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Viggen disaster - maybe

3.2K views 22 replies 14 participants last post by  mytfour  
#1 ·
I'm usually a lurker - reading everybody else's posts. But now I'm in real need of some help.
My 2000 Viggen - 76k miles:
JSP Stage 3+
JSP 3" turbo back
ETS I/C

Here's what happened yesterday - out on the highway, playing with a WRX running pretty hard. Car was running great - it'll spike at about 19-20 psi, then settle to around 16 - which was exactly what was happening. With no noise or drama, it started missing, and the boost gauge was fluttering like crazy.

I got if off the road, and could tell I was on no more than 3 cylinders. Popped the hood - missing & shuddering, but the engine was not noisy. (I've blown a 9.3 T5 - I know that death knock!) Limped it home and started checking:
*Vacuum lines (all silicone) - tight and connected
*I/C hoses - intact and tight
*pulled the plugs - #1 & #2 looked fouled or almost, #3 & #4 looked great, so I replaced them all with the NGK BCPR7ES
*Looked at the piston tops while I was there all looked great - #4 is a little sooty
*Swapped in my spare DI cassette
*Swapped in a known good BPC valve
*Checked BPC lines

So...nothing made any difference. The engine makes no unusual noise, and when I drove it home, it would still build boost readily (of course, I was babying it) - just missing. Sounds like a Subaru.

Oh - and the CEL came on solid then started flashing. I pulled the battery cables after each thing I tried to reset the ECU.

I'm not sure I want to get inside the engine in my garage, but also afraid to drive to the nearest indie Saab garage.
Any ideas?
 
#11 ·
Thanks for all the responses. The MAF is about a year old, and has only maybe 2k miles through it. The DI on the car is about the same age, and the other one was working fine when I replaced it as a precaution. I don't have a OBD scan tool, but I'll try to borrow one and get the codes.
I agree - compression check makes sense. I'm worried about valve train, since the pistons are still intact. That is yet another tool I don't have - I can get mey hands on one, though.
 
#15 ·
The flashing CEL is caused by your misfire. When its flashing like that its indicating that your car is missing enough to cause catalytic converter failure so I wouldnt worry about whats causing the flash, but whatever else it may have stored could tell you a little about whats up. Do you have any way to test your injectors?
 
#18 ·
I actually HAVE replaced the front O2 sensor! The only smell from the car is that really rich odor - like an old carbureted muscle car. The cat is a 3" Magnaflow race cat - only about a year old.

Will check for a leaking cylinder tonight - my greatest fear is a burnt piston! Oh well...it's only money. Good excuse to put a forged set in anyhow...
 
#21 ·
Thanks for all the input guys. It looks like I'm going to be replacing pistons after all.

Anybody familiar with a Saab garage in the Greenville or Spartanburg, SC area? I'm not doing this one myself. As Strother Martin said in Cool Hand Luke - "a man's got to know his limitations..."
 
#22 ·
Well, I picked up a compression tester and confirmed where the issues is - no. 1 cylinder has zero compression. Hope that the cylinder walls aren't scored - I'd love to just have a new set of forged pistons stuffed in and get back on the road!

So, no one can offer any suggestions on who in SC might be able to help with this? I guess I'd be able to drag the Viggen into NC or GA if there's no other choice...
 
#23 ·
Well, tore the engine down, and got a surprise. NO holes in the pistons...but there was a stuck valve in #1 cylinder, and of course it collided with the piston. Going to rebuild the entire thing anyhow - forged pistons, T5 cams, new timing set, bearings, etc., but this wasn't at all what I expected. No excessive rpms (as in missed shifts), just running it hard.