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2002 Saab 9-5 repairs by problem area

Engine (51%)

Transmission and Drivetrain (3%)

Brakes and Traction Control (3%)

Suspension and Steering (10%)

Electrical and Air Conditioning (24%)

Paint, Rust, Leaks, Rattles, and Trim (3%)

Other (6%)

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Chart based on 163 repairs.

See TSBs and recalls for the 2002 Saab 9-5.

2002 Saab 9-5 engine repair cost distribution

$2500+ (1%)

$1000 - $2499 (15%)

$500 - $999 (12%)

$100 - $499 (32%)

< $100 (40%)

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Chart based on 68 repair trips. The repair cost chart excludes repairs made under warranty, do-it-yourself repairs, and repair trips that include maintenance.

134000 mi

Car shows problem in muffler. There is a leakage at the joint. This makes the car too noisy. Mechanic said it would take him $300 to fix it. I am not sure how much it should cost. Mechanic inspected the car and said probably it is the catalytic converter which cost $2250/- plus labour, work sums up to $2700. Not sure if it is catalytic converter, although check engine light was on even before the muffler leakage.

135000 mi

US $450

Replaced the generic catalytic converter assembly which comes with attached muffler cost around $350. No sound, passed inspection, and car works smooth.

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US $150	Heater bypass valve
US $40	Owner did PCV#6 fix
117800 mi US $80	Replaced leaking heater control valve/coolant bypass valve in about 45 minutes. Used part for '01 Cadillac Catera from Advance Auto Parts.
128000 mi US $300	Replaced 2 PCV hoses, replaced belt & idler pulley, along with routine 120k service
136000 mi US $60	Replaced turbo bypass valve. Check engine light, read OBD2 code as P1110 (vacuum leak), some small stuttering on acceleration. TBV would not hold vacuum, probably ruptured diapragm.
144000 mi US $80	pinhole in heater hose, thermostat replaced, thermocouple replaced
155000 mi US $320	Replaced DIC and spark plugs.
175000 mi US $40	Replaced EVAP valve which was causing rough idle.
180000 mi US $900	oil leak on right side of engine
187000 mi US $380	Replaced ruptured radiator hoses Replaced motor mount
189000 mi US $55	Replaced leaking heater bypass valve.
198000 mi US $225	CEL. Replaced DIC and spark plugs.
229300 mi US $608	replaced radiator

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94000 mi US $1000	Replaced accessory belt tensioner, two idler pulleys and belt. Reverted to original long belt design after dealer converted to short belt design which bypassed one idler. Addressed an NVH issue at idle.
135000 mi US $300	Xmsn mount
155000 mi US $700	replaced worn out transmission and engine mounts replaced in tank fuel pump replaced ignition cassette replaced cam cover gasket
163000 mi US $60	replaced failed coolant temp sensor, replaced thermostat, flush and fill coolant

74000 mi US $10	Leaking valve cover gasket was replaced.
76000 mi US $800	The thermostat needed to be replaced.
114800 mi US $90	Oil pressure sender failed - low pressure light did not illuminate as it should have.
120000 mi	CEL illuminated on dash, code showed turbocharger bypass valve problem. Found loose vacuum hose, replaced the hose. Needed to have the code reset to extinguish the light.

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102000 mi US $1300	Fuel pump replaced replaced thermostat
114000 mi US $1250	replace ignition cassette, replace valve cover gaskets, replace oil sensor
118000 mi US $1100	CPS, cooling system, oil leaks

