2003 Saab 9-3

The Saab 9-3's direct ignition (DI) cassette is the single most common failure on this vehicle. The cassette contains all four ignition coils and sits directly on top of the spark plugs. It fails due to heat stress and internal insulation breakdown, causing misfires, rough running, check engine light, and reduced power. Some owners go through multiple cassettes over the vehicle's life.

Replace the direct ignition cassette with an OEM or quality aftermarket unit. Replace the spark plugs at the same time. The updated cassette (Saab part 12787707 or equivalent) has improved heat resistance. Running the engine with a failing cassette can damage the catalytic converter from unburned fuel.

The crankshaft position sensor (CKP) fails without warning, causing the engine to stall suddenly while driving with no ability to restart. The sensor provides the primary timing reference for the engine control module, and its failure leaves the ECM unable to fire the ignition or fuel injectors. There is often no preceding warning light or drivability issue.

Replace the crankshaft position sensor. The sensor is located on the front of the engine near the crankshaft pulley and is relatively accessible. Use an OEM-quality replacement sensor, as cheap aftermarket sensors have a high failure rate on Saab engines. Keep a spare sensor in the vehicle as a precautionary measure.

The electronic throttle body develops internal motor or position sensor faults, causing the engine to enter limp mode with severely reduced power. A 'Reduced Engine Power' message appears on the instrument cluster. The throttle body may also cause erratic idle speed, surging, and hesitation during acceleration. The issue is more common in high-mileage vehicles.

Replace the electronic throttle body. The engine control module must relearn the idle parameters after installation, which requires a specific relearn procedure using a Tech 2 diagnostic tool or compatible scan tool. The intake manifold and air filter should be inspected and cleaned during the repair.

The neutral safety switch (also called the transmission range sensor) on automatic transmission models fails, preventing the engine from starting or causing it to start in gear. In some cases, the gear indicator on the dash displays the wrong gear, and the reverse lights may not function. The switch is exposed to road spray and corrodes over time.

Replace the neutral safety switch / transmission range sensor. The connector should be inspected for corrosion and cleaned with electrical contact cleaner. Adjust the switch to the correct position using the alignment tool during installation. A Tech 2 relearn procedure may be needed to clear transmission fault codes.

The SID display located between the gauges progressively loses pixel rows, making it impossible to read important vehicle information such as gear selection, odometer, trip computer data, and warning messages. The issue is caused by degrading ribbon cable connections between the LCD panel and the circuit board inside the display unit.

The SID unit can be removed and sent to a specialist repair shop that resolders the ribbon cable connections to the LCD panel. Alternatively, a rebuilt or new SID unit can be installed. Some owners use aftermarket SID repair kits with new ribbon cables. The repair requires removing the instrument cluster surround.

TI AUTOMOTIVE IS RECALLING CERTAIN FUEL PUMPS, PART NUMBERS TU456 AND TU303, SOLD UNDER VARIOUS BRAND NAMES AS AFTERMARKET AND REPLACEMENT EQUIPMENT FOR THE MOTOR VEHICLES LISTED ABOVE. THE DEFECTIVE FUEL PUMP MAY SEIZE, STOPPING THE FUEL FLOW TO THE ENGINE CREATING A STALLING CONDITION.

A VEHICLE CRASH COULD OCCUR SHOULD THE ENGINE STALL WHILE IN USE.

TI AUTOMOTIVE WILL NOTIFY OWNERS OF RECORD AND WILL REPLACE ANY DEFECTIVE FUEL PUMP WITH A NEW OR REWORKED FUEL PUMP FREE OF CHARGE. THE SAFETY RECALL BEGAN ON FEBRUARY 22, 2011. OWNERS MAY CONTACT TI AUTOMOTIVE AT 1-866-867-3759 OR LOG ON TO WWW.RECALLRESPONSE.COM.

ON CERTAIN PASSENGER VEHICLES, THE FUEL PUMP RETAINING TABS HOLDING THE FUEL LINES WERE DAMAGED DURING PRODUCTION.

OVER TIME, THIS COULD CAUSE THE FUEL LINES TO LOOSEN FROM THE PUMP RESULTING IN FUEL LEAKAGE. IF AN IGNITION SOURCE WERE PRESENT, THE FUEL MAY IGNITE RESULTING IN A VEHICLE FIRE.

DEALERS WILL DEVELOP A SECURING BRACKET THAT WILL SECURE THE FUEL LINES TO THE FUEL PUMP EVEN IF THE PLASTIC RETAINING TABS SHOULD BREAK. THE RECALL BEGAN ON JUNE 13, 2007. THIS IS AN EXPANSION OF PREVIOUS RECALL CAMPAIGNS - SEE 04V557 AND 06V126. OWNERS MAY CONTACT SAAB AT 1-800-955-9007.

CERTAIN SPORT SEDAN AND CONVERTIBLE PASSENGER VEHICLES WERE PRODUCED WITH A VACUUM PIPE CHECK VALVE FOR THE BRAKE BOOSTER THAT MAY FAIL FROM EXPOSURE TO ELEVATED TEMPERATURES. THIS COULD RESULT IN SUDDEN LOSS OF POWER BRAKE ASSIST, USUALLY WITH LITTLE OR NO WARNING.

IF THIS CONDITION WERE TO OCCUR WHEN MINIMUM STOPPING DISTANCE IS REQUIRED, A CRASH COULD OCCUR.

DEALERS WILL INSTALL A NEW REDESIGNED CHECK VALVE. THE RECALL BEGAN ON MARCH 17, 2006. OWNERS SHOULD CONTACT SAAB AT 1-800-955-9007.

ON CERTAIN PASSENGER VEHICLES, THE ENGINE MANAGEMENT SYSTEM SOFTWARE MAY CAUSE ENGINE HESITATION OR STALLING.

IF THE VEHICLE STALLS AS A RESULT OF THIS CONDITION, IT CAN BE RESTARTED IMMEDIATELY.

DEALERS WILL UPDATE THE ENGINE MANAGEMENT SYSTEM. OWNERS MAY CONTACT SAAB AT 1-800-955-9007.

SOME SPORT SEDANS WERE BUILT WITH SEAT BELT RETRACTORS THAT WERE DAMAGED DURING THE MANUFACTURING PROCESS. IF DAMAGED, OVER TIME, THE AUTOMATIC TENSIONING SYSTEM (ATS) CABLE IN THE SEAT BELT RETRACTOR COULD BREAK CAUSING THE BELT WEBBING TO NOT RETRACT.

IN THE EVENT OF A CRASH, A FRONT SEAT OCCUPANT MAY RECEIVE MORE SEVERE INJURIES.

DEALERS WILL REPLACE THE SEAT BELT RETRACTOR ASSEMBLIES. THE RECALL BEGAN ON JANUARY 24, 2005. OWNERS SHOULD CONTACT SAAB AT 1-800-955-9007.