Intercooler split
Discussion
Is this a common fault?
I have an 03 2.2D Saab 93, and a couple of months ago the engine management light came on and the car went into "limp-home" - I thought I was running out of diesel (the SID was at about 6 miles left or something) so filled up 1/2 a mile later and it was fine - light went off a few days later.
I have noticed odd periods where it seemed to be running a bit rougher, and fuel consumption has been slightly high (by about 2mpg according to the SID) but I thought the injectors were maybe just needing cleaned etc.
Anyway, last Friday, same again, light on and limp-home with no power. Next day everything fine. I decided to book it in to the dealer on Friday there. Then it happened again on Thursday but I stopped, switched off, on again and it was fine.
Dealer diagnosed a cracked intercooler, and said that it isn't covered by the Saab extended warranty. Cost me £600 to get it replaced. Later I was speaking to a friend who said that he had a 93 diesel and exactly the same thing happened to him.
I looked at the old part today (I insisted they give it back) and it's clearly not been damaged by a stone or anything - it's just burst under pressure (for all the pressure that's in them - about 22 psi I understand!) - the bottom edge of the cooler is clearly bowed outwards and the fins are distorted and covered in oil - dunno how the oil gets there as there is no oil pipe anywhere near it as far as I can see.
Checked the warranty document and it doesn't list the intercooler in the parts that are covered. On the other hand, it's not listed in the parts that aren't covered, either.
So question is: How common a problem is this? Is this a known weak spot (so specifically excluded from the extended warranty?)
Any advice appreciated.
I have an 03 2.2D Saab 93, and a couple of months ago the engine management light came on and the car went into "limp-home" - I thought I was running out of diesel (the SID was at about 6 miles left or something) so filled up 1/2 a mile later and it was fine - light went off a few days later.
I have noticed odd periods where it seemed to be running a bit rougher, and fuel consumption has been slightly high (by about 2mpg according to the SID) but I thought the injectors were maybe just needing cleaned etc.
Anyway, last Friday, same again, light on and limp-home with no power. Next day everything fine. I decided to book it in to the dealer on Friday there. Then it happened again on Thursday but I stopped, switched off, on again and it was fine.
Dealer diagnosed a cracked intercooler, and said that it isn't covered by the Saab extended warranty. Cost me £600 to get it replaced. Later I was speaking to a friend who said that he had a 93 diesel and exactly the same thing happened to him.
I looked at the old part today (I insisted they give it back) and it's clearly not been damaged by a stone or anything - it's just burst under pressure (for all the pressure that's in them - about 22 psi I understand!) - the bottom edge of the cooler is clearly bowed outwards and the fins are distorted and covered in oil - dunno how the oil gets there as there is no oil pipe anywhere near it as far as I can see.
Checked the warranty document and it doesn't list the intercooler in the parts that are covered. On the other hand, it's not listed in the parts that aren't covered, either.
So question is: How common a problem is this? Is this a known weak spot (so specifically excluded from the extended warranty?)
Any advice appreciated.
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