulbarton,Norfolk
Car Model: TTid's only now :-(
Just a small metal ring gasket/washer.

It's pretty snug fit anyway with the milled surfaces.


A20DTH inlet manifold is the same plastic item I believe, so those gaskets should fit the car (53053800 gasket kit).

Also, if you are having the inlet off (major work!), consider the A20DT or A20DTL inlet new, it doesn't have any swirl flaps :-) Pt no. 55565592 I believe.


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 Post subject: Re: TTID Aero daily
PostPosted: Tue Nov 13, 2018 9:11 pm 
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Joined: Thu May 05, 2011 11:09 am
Posts: 1439
Location: Aberdeen
Car Model: MY99 9-3 SE HOT
wrighar wrote:
Just a small metal ring gasket/washer.

It's pretty snug fit anyway with the milled surfaces.


A20DTH inlet manifold is the same plastic item I believe, so those gaskets should fit the car (53053800 gasket kit).

Also, if you are having the inlet off (major work!), consider the A20DT or A20DTL inlet new, it doesn't have any swirl flaps :-) Pt no. 55565592 I believe.


Interesting, all the one's I've happened across seem to have swirl flaps, I might have to do some digging. I would love to replace the inlet with brand new but I think funds might be a bit tighter going towards the festive season.

Can you just remove the flaps but leave the spindles in place so everything works as normal but the flaps don't break off and kill the engine?


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 Post subject: Re: TTID Aero daily
PostPosted: Tue Nov 13, 2018 9:43 pm 
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UKS Veteran
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Joined: Wed May 12, 2004 9:46 pm
Posts: 14797
Location: Mulbarton,Norfolk
Car Model: TTid's only now :-(
Steve 9000 wrote:
wrighar wrote:
Just a small metal ring gasket/washer.

It's pretty snug fit anyway with the milled surfaces.


A20DTH inlet manifold is the same plastic item I believe, so those gaskets should fit the car (53053800 gasket kit).

Also, if you are having the inlet off (major work!), consider the A20DT or A20DTL inlet new, it doesn't have any swirl flaps :-) Pt no. 55565592 I believe.


Interesting, all the one's I've happened across seem to have swirl flaps, I might have to do some digging. I would love to replace the inlet with brand new but I think funds might be a bit tighter going towards the festive season.

Can you just remove the flaps but leave the spindles in place so everything works as normal but the flaps don't break off and kill the engine?


Apparently it's from a A20DTH 160PS engine

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 Post subject: Re: TTID Aero daily
PostPosted: Sun Dec 09, 2018 7:25 pm 
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Joined: Thu May 05, 2011 11:09 am
Posts: 1439
Location: Aberdeen
Car Model: MY99 9-3 SE HOT
Having done a LOT of googling, I've decided to keep the swirl flaps as the positives (low down power, reduced smoke and better MPG) seem to outweigh the one negative (possible ingestion by engine). Now I've decided that the best thing to do is to order the A20DTJ inlet from the newer Astras etc as apparently they are less prone to breakage. To hopefully reduce the chance of engine destruction further I'll be getting the EGR mapped out and blanked off as it seems the issue is build up of carbon and oil mist mixing and jamming them causing them to work harden and break off.

At the same time I'll be replacing the EGR valve gasket that sits between the valve and the cooler (part number 55573360) as I am 100% losing coolant from there as you can see dried coolant around it and level drops over a few weeks.

I have a long weekend this weekend so the plan is to start Friday and that leaves me plenty time to take my time and be methodical with everything...even if I don't get it done I have my OG 93 which I have enjoyed driving again over the past week...just a shame about the 20ish MPG :lol:

Also does anyone have any recommendations for remapping? I've seen celtic tuning mentioned but I'm dubious of their claimed output...also I don't want to max everything out, just a mild remap would be nice


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 Post subject: Re: TTID Aero daily
PostPosted: Tue Dec 18, 2018 8:15 pm 
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Saab Nut
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Joined: Thu May 05, 2011 11:09 am
Posts: 1439
Location: Aberdeen
Car Model: MY99 9-3 SE HOT
Timing belt/water pump and inlet all done...Also found the inlet was leaking coolant a little and number one swirl flap was M.I.A
ImageIMG-20181215-WA0000 by Steve, on Flickr
Number 4 was loose on it's post not far off joining number 1...can't find any signs of it at all

This was replaced and the original have very little of the red gaskety material on it
ImageIMG_20181215_235538 by Steve, on Flickr

Not the worst job I've done but it was hampered by a snapped inlet stud which was fixed by a few choice words, a drill and a tap

It's like a different car, low down power is instant and MPG is creeping up


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 Post subject: Re: TTID Aero daily
PostPosted: Mon Dec 24, 2018 6:03 pm 
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Saab Nut
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Joined: Thu May 05, 2011 11:09 am
Posts: 1439
Location: Aberdeen
Car Model: MY99 9-3 SE HOT
Not too much to add but fitted this and it seems to have made a difference mpg and power wise
ImageIMG_20181222_203113 by Steve, on Flickr

And trying out a different colour combo from my OG93 (black and red)
ImageIMG_20181222_212210 by Steve, on Flickr

I'm not 100% on it yet but it's easliy changed if I don't like it...Yes the car is filthy :lol:


