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Hi All,
Just though I’d share with you my experiences with regard to EGR’s DPF’s and tuning boxes, on my 2007 Saab 93 1.9TiD150 Auto. It’s quite long and detailed, but hopefully you’ll find it interesting..!
At the beginning of July I got a tuning box from ebay, with 8 settings. I read about others with the same box running on setting 8, so fitted mine on setting 7. Performance was impressive, but it went into limp mode after a couple of days. I connected up to my op-com and found a fault code relating to DPF saturation so I removed the tuning box, and forced a regeneration. (it ran at 3000rpm for about 10min, and dpf saturation figure went from 49% to 70%.. seemed odd way around but improved the fault)
All was fine for a week, so I refitted the tuning box, this time on setting 3 as recommended by the suppliers. It ran well for another few weeks, until on Friday when leaving work after travelling about 300 yards it completely lost power. It felt ok on tick-over, but revved in a very lumpy way between 1000 and 2000rpm. Once over 2000rpm it sounded and felt ok. I removed the tuning box but it stayed the same, so I put the gearbox over into manual to try and keep the revs up to get home. After about 5 miles the EML (engine management light) came on and went into limp mode. I limped home with the engine giving out less and less power, until it eventually stalled and wouldn’t restart, luckily about 20metres from my house! I pushed it the rest of the way, and left it there till the morning.
The next day I tried to start it, but it only ran for about 4 seconds before stalling again.
I plugged op-com in and found the fault code was p2279 Air intake leak detected, and looked this up on the net. A couple of posts on Vectra-C suggested it could be either the EGR or the DPF. The DPF saturation reading was 26%.
The removed EGR seemed to move about 2 or 3 mm when activated by op-com, but the test wasn’t conclusive as I wasn’t sure whether the valve needed assistance from exhaust pressure or manifold vacuum to operate.
I then removed the DPF, and found it looked pretty well blocked. I flushed it out using a gallon of unleaded, pouring it through backwards about 7 times (filtering the petrol through a sock between flushes). The first couple of flushes liquid flow was slow, but as it cleared the petrol was flowing through much faster by the end. I then poured 2 buckets of plain hot water through to clean the petrol out. It looked like new inside both ends by the time I’d finished, and the hot water was flying through. I left it to drain while I had a brew, and refitted it.
The engine started, and was great on tick-over, but wouldn’t rev.
I decided as a process of elimination to blank off the EGR to see if that had any effect, so a made a solid copy of the bottom gasket out of a coke can. The engine started, and revved freely. It felt sorted – Result..!
I took it for a drive and performance was superb, but fault codes relating to no EGR flow came up (no surprise there..) but after about 10 mins it went into limp mode with p1901-75 “DPF high differential pressure”.
I knew the DPF was like new inside, so with op-com I hit the “replace DPF” button, which reset the saturation to 0%, and the distance since regen to zero.
I removed and thoroughly cleaned the EGR, and activated it using op-com, this time getting about 8mm of travel. EGR refitted and blank removed, the engine felt like it had a bit less grunt, but the op-com readings for the EGR operation were stable and the “no EGR flow” fault stayed away.
Using the car yesterday, the EML comes on every 5 mins or so with p1901-75 “DPF high differential pressure”. I just hit “clear fault codes” and keep driving. I’ve been watching the DPF differential pressure readings, which sit around 10kpa at idle, around 40kpa steady acceleration, and upto 94kpa on full throttle.
I tried last night to force a DPF regeneration, which took the revs to 3k as expected, but the EML came on after about 2mins, the revs ramped down, and the little box popped up to say “regeneration completed”. But, the EML was on, and in limp mode. I reset the fault codes and drove it, but I’m still getting p1901-75 with the EML and limp mode.
DPF readings are now 14% saturation and 85km since regen.
This morning I tried disconnecting the two hoses going to the Differential pressure sensor (on the bulkhead, behind the EGR) and the car drove without the EML coming on, but with a fault code present relating to differential pressure connection problems.

So, my current thinking is to leave it a little longer with the 2 hoses disconnected from the differential pressure sensor, and have another try at forcing a regeneration at some point – either with or without the sensor, but maybe the regen process uses this pressure differential to decide when regen is complete?

