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900SET Surging Issue & P0304 CEL Light
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Posted by Jon R [Email] (more from Jon R) on Tue, 19 May 2009 06:09:25 Share Post by Email
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The car is a 1996 Saab 900 SET 5 spd. The CEL code reads as P0304 (Cylinder 4 Misfire) Keep in mind I have been constantly erasing this code after every part I have replaced and it still reoccurs. I first tried the basics, first was replacing spark plugs with new ones (These are NGK gapped to .039) I noticed that the first 3 plugs are a darker color than cylinder 4 plug. I even tried replacing and swapping the plugs again with another new set and got the same result. So then, I tried swapping DI Cassette with a good known working one from my other Saab. No difference. I tried also swapping fuel injectors assuming the cylinder 4 injector may have been faulty. Same result. I then tried cleaning the AIC valve and that also made no difference. So then I tried replacing the AIC valve with a good known working one and the CEL still on. I also double checked the flow arrow direction on the AIC valve and made sure it was pointing away from the Throttle Body (according to AllData). Also tried cleaning the Throttle Body which also made no difference. I then tried checking for continuity from the ECM to the plug going into the DIC and that checked out ok. I then tried cleaning the purge valve with some carb cleaner a little bit but it didn’t do anything. I looked for the location of the purge valve on my 9000 to see if I could swap it out but couldn’t seem to locate it so I just cleaned it instead.

So anywho… here's whats going on most recently. I’ve noticed a surging issue which has been going on in addition to the CEL Light. After reving or driving the car it will surge at idling speed and go from 1000rpm up to around 2200 rpm and just go back and forth. I test drove the car and once again cleared the code which came back on shortly and noticed the CEL started flashing (about 9 times when I came to a stop light). Drove for a while longer and at another stop light the CEL flashed around 14 times or so. I didn’t really notice it flash again after driving it a couple more times.

Another note, before purchasing this car it had a blown headgasket. So I ended up having to flush the coolant out a few times and replaced all engine gaskets. Also replaced both Oxygen sensors (Bosch) and installed a new battery. Car then passed inspection and drove fine for about 1000 miles before the CEL had started occurring. Later on I noticed the valve cover gasket was leaking because it was not seated properly so I purchased a new one (I recommend some gasket sealant it’s the only way to keep in place). I have also checked and replaced many old Vac lines with new ones. So, now I’m stumped… the only things I can think of are swapping the purge valve or a faulty ECM (seems rare but its all I got).

Another minor note I did happen to put in some Gumout cleaner in the gas tank before these symptoms occurred. Also after erasing these codes and retesting so many times there have been a couple of times where I have noticed a P0300 Multiple Misfiring code but then it later would change back to the P0304 on Cylinder 4 Misfire.
Any other ideas or input would be greatly appreciated!


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