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PostPosted: Mon Jun 10, 2019 10:34 pm 
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Joined: Sat Jan 18, 2014 3:23 pm
Posts: 1881
Location: Sussex
Car Model: '04 9-5 Aero est., '97 9K Aero
sounds wrote:
Perhaps my memory is failing me, but I'm 99% sure the one which stays in place (located near the power steering reservoir) is between the purge solenoid and throttle body, the one to be eliminated is part of the second leg which tees into this line and connects to the cobra pipe (as highlighted in red in the diagram above). Can't check though, as my current 9-5 is a 2005 model year - so therefore doesn't have it ...


Agreed.


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PostPosted: Wed Jun 12, 2019 2:05 pm 
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Joined: Wed May 11, 2016 11:19 am
Posts: 23
Location: The Cronx
Car Model: 9-5 HOT Aero Wagon
Thanks again for all your help guys, fully deleted the pipe and check valve, could feel some restriction at the top end under pressure so wound the actuator out 1/2 turn and I'm now boosting freely to 14.6psi 8)

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9-5 MY2002 HOT Aero Wagon
'72 Cal-look Beetle


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PostPosted: Wed Jun 12, 2019 3:32 pm 
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Joined: Thu Feb 14, 2008 10:47 am
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Location: Queenborough, Kent
Car Model: 9k, 9-5 Aero & a Jaaag
Good to hear it’s now working properly, 1 Bar is about right for a stock 9-5 Aero.

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'98 9000 2.3T CSE, stage 3
'04 9-5 Aero manual, stage 3
'08 Jaguar XFR


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PostPosted: Thu Jun 13, 2019 10:14 am 
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Joined: Wed May 11, 2016 11:19 am
Posts: 23
Location: The Cronx
Car Model: 9-5 HOT Aero Wagon
Just thought I'd do a little list of things that were checked/replaced sorting the issue (some of this was unnecessary, done only for piece of mind in the future as car is already over 180k)

    Vac hoses including BCV hoses replaced
    Cobra to compressor o-ring and V clamp replaced
    Throttle body inlet pipe o-ring replaced
    Full bolt mod carried out: T-piece between BCV and Cobra deleted, then EVAP hose section back to and including check valve located next to power steering reservoir deleted.
    Wastegate actuator replaced.
    Intercooler hoses checked and tightened (Maptun replacements fitted around a year ago)
    Brake booster vacuum pump + pipework checked for leaks (auto box only)
    Top cap on Maptun recirculating dump valve had loosened off so cleaned and tightened up

Def worth whipping out the old Fuse #17 for at least an hour after any major adjustments too.

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9-5 MY2002 HOT Aero Wagon
'72 Cal-look Beetle


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PostPosted: Thu Jun 13, 2019 4:01 pm 
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Joined: Thu Feb 14, 2008 10:47 am
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Location: Queenborough, Kent
Car Model: 9k, 9-5 Aero & a Jaaag
If it makes you feel any better, I did most of what you did (and more) chasing the lack of power when warm on one of my previous 9-5 Aero estates, which turned out to be due to a partially stripped thread on the thermostat cover ... :wall:

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'98 9000 2.3T CSE, stage 3
'04 9-5 Aero manual, stage 3
'08 Jaguar XFR


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PostPosted: Thu Jun 13, 2019 4:23 pm 
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Joined: Sat Jan 18, 2014 3:23 pm
Posts: 1881
Location: Sussex
Car Model: '04 9-5 Aero est., '97 9K Aero
“Full bolt mod carried out: T-piece between BCV and Cobra deleted, then EVAP hose section back to and including check valve located next to power steering reservoir deleted.”

How does your fuel vapour get from the charcoal canister into the intake tract? If I read you right you’ve deleted both the routes.

cardboaardcutout


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PostPosted: Mon Jun 24, 2019 10:53 am 
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Joined: Wed May 11, 2016 11:19 am
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Location: The Cronx
Car Model: 9-5 HOT Aero Wagon
cardboardcutout wrote:
“Full bolt mod carried out: T-piece between BCV and Cobra deleted, then EVAP hose section back to and including check valve located next to power steering reservoir deleted.”