Into the future I’d also like to blank off the EGR, or restrict it, or even allow it to draw in clean air via a pipe from the airbox (pre-maf of course), having noticed a definite improvement in performance with it blanked off.

I’m not sure if this was all caused by the tuning box, or if the EGR was sooted up and lazy in operation already, but I’ve learnt a lot about this EGR/DPF stuff this weekend..!
I hope some of you will find all this interesting, and I’d welcome any suggestions you may have for dealing with my current p1901-75 “DPF high differential pressure” fault.

Cheers, Kev.
 

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Kev, brilliant and very helpful post, thanks.

Are you willing to divulge the make of Tuning Box? The reason I ask is I have a Tuning-Diesels Synergy 1, having had one of their earlier ones on my BMW-engined Rover 75 diesel, with fantastic results, right throughout the range - I also had a straight-through EGR bypass pipe fitted. Did 50000+ miles with no problems, hence having no hesitation in going back to them for one for the Saab.

But when I put the Synergy on the Saab - manual 16v TiD, '06 reg, 58000 miles - I had the same as you, OK for a few days (admittedly I had it at posn 9, the maximum, as that's how I'd run it on the Rover), then limp home mode. OK on restart (but with engine light on) then it dropped to limp mode again after a few miles.

Dealer diagnosed EGR, and replaced it, even though I'd put a new one on only a couple of months previously. The car was OK for a while, so I put the Synergy back on, but history repeated itself. I then found a receipt the previous owner had left in the car, for an EGR valve fitted only last October! Told the dealer, who checked a bit deeper, and diagnosed a regeneration needed, which they did.

I sent the Synergy back, to be checked, and was advised it was OK, but they didn't advise running on max setting with this engine, use either setting 3, or no higher than 5 or 6, depending on whether I wanted low down improvement, or more top end.

I've not yet re-fitted it, but until I read your post, I was thinking about doing so. I think maybe I'll wait a while.................

In the meantime, would you mind posting an idiot guide to 'forcing a regeneration' of the particulate filter, please?

Many thanks

Malcolm
 

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Interesting stuff.

1) When you say you activated the EGR via OP-COM and noticed how far it moved, how did you do that? Is that with EGR unbolted from the engine but with electrical connector connected, ignition on but engine not running, and selecting the Test EGR button (or whatever it's called -I forget) under the Special Functions menu? Would like to try the same thing myself to back up some investigations I'm doing (and will upload in due course)

2) And I echo baxlin's request for how to do the dpf regen: I'm on OP-Com v1.33 and can't see the regen option.

Thanks
 

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Discussion Starter #4
Baxlin: PM sent with box name..!

Off the top of my head, when you first log into the engine you get options of "read codes" and "clear codes" along the bottom, and on the right there's a vertical stack of buttons. I think they are "measuring blocks" "output tests" "special functions" and "programming".
It's in "programming" on the second page.

I'll try to get some screen shots and post them up..


As for the EGR test, Yep.. EGR physically disconected but electrically connected. Ignition on, engine NOT running. In "output tests", "EGR solenoid" activate and deactivate makes the valve open and close by about 6-8mm..
 

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Discussion Starter #5
I had a thought on the way home, so pulled over and with the engine running checked how much gas flow was coming out of the disconnected differential pressure hoses..
The fat one (from the front end of the DPF) was flowing plenty of exhaust gas, but the thin one (from the rear end of the DPF) had nothing coming out of it..

So maybe the DPF isn't as clear as i thought it was..
 

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Interesting

I run a Synergy 2 on full boost and fuel. Goes like the clappers with very little smoke and no limp ever encountered.
 

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Discussion Starter #8
how did you activate the EGR in OP-COM... I looked for the option, but could not find it..?[/b]
As above, I logged into the Z19DTH engine ecu, and In "output tests", "EGR solenoid" activate and deactivate makes the valve open and close by about 6-8mm..I should also add, i've been logging in as a vectra-c with a z19dth engine..
 

