Bulletins


BulletinBulletin dateReplacement BulletinItem no.SummaryAdded
ELECTRICAL SYSTEM
36206/21/1999608360Customer may complain of the horn sounding on its own or the steering wheel radio controls operating intermittently. *tt11/23/1999
ELECTRICAL SYSTEM - IGNITION - MODULE
248226109/01/2000618671Subject regarding campaign instructions for recall 724 on replacing the engine control module (ecm). *tt04/19/2001
ELECTRICAL SYSTEM - WIRING - INTERIOR/UNDER DASH
38109/01/1999610155Subject regarding the spare parts programming of miu. *tt04/19/2000

Investigations


NHTSA IDManufacturerDate openDate closeSubjectRecall campaign
ELECTRICAL SYSTEM
PE05017SAAB CARS USA, INC.04/07/200509/23/2005ENGINE STALL/ ENGINE COMPARTMENT FIRES06V410000
 Odi opened pe05-017 based on 35 reports of alleged engine stalling due to the failure of the idm cassette on the subject vehicles.all complainants reported that the engine shut down suddenly without warning and most reported that the vehicle would not restart.in 3 incidents, the complainants reported smoke and/or fire resulted from the idm failure.during pe05-017, additional failure data was identified as noted in the failure report summary above.the complaint data represents incidents where the complainants alleged a stall or fire.on september 13, 2005, general motors (gm) notified nhtsa of a safety defect on 95,081 my 2000-2002 saab 9-3 and 9-5 vehicles with 4-cylinder gasoline engines and 8,117 my 2001 9-5 vehicles with 6- cylinder gasoline engines (recall 05v-399).the notification stated that certain vehicles within these populations may experience overheating and burnout of the isolated gated bipolar transistor (igbt) within the idm due to increased susceptibility to electrical loads.overheating of the igbt occurs most often at engine start-up for both a 4-cylinder and 6-cylinder engine, but it may also occur while the engine is running.when the idm fails on a 4-cylinder while it is running, the engine may stall without warning, with no ability to be restarted.when the idm fails on a 6-cylinder engine while it is running, the driver will initially experience reduced power and rough operation because the engine will only be running on three cylinders.the check engine light will flash.if the driver continues, unburnt fuel in the exhaust can cause thermal damage to the catalytic converter.the engine may stall and not restart.thermal damage to other underhood components and the underbody may also result from prolonged driving.the recall population encompasses 84% of the stalling and fire complaints (215 for vehicles with 4-cylinder engines and 36 for vehicles with 6-cylinder engines).the 36 months in service (mis) stalling rates for each model year of recalled vehicles with 4-cylinder engines were all greater than two percent.although the 36 mis stall rate for the recalled my 2001 vehicles with v6 engines was lower, at 1.3 percent, these vehicles also had the highest rate of confirmed (open flame verified) fires at 62 per 100,000 vehicles.gm will instruct owners to bring their vehicles to a dealer for idm inspection and replacement, if necessary.consequently, this investigation is closed.odi will monitor the effectiveness of the scope and remedy of gm's action and take further action if warranted.
