UKSaabs

Agreed.

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

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

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

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

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 ...

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

“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

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

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

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)

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)

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:

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

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)

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

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)

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

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

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

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)