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sorry... thought you where talking about a replace egr setting within op-com to re-set the egr settings within the ecu after replacing or cleaning the valve.
 

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Interesting

I run a Synergy 2 on full boost and fuel. Goes like the clappers with very little smoke and no limp ever encountered.[/b]
As you say, interesting - IIRC that's the hooligan version isn't it?

Forgive me if my memory's wrong, but wasn't there a thread about this a while ago? At the time, I seem to recall my Synergy 1, as recommended by the manufacturer, was going great guns.

So, do I put back on the car?????????

malcolm
 

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As you say, interesting - IIRC that's the hooligan version isn't it?

Forgive me if my memory's wrong, but wasn't there a thread about this a while ago? At the time, I seem to recall my Synergy 1, as recommended by the manufacturer, was going great guns.

So, do I put back on the car?????????

malcolm[/b]
Yeah it's the one with the boost control too ;)

You spoken to Ron about it?
 

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Yeah it's the one with the boost control too ;)

You spoken to Ron about it?[/b]
Yes, I sent the unit back to them, and spoke to Darren, as Ron wasn't around. They'd had a look it the unit, and 'detuned' it a bit, and recommended I didn't use the highest setting. As I said, I'm a bit wary of re-fitting it!
 

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Yes, I sent the unit back to them, and spoke to Darren, as Ron wasn't around. They'd had a look it the unit, and 'detuned' it a bit, and recommended I didn't use the highest setting. As I said, I'm a bit wary of re-fitting it![/b]
I reckon you should give it a whirl and just make sure you are in a position to get it off and reset if you need to.
 

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Hi all,

Have had a look at the Synergy boxes and they seem quite complex for what I am after with the MAF half that I don't even understand.

Is this a good option for a 93 05 1.9 TID?

As it seems it could go either way - Good with no problems or good for a week or so before causing EML to appear.

Any advice on this would be much appreciated.

Regards,

Deano
 

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I think the site makes it look over complicated. You don't really need to worry about MAF compensation. I have the Synergy 2b which connects to the fuel rail and MAP sensor. Takes 10 mins to fit and gives you control over boost and fuel meaning you get better overall results with less smoke. They are £200 which is much cheaper than the nearest rival which IMHO will give you grief. I haven't had any box related issues with mine and mines on full.
 

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OK guys, I'm interested in one of these Synergy boxes, but a bit confused by the web-sites. Which one are you talking about, and what's the difference please?

http://www.dieseltuningdirect.com/contact.html

http://tuning-diesels.com/Products/prod2.htm

Thanks, Iain[/b]
Iain, it's deffo www.tuning-diesels.com as far as I'm concerned, even though the other one seems to have registered the name Synergy. As I suggested, speak to Ron at tuning-diesels, I find he's very helpful. The number is 0845 539 3970.

HTH

Malcolm
 

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Slightly off topic, but not far!!

I've spoken to Ron at Tuning-diesels again about mine, and he suggested also fitting the restrictive gasket to the EGR valve, which I understand Fiat make. He mentioned that Vauxhall don't seem too keen, so another mixed message for this engine!!

However, I'd like to give it a try, but don't fancy the home-made route, so does anyone have the part number, or know a stockist who'd know what I'm asking for??

Thanks in advance

Malcolm
 

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Slightly off topic, but not far!!

I've spoken to Ron at Tuning-diesels again about mine, and he suggested also fitting the restrictive gasket to the EGR valve, which I understand Fiat make. He mentioned that Vauxhall don't seem too keen, so another mixed message for this engine!!

However, I'd like to give it a try, but don't fancy the home-made route, so does anyone have the part number, or know a stockist who'd know what I'm asking for??

Thanks in advance

Malcolm[/b]
I have the fiat gasket fitted. The Fiat dealer I got it from was not surprised and new exactly why I wanted it. It needed a further 3 10mm holes in it to get it to stop throwing a code but it's fine now. I also fitted a gasket the other side of the EGR to restrict flow going in. I made this out of a coke tin ;)

Part number from fiat....

Check this thread

http://www.saabscene.com/forum/index.php?showtopic=31650785
 
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