PE05017SAAB CARS USA, INC.04/07/200509/23/2005ENGINE STALL/ ENGINE COMPARTMENT FIRES05V399000
 Odi opened pe05-017 based on 35 reports of alleged engine stalling due to the failure of the idm cassette on the subject vehicles.all complainants reported that the engine shut down suddenly without warning and most reported that the vehicle would not restart.in 3 incidents, the complainants reported smoke and/or fire resulted from the idm failure.during pe05-017, additional failure data was identified as noted in the failure report summary above.the complaint data represents incidents where the complainants alleged a stall or fire.on september 13, 2005, general motors (gm) notified nhtsa of a safety defect on 95,081 my 2000-2002 saab 9-3 and 9-5 vehicles with 4-cylinder gasoline engines and 8,117 my 2001 9-5 vehicles with 6- cylinder gasoline engines (recall 05v-399).the notification stated that certain vehicles within these populations may experience overheating and burnout of the isolated gated bipolar transistor (igbt) within the idm due to increased susceptibility to electrical loads.overheating of the igbt occurs most often at engine start-up for both a 4-cylinder and 6-cylinder engine, but it may also occur while the engine is running.when the idm fails on a 4-cylinder while it is running, the engine may stall without warning, with no ability to be restarted.when the idm fails on a 6-cylinder engine while it is running, the driver will initially experience reduced power and rough operation because the engine will only be running on three cylinders.the check engine light will flash.if the driver continues, unburnt fuel in the exhaust can cause thermal damage to the catalytic converter.the engine may stall and not restart.thermal damage to other underhood components and the underbody may also result from prolonged driving.the recall population encompasses 84% of the stalling and fire complaints (215 for vehicles with 4-cylinder engines and 36 for vehicles with 6-cylinder engines).the 36 months in service (mis) stalling rates for each model year of recalled vehicles with 4-cylinder engines were all greater than two percent.although the 36 mis stall rate for the recalled my 2001 vehicles with v6 engines was lower, at 1.3 percent, these vehicles also had the highest rate of confirmed (open flame verified) fires at 62 per 100,000 vehicles.gm will instruct owners to bring their vehicles to a dealer for idm inspection and replacement, if necessary.consequently, this investigation is closed.odi will monitor the effectiveness of the scope and remedy of gm's action and take further action if warranted.
ELECTRICAL SYSTEM - IGNITION
PE05017SAAB CARS USA, INC.04/07/200509/23/2005ENGINE STALL/ ENGINE COMPARTMENT FIRES06V410000
 Odi opened pe05-017 based on 35 reports of alleged engine stalling due to the failure of the idm cassette on the subject vehicles.all complainants reported that the engine shut down suddenly without warning and most reported that the vehicle would not restart.in 3 incidents, the complainants reported smoke and/or fire resulted from the idm failure.during pe05-017, additional failure data was identified as noted in the failure report summary above.the complaint data represents incidents where the complainants alleged a stall or fire.on september 13, 2005, general motors (gm) notified nhtsa of a safety defect on 95,081 my 2000-2002 saab 9-3 and 9-5 vehicles with 4-cylinder gasoline engines and 8,117 my 2001 9-5 vehicles with 6- cylinder gasoline engines (recall 05v-399).the notification stated that certain vehicles within these populations may experience overheating and burnout of the isolated gated bipolar transistor (igbt) within the idm due to increased susceptibility to electrical loads.overheating of the igbt occurs most often at engine start-up for both a 4-cylinder and 6-cylinder engine, but it may also occur while the engine is running.when the idm fails on a 4-cylinder while it is running, the engine may stall without warning, with no ability to be restarted.when the idm fails on a 6-cylinder engine while it is running, the driver will initially experience reduced power and rough operation because the engine will only be running on three cylinders.the check engine light will flash.if the driver continues, unburnt fuel in the exhaust can cause thermal damage to the catalytic converter.the engine may stall and not restart.thermal damage to other underhood components and the underbody may also result from prolonged driving.the recall population encompasses 84% of the stalling and fire complaints (215 for vehicles with 4-cylinder engines and 36 for vehicles with 6-cylinder engines).the 36 months in service (mis) stalling rates for each model year of recalled vehicles with 4-cylinder engines were all greater than two percent.although the 36 mis stall rate for the recalled my 2001 vehicles with v6 engines was lower, at 1.3 percent, these vehicles also had the highest rate of confirmed (open flame verified) fires at 62 per 100,000 vehicles.gm will instruct owners to bring their vehicles to a dealer for idm inspection and replacement, if necessary.consequently, this investigation is closed.odi will monitor the effectiveness of the scope and remedy of gm's action and take further action if warranted.