17600 mi	Dealer replaced coolant temperature sensor under warranty.
25300 mi	Dealer reprogrammed computer under warranty in response to a no-start condition. Car had to be towed to dealer.
45000 mi	Dealer replaced coolant temperature sensor under warranty (second warranty replacement).
72000 mi	Replaced 2 direct ignition (DI) cassettes. Car had to be towed. Eventually covered in 2007 by Saab recall for this problem.
73500 mi	Dealer replaced catalytic converter under warranty, to correct check engine light "on" condition. Failure due to prior failure of DI cassette, which was covered by Saab recall.
123000 mi US $800	Replaced failed fuel pump assembly (first time for this replacement).
129000 mi US $250	Replaced crankshaft position sensor (first replacement) - the part is $80, buy and carry a spare in your car. This failure left us stranded during a driving vacation. Cost shown does not include towing, hotel, meals or rental car charges also incurred.
152000 mi US $495	Thermostat failed (first time for this repair). Replaced thermostat assembly, intake manifold gasket, temperature sensor and coolant.
157000 mi US $1578	replaced engine mount and transmission mount (first replacement for both) in shop for transmission mount replacement - mechanic noticed a squealing timing belt idler bearing. in shop for transmission mount replacement - mechanic noticed a squealing timing belt idler bearing. replaced engine mount and transmission mount (first replacement for both)
168700 mi US $2200	Rebuilt and reinstalled turbocharger unit. Had been showing signs of wear (blue smoke at startup) for almost a year. rebuilt turbocharger assembly
212000 mi US $1215	Replaced timing belt and idler pulleys. Replaced torsion rod (links engine to frame).
219000 mi US $500	Replaced water pump
221000 mi US $700	Plastic tank on radiator cracked. Replaced radiator & refilled coolant.
230500 mi US $287	Replaces oxygen sensor in response to check engine light

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174400 mi

RH, LH motor mounts.

167000 mi US $300	pollution hose deteriorated and was replaced.
183000 mi US $380	Oil clogged screen, piston rod knocking, possibly at main crankshaft bearing. Will not be repairing. Great car up until now.

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112000 mi

US $100

heater bypass valve leaking fluid

95880 mi C $360	check engine light..source of problem was intermittent functioning of engine temp gauge. replaced sensor.
106340 mi C $75	Problem with heating gauge...Diagnosed Sensor problem and /or thermostat. Changed both and problem rectified. Took me about 2.5 hours.

108000 mi US $10	One pulley (plastic wheel) of the accessory belt
120000 mi US $160	Replaced PCV hoses with updated hoses. Commonly called PCV #6.
123000 mi US $56	Turbo-bypass valve (aka "Hooter" valve) replaced. Also replaced a vacuum hose.
123000 mi US $18	...and replaced the water pump
128000 mi US $340	Replaced Ignition Cassette

91200 mi	Computer lit fault codes for cylinders 1,2,3,4 misfiring. Replaced spark plugs with SAAB specification. Misfire codes returned after a week of driving. Further analysis indicates failing direct ignition cassette. Not affecting driving
92000 mi	Failing direct ignition cassette.

61500 mi	Wife took car to dealer because of intermittent power loss. Dealer downloaded updated software to ECM.
63570 mi	Took car back three days later with same loss of power issue. Dealer kept car 10 days, cleaned fuel injectors.
64500 mi	Took car back to dealer yet again because of loss of power. Dealer kept car two week, determined the ECM Saab sent was defective. Replaced ECM.

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214000 mi

US $69

Engine sputtered and malfunctioned, threw codes p106 and p107, MAP sensor. Replaced 2 vacuum hoses, good as new.

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66000 mi US $300	Engine would stutter and check-engine light flash. Mechanic disassembled fuel injection system and cleaned injectors and rails
68000 mi US $235	Crankshaft sensor failed and needed to be replaced

74000 mi

US $1200

Coolant leak. Heater control valve and associated hoses replaced.

90000 mi

US $110

Vehicle exhibited a moaning sound under moderate acceleration up hill. Power delivery gradually turned choppy. Started having problems starting. Main fuel computer is dead. Unique to exact car - not just to model. Awaiting results. The vehicle wouldn't start. It would turn over but that was it. I thought it was a fuel pump. It turned out to be a fuel computer that governs entire fuel system. Mechanic hacked computer as it is specific to this exact car!

99000 mi US $250	replaced the coolant bypass valve.
100000 mi US $670	Leaking oil pressure switch;
100000 mi	OIL LEAK FROM EITHER THE HEAD GASKET OR THE TIMING COVER.