How does your fuel vapour get from the charcoal canister into the intake tract? If I read you right you’ve deleted both the routes.

cardboaardcutout


Sorry, not a great explanation! T-piece still in place and connected to charcoal canister, but hose from BCV/Cobra deleted, t-piece blocked off and check valve after t-piece deleted.

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9-5 MY2002 HOT Aero Wagon
'72 Cal-look Beetle


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PostPosted: Mon Jun 24, 2019 10:58 am 
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Joined: Wed May 11, 2016 11:19 am
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Location: The Cronx
Car Model: 9-5 HOT Aero Wagon
sounds wrote:
If it makes you feel any better, I did most of what you did (and more) chasing the lack of power when warm on one of my previous 9-5 Aero estates, which turned out to be due to a partially stripped thread on the thermostat cover ... :wall:


Such a minefield isn't it, at one point while investigating I found that the o-ring at the throttle body/intake pipe join had collapsed and melted at the back left where the foam insulator protects the sensor. Take a quick look and you'd say it was fine but about a 5mm section of it had just stretched and melted!

It's by no means been just one thing causing problems here anyway, car has never run as well as it does now though so all worth it 8)

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9-5 MY2002 HOT Aero Wagon
'72 Cal-look Beetle


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PostPosted: Sun Aug 18, 2019 4:58 pm 
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Joined: Sun Oct 28, 2007 11:31 am
Posts: 2393
Location: Chatham, Kent.
Car Model: 9-5 Aero 2002
sgould wrote:
I'm at home now and have the pictures!

This is the pipe you need to remove.

Attachment:
EVAP mod.png


Will, with ref to the hose we have to remove, my hose has come apart at the t, can I remove the t and replace with a straight thru and then block the redundant hose instead of removing it as a temp measure?

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2002 9-5 Aero Saloon Manual. Noobtune Stage III
2000 9-5 Aero Estate Auto. Maptun Stage I (Broken)


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PostPosted: Sun Aug 18, 2019 5:02 pm 
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Joined: Sun Oct 28, 2007 11:31 am
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Location: Chatham, Kent.
Car Model: 9-5 Aero 2002
sounds wrote:
Double-check near the power steering reservoir, as (unless it’s been replaced) the non-return valve near the headlight is the one in the second leg (that you ideally need to eliminate).


Dan, mine has a NR valve near the steering res, are you saying there is another behind the headlamp? Mine has a blue coloured joint near the headlamp but not sure if its just a connection in the line.

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2002 9-5 Aero Saloon Manual. Noobtune Stage III
2000 9-5 Aero Estate Auto. Maptun Stage I (Broken)


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PostPosted: Sun Aug 18, 2019 5:06 pm 
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Joined: Thu Feb 14, 2008 10:47 am
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Location: Queenborough, Kent
Car Model: 9k, 9-5 Aero & a Jaaag
phil_saab wrote:
sounds wrote:
Double-check near the power steering reservoir, as (unless it’s been replaced) the non-return valve near the headlight is the one in the second leg (that you ideally need to eliminate).


Dan, mine has a NR valve near the steering res, are you saying there is another behind the headlamp? Mine has a blue coloured joint near the headlamp but not sure if its just a connection in the line.
Phil, yes there are two legs - going from memory, the NRV for the one that links back to the throttle is near the PS reservoir, the other (in the leg you can delete) is behind the RH headlight. Bear in mind that some of that pipework is covered in sticky back foam which may hide what lurks beneath ...

In respect of tee pieces, effectively you need to replace both existing tee pieces in the dotted red line in diagram Will posted (reproduced below) with straight-through couplers:

Image

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'98 9000 2.3T CSE, stage 3
'04 9-5 Aero manual, stage 3
'08 Jaguar XFR


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PostPosted: Sun Aug 18, 2019 5:26 pm 
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Joined: Sun Oct 28, 2007 11:31 am
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Location: Chatham, Kent.
Car Model: 9-5 Aero 2002
Copy that Dan, all is now clear. Will have to wait till next weekend now, carpark is getting dark and I have work all next week. So effectively I remove both T - pieces and replace with straight couplers, I can then remove the red dotted line in Wills diagram.

