Replaced ignition switch/key/ security module on 1999 saab 9-5 now won't start, will turn over

SOURCE: I need instructions for replacing the turbo on a Saab 1999 9-5 4 cyl turbo

Hi, I have done this and it is not too bad, but will take you about 4 hours if you are good, and longer if you have not done much mechanics.

The trick is to find a reasonably priced turbo, check ebay. There is a dude on there that just does rebuilt turbos. Very good, got mine for $

I have been reading up on turbo replacement procedure and I have found this list: First, there are a couple of questions that I have about the list:

2 air openings, pretty easy to figure out
2 exhaust openings, pretty easy to figure out
3 round openings in the center, all banjo bolts?
1 round / two bolt opening in the center.
1 Hose fitting off of the waste-gate
1 Hose fitting off of the air side of the turbo.

STEP 1 Open the expansion tank cap to release the system pressure.
STEP 2 Raise the car & Remove the lower front cover under the car
STEP 3 Drain off the coolant & Remove the turbo brackets
STEP 4 Loosen the return fitting and the pipe from the turbo to the block
STEP 5 Loosen the oil pipe between the filter adapter and the turbo
STEP 6 Lower the car to the floor & Remove the bypass valve & Unplug the connector from the control valve
STEP 7 Disconnect the mass air flow sensor connector & Loosen the hoses to the turbo
STEP 8 Remove the crankcase banjo bolt from the intake manifold and unscrew the bolt from the cam cover
STEP 9 Move the pipe and wiring aside & Remove the engine lifting eye
STEP 10 Remove the mass air flow sensor and air hose
STEP 11 Remove the exhaust manifold heat shield by removing the nut and two clips from underneath
STEP 12 Undo the intake manifold clamp at the turbo & remove the intake
STEP 13 Disconnect the hose clip on the hose between the intercooler & turbo & plug it to keep something from falling in it
STEP 14 Loosen the front exhaust system from the turbo & lower the front exhaust system away from the turbo (DO NOT BEND -THE FLEX HOSE)
STEP 15 Remove the oil pipe from the oil filter adapter & grab the copper washers
STEP 16 Loosen the coolant pipe by the turbo & grab the copper washers & loosen the coolant pipe bolt
STEP 17 Remove the coolant return pipe from the cylinder head & pressure sensor bracket. Once again, Grab the copper washers
STEP 18 Undo the coolant return pipe bolt by the turbo
STEP 19 Undo the nuts securing the turbo to the exhaust manifold. (spray the nuts with WD40)
STEP 20 Install in Reverse


Just did this for the first time. Here are a few hints that may help others.

1) PB BLASTER is your friend. Remove the exhaust top front heat shield and hit exhaust nuts with PB Blaster as soon as you start the job, or night before.

2) Make sure that you have 12mm closed end wrench with AND without ratchet. Also a 1/2 size 12mm socket if you can find / make. These will help.

3) You don't have to remove the oil filter, but there one bolt that it would be nice for. I did not and did manage to get the job done.

4) Take you time. More of finding the right tool combination for each bolt.

5) Two banjo bolts on the turbo were really on there. Needed to use a mini-acetylene torch to eat up.

6) Have extracting sockets and bits ready just in case there are issues getting bolts / nuts off.

Turbo had quite a bit of end-play, but spun fine. Classic symptoms, blue smoke at start up and from time to time when driving. It was also making a bit of noise at idle.

jeffo2 ort11


Also, should get new copper washers. I did not have I have some micro leaks from time to time but nothing bad.

SOURCE: key replacement cost 2008 Saab 7x aero

Is it just a "physical" fit problem?
Because if it is merely this and not your electronics you could always buy another key on ebay like this
http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=310130782609

.......then all you would have to do is pop open the casing like you were going to remove the battery, instead pulling the little circuit board also and replacing it with your own one in your damaged fob!!

SOURCE: Ignition Switch Removal

you'll need to remove the console, as the key switch is between the seats. remove the shift boot cover and undo two console hold down screws (Torx 25) in front of the shift lever; there are two more in the aperture remaining when you take out the rear ashtray. Turn on the ignition key so you can put the shifter into neutral, and slide the console up and out between the seats (squeeze fit between the seat belt connectors) It's much easier if you get a sacrificial key cut, then cut the lobes off it!

with the console out, you'll need to remove the gear shift housing, for which there's a special Saab tool - they are 3 point heads. A six point socket with 3 points filed out might work. rotate the gear shift housing 90 deg to one side, to get at it's bottom, where there are two screws holding its cover in place.

With the cover off, you'll find two screws (T25) one on either side of the switch, holding the switch in place. Remove these and you have the switch. Note connections and alignments for re-assembly.

Hope this helps, if it does please give a "thumbs up"

Thanks

Saabreur

SOURCE: 91 Saab 900 Ignition switch is stuck in lockout can not turn key.

Thanks for returning and placing your comments. This "jiggled the key while held the shifter all the way back released!" quickly solved my problem today. Otherwise I was in panic how to move my parked car out of restricted street cleaning side. You should add this to saabsite forum. Saab 9-3, 2002

SOURCE: Saab 9-3 SE won't start!!!

My boyfriend was having the same problem with his 2002 9-3 and in reading the user manual i found the following...when the car wouldn't start this morning he tried it and instead of having to wait 15 minutes for it to start, it started right up. Oh and his screen didn't give an error.

Electronic starting interlock
(immobilizer)
When the key is inserted in the ignition, a
signal is sent to the receiver. If the signal is
verified, the engine can be started.
Each time the key is removed from the ignition,
the electronic immobilizer is activated.
If a fault is detected (e.g. in the transmitter)
”KEY NOT ACCEPTED” will appear on the
SID.
In this case, you can still start the car if you
turn the ignition key to ON and press one of
the buttons on the key.
Take the car to an authorized Saab dealer to
have the system checked.

If the car does not start
If the text "KEY NOT ACCEPTED" appears
on the SID when the engine refuses to start,
the trouble may be a fault in the transponder
of the key or in the receiver of the ignition
switch. Proceed as follows:
• Turn the key back to the LOCK position.
• Turn the key to the ON position.
• Press one of the buttons on the remote
control (the LED on top of the dash stops
flashing).
• Start the engine.
Try the other key. If it works, the trouble is in
the first key.
Call on an authorized Saab dealer for
inspection and correction