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 Post subject: Re: TTID Aero daily
PostPosted: Mon Dec 24, 2018 6:12 pm 
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UKS Veteran
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Joined: Wed May 12, 2004 9:46 pm
Posts: 14797
Location: Mulbarton,Norfolk
Car Model: TTid's only now :-(
One of those would still throw a CEL on mine on down slope over run, so I just fitted a full blank and had CEL 365days a year instead :-)

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 Post subject: Re: TTID Aero daily
PostPosted: Mon Dec 24, 2018 6:35 pm 
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Joined: Thu May 05, 2011 11:09 am
Posts: 1439
Location: Aberdeen
Car Model: MY99 9-3 SE HOT
So far so good :lol: that's the plan eventually but having it mapped out eventually so will probably switch to a full blank then...lower revs certainly seem perkier with it fitted


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 Post subject: Re: TTID Aero daily
PostPosted: Mon Dec 24, 2018 8:14 pm 
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Joined: Sun Feb 07, 2010 8:32 pm
Posts: 3045
Location: Kent
Car Model: og aero,Viggen,TTID wagon
Steve 9000 wrote:
Not too much to add but fitted this and it seems to have made a difference mpg and power wise
ImageIMG_20181222_203113 by Steve, on Flickr

And trying out a different colour combo from my OG93 (black and red)
ImageIMG_20181222_212210 by Steve, on Flickr

I'm not 100% on it yet but it's easliy changed if I don't like it...Yes the car is filthy :lol:


That looks like a fantastic workshop / garage you have , I'm jealous :D


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 Post subject: Re: TTID Aero daily
PostPosted: Thu Dec 27, 2018 10:28 pm 
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Saab Nut
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Joined: Thu May 05, 2011 11:09 am
Posts: 1439
Location: Aberdeen
Car Model: MY99 9-3 SE HOT
keeny wrote:
Steve 9000 wrote:
Not too much to add but fitted this and it seems to have made a difference mpg and power wise
ImageIMG_20181222_203113 by Steve, on Flickr

And trying out a different colour combo from my OG93 (black and red)
ImageIMG_20181222_212210 by Steve, on Flickr

I'm not 100% on it yet but it's easliy changed if I don't like it...Yes the car is filthy :lol:


That looks like a fantastic workshop / garage you have , I'm jealous :D


it's not bad :lol:

It's shared which makes it cheaper but it's big enough as that pic is only my half


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 Post subject: Re: TTID Aero daily
PostPosted: Sun Feb 10, 2019 9:42 pm 
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Saab Nut
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Joined: Thu May 05, 2011 11:09 am
Posts: 1439
Location: Aberdeen
Car Model: MY99 9-3 SE HOT
Small update

Seen BillJ had an offer on braided lines (in purple) so splashed out and ordered a set for the TTiD and a set for my OG93....impressed, they are so much better quality than the Goodridge ones

So spent today fitting them along with new rear discs and pads, and rebuilding the NSR caliper as it's always been a bit sticky
ImageIMG_20190210_115051 by Steve, on Flickr
ImageIMG_20190210_132211 by Steve, on Flickr

Now everything seemed to be going great, only had to replace 2 brake pipes for being corroded until I went to fit the OSR caliper after fitting the new discs and pads...it was too small. Seems a previous 'mechanic' had fitted the caliper for solid discs and since they were so worn down it went on no problem with the old ones. A panicked phonecall to work 5 mins before closing and thankfully we had a new one on the shelf, and my co worker even drove out of his way to drop it off for me...owe him a case of beer for that :lol:
ImageIMG_20190210_185142 by Steve, on Flickr

Noticed I've picked up a weep on the EGR cooler housing so have ordered one for next weekend


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 Post subject: Re: TTID Aero daily
PostPosted: Mon Feb 11, 2019 3:32 pm 
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Joined: Tue Aug 16, 2016 11:38 pm
Posts: 75
Location: Cheltenham
Car Model: saab 9-5 Aero HOT 2003
Don't go with Celtic Tuning. My dad got his car remapped by Celtic tuning and even though it got 240Bhp on the Dyno. The map is written badly and slowly degrades over time when it is re-read from the memory in the ECU.


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 Post subject: Re: TTID Aero daily
PostPosted: Mon Feb 11, 2019 4:27 pm 
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Full Pressure Turbo

Joined: Mon Mar 18, 2013 8:47 pm
Posts: 645
Location: Sunny Chester
Car Model: 9-3SW Sportwagon Aero TTiD
Mine made 237.8bhp on the rollers and 502nm and its absolutely fine, mine was live mapped though.


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 Post subject: Re: TTID Aero daily
PostPosted: Mon Feb 18, 2019 9:49 pm 
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Saab Nut
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Joined: Thu May 05, 2011 11:09 am
Posts: 1439
Location: Aberdeen
Car Model: MY99 9-3 SE HOT
Not much to add apart from, finally got it washed and added a coat of Auto finesse Aqua coat, which I am very impressed with...keeps the wax/sealant topped up nicely
ImageIMG_20190218_075104 by Steve, on Flickr


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 Post subject: Re: TTID Aero daily
PostPosted: Wed Apr 03, 2019 8:35 pm 
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Saab Nut
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Joined: Thu May 05, 2011 11:09 am
Posts: 1439
Location: Aberdeen
Car Model: MY99 9-3 SE HOT
Not too much to report, Had the grilles painted anthracite which makes the front end a bit meaner (for a diesel :lol: )
ImageIMG_20190324_141243 by Steve, on Flickr


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