PE05017SAAB CARS USA, INC.04/07/200509/23/2005ENGINE STALL/ ENGINE COMPARTMENT FIRES05V399000
 Odi opened pe05-017 based on 35 reports of alleged engine stalling due to the failure of the idm cassette on the subject vehicles.all complainants reported that the engine shut down suddenly without warning and most reported that the vehicle would not restart.in 3 incidents, the complainants reported smoke and/or fire resulted from the idm failure.during pe05-017, additional failure data was identified as noted in the failure report summary above.the complaint data represents incidents where the complainants alleged a stall or fire.on september 13, 2005, general motors (gm) notified nhtsa of a safety defect on 95,081 my 2000-2002 saab 9-3 and 9-5 vehicles with 4-cylinder gasoline engines and 8,117 my 2001 9-5 vehicles with 6- cylinder gasoline engines (recall 05v-399).the notification stated that certain vehicles within these populations may experience overheating and burnout of the isolated gated bipolar transistor (igbt) within the idm due to increased susceptibility to electrical loads.overheating of the igbt occurs most often at engine start-up for both a 4-cylinder and 6-cylinder engine, but it may also occur while the engine is running.when the idm fails on a 4-cylinder while it is running, the engine may stall without warning, with no ability to be restarted.when the idm fails on a 6-cylinder engine while it is running, the driver will initially experience reduced power and rough operation because the engine will only be running on three cylinders.the check engine light will flash.if the driver continues, unburnt fuel in the exhaust can cause thermal damage to the catalytic converter.the engine may stall and not restart.thermal damage to other underhood components and the underbody may also result from prolonged driving.the recall population encompasses 84% of the stalling and fire complaints (215 for vehicles with 4-cylinder engines and 36 for vehicles with 6-cylinder engines).the 36 months in service (mis) stalling rates for each model year of recalled vehicles with 4-cylinder engines were all greater than two percent.although the 36 mis stall rate for the recalled my 2001 vehicles with v6 engines was lower, at 1.3 percent, these vehicles also had the highest rate of confirmed (open flame verified) fires at 62 per 100,000 vehicles.gm will instruct owners to bring their vehicles to a dealer for idm inspection and replacement, if necessary.consequently, this investigation is closed.odi will monitor the effectiveness of the scope and remedy of gm's action and take further action if warranted.
ELECTRICAL SYSTEM - IGNITION - MODULE
PE05017SAAB CARS USA, INC.04/07/200509/23/2005ENGINE STALL/ ENGINE COMPARTMENT FIRES05V399000
 Odi opened pe05-017 based on 35 reports of alleged engine stalling due to the failure of the idm cassette on the subject vehicles.all complainants reported that the engine shut down suddenly without warning and most reported that the vehicle would not restart.in 3 incidents, the complainants reported smoke and/or fire resulted from the idm failure.during pe05-017, additional failure data was identified as noted in the failure report summary above.the complaint data represents incidents where the complainants alleged a stall or fire.on september 13, 2005, general motors (gm) notified nhtsa of a safety defect on 95,081 my 2000-2002 saab 9-3 and 9-5 vehicles with 4-cylinder gasoline engines and 8,117 my 2001 9-5 vehicles with 6- cylinder gasoline engines (recall 05v-399).the notification stated that certain vehicles within these populations may experience overheating and burnout of the isolated gated bipolar transistor (igbt) within the idm due to increased susceptibility to electrical loads.overheating of the igbt occurs most often at engine start-up for both a 4-cylinder and 6-cylinder engine, but it may also occur while the engine is running.when the idm fails on a 4-cylinder while it is running, the engine may stall without warning, with no ability to be restarted.when the idm fails on a 6-cylinder engine while it is running, the driver will initially experience reduced power and rough operation because the engine will only be running on three cylinders.the check engine light will flash.if the driver continues, unburnt fuel in the exhaust can cause thermal damage to the catalytic converter.the engine may stall and not restart.thermal damage to other underhood components and the underbody may also result from prolonged driving.the recall population encompasses 84% of the stalling and fire complaints (215 for vehicles with 4-cylinder engines and 36 for vehicles with 6-cylinder engines).the 36 months in service (mis) stalling rates for each model year of recalled vehicles with 4-cylinder engines were all greater than two percent.although the 36 mis stall rate for the recalled my 2001 vehicles with v6 engines was lower, at 1.3 percent, these vehicles also had the highest rate of confirmed (open flame verified) fires at 62 per 100,000 vehicles.gm will instruct owners to bring their vehicles to a dealer for idm inspection and replacement, if necessary.consequently, this investigation is closed.odi will monitor the effectiveness of the scope and remedy of gm's action and take further action if warranted.