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2002 9-5 Aero Saloon Manual. Noobtune Stage III
2000 9-5 Aero Estate Auto. Maptun Stage I (Broken)


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PostPosted: Sun Aug 18, 2019 6:09 pm 
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Joined: Sun Jan 26, 2014 9:41 am
Posts: 3462
Location: Royal Tunbridge Wells
Car Model: '03 9-5 2.3 Vector Auto Estate
Check the routing on the actual car for connector types, I could not get the pipes off the existing connectors at the evap valve to change them. I replaced mine when the connection to the evap valve split adjacent to the headlight. The old pipe is quite hard and removing take a bit of effort. I used petrol grade pipe for the replacement. Basically I replaced the run from the evap valve to the TB with a new NRV in it (the existing is virtually moulded into the hard pipe) and put a straight connector into the pipe from the air pipe. I used an 'L' connector for the line to the evap valve from the TB as it fitted better.

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Alan

'03 Saab 9-5 2.3t Vector Estate Auto Noob Stg 1
'01 Saab 9-3 2.0t SE Vert
'81 Triumph TR7 DHC


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PostPosted: Sun Aug 18, 2019 6:53 pm 
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Joined: Sun Oct 28, 2007 11:31 am
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Location: Chatham, Kent.
Car Model: 9-5 Aero 2002
Thanks Alan, think i have got it all sorted in my mind now, just got to buy a couple straight connectors and another NRV and i will be sorted for next weekend. Think i may purchase a length of fuel pipe as well just in case.

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2002 9-5 Aero Saloon Manual. Noobtune Stage III
2000 9-5 Aero Estate Auto. Maptun Stage I (Broken)


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PostPosted: Sun Aug 18, 2019 7:48 pm 
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Joined: Thu Feb 14, 2008 10:47 am
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Location: Queenborough, Kent
Car Model: 9k, 9-5 Aero & a Jaaag
When I did this on my old 52-reg estate, I seem to remember ordering 6mm and 8mm fuel hose, NRVs in both sizes, straight couplers (in 6mm I think?) and a straight reducer - which I think was 8mm to 6mm. I have a feeling I ran 8mm from throttle body to evap purge solenoid - with the 6mm reducer at the valve end - and one of the straight couplers on the line between cobra pipe takeoff and the APC solenoid. I know I've got some of the bits leftover in the garage still :roll:

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'98 9000 2.3T CSE, stage 3
'04 9-5 Aero manual, stage 3
'08 Jaguar XFR


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PostPosted: Sun Aug 18, 2019 8:25 pm 
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Location: Royal Tunbridge Wells
Car Model: '03 9-5 2.3 Vector Auto Estate
phil_saab wrote:
Thanks Alan, think i have got it all sorted in my mind now, just got to buy a couple straight connectors and another NRV and i will be sorted for next weekend. Think i may purchase a length of fuel pipe as well just in case.


Phil, I note you are in Chatham. I am not fit for much travel at the moment (recent op in Medway and a few complications) but if you are around TW you are welcome to come and see my piping anytime.

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Alan

'03 Saab 9-5 2.3t Vector Estate Auto Noob Stg 1
'01 Saab 9-3 2.0t SE Vert
'81 Triumph TR7 DHC


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PostPosted: Mon Aug 19, 2019 4:19 am 
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Joined: Sun Oct 28, 2007 11:31 am
Posts: 2393
Location: Chatham, Kent.
Car Model: 9-5 Aero 2002
Thanks Alan, Im in Paddock Wood quite a lot so one day I may well give you a shout fella.

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2002 9-5 Aero Saloon Manual. Noobtune Stage III
2000 9-5 Aero Estate Auto. Maptun Stage I (Broken)


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