PE05017SAAB CARS USA, INC.04/07/200509/23/2005ENGINE STALL/ ENGINE COMPARTMENT FIRES06V410000
 Odi opened pe05-017 based on 35 reports of alleged engine stalling due to the failure of the idm cassette on the subject vehicles.all complainants reported that the engine shut down suddenly without warning and most reported that the vehicle would not restart.in 3 incidents, the complainants reported smoke and/or fire resulted from the idm failure.during pe05-017, additional failure data was identified as noted in the failure report summary above.the complaint data represents incidents where the complainants alleged a stall or fire.on september 13, 2005, general motors (gm) notified nhtsa of a safety defect on 95,081 my 2000-2002 saab 9-3 and 9-5 vehicles with 4-cylinder gasoline engines and 8,117 my 2001 9-5 vehicles with 6- cylinder gasoline engines (recall 05v-399).the notification stated that certain vehicles within these populations may experience overheating and burnout of the isolated gated bipolar transistor (igbt) within the idm due to increased susceptibility to electrical loads.overheating of the igbt occurs most often at engine start-up for both a 4-cylinder and 6-cylinder engine, but it may also occur while the engine is running.when the idm fails on a 4-cylinder while it is running, the engine may stall without warning, with no ability to be restarted.when the idm fails on a 6-cylinder engine while it is running, the driver will initially experience reduced power and rough operation because the engine will only be running on three cylinders.the check engine light will flash.if the driver continues, unburnt fuel in the exhaust can cause thermal damage to the catalytic converter.the engine may stall and not restart.thermal damage to other underhood components and the underbody may also result from prolonged driving.the recall population encompasses 84% of the stalling and fire complaints (215 for vehicles with 4-cylinder engines and 36 for vehicles with 6-cylinder engines).the 36 months in service (mis) stalling rates for each model year of recalled vehicles with 4-cylinder engines were all greater than two percent.although the 36 mis stall rate for the recalled my 2001 vehicles with v6 engines was lower, at 1.3 percent, these vehicles also had the highest rate of confirmed (open flame verified) fires at 62 per 100,000 vehicles.gm will instruct owners to bring their vehicles to a dealer for idm inspection and replacement, if necessary.consequently, this investigation is closed.odi will monitor the effectiveness of the scope and remedy of gm's action and take further action if warranted.

Consumer Complaints


Fail datemilesoccurencesPurchase date
ELECTRICAL SYSTEM
09/30/20091288001
 For my 1999 saab 9-3, base engine, i replaced the direct ignition cassette, at 128,800 miles on the odometer. the part alone was $488 and the total installation cost and parts (including a hose and four spark plugs) was $760. model years 2000 through 2002 were recalled for this part. *tr
12/31/2008138000
 Tl*the contact owns a 1999 saab 9-3. while driving approximately 55 mph in the snow, the driver's side air bag suddenly deployed without an impact or crash occurring. there were no injuries. later that day, the air bag indicator illuminated. her mechanic stated that the air bags would not function properly and ensure maximum protection in the event of a crash. the vehicle was taken to a certified mechanic for diagnostic testing and the wiring was determined to be the cause of the failure. the manufacturer would not assist because the vehicle was no longer under warranty. the current mileage was approximately 141,000 and failure mileage was approximately 138,000.
02/10/2007111500112/04/2002
 I have a 1999 saab 9-3 with manual climate control. the blower switch was erratic for a few weeks (on/off position shifted) but last night during a short journey the blower would not turn off and a bad odor became present in the cabin. this morning i investigated and found that the blower switch and wiring connector and wires have melted. it is likely that if the journey had been longer a fire would have resulted. the switch and connector and wires need to be replaced, and the reason for the blower switch erratic behavior needs to be investigated. *jb
01/22/2005110/13/1999
 Dic (direct ignition cassette) failure, also known as the idm cassette or ignition coil. i have read several other complaints of the ignition cassette failing and this is a major safety issue. it is an expensive repair, as well. appears that there is a pending recall on the 2000-2002 models and i would like to see the recall extend to the 1999 models; same module. i would not have been aware of the pending recall on the 2000-2002 models except that i have a friend who received a letter and i decided to investigate. please advise why the defect investigation pe05017 was closed pending gm's actions on the 2000-2002 models. the 1999 model and any other affected models should be covered by any recall, as well. i'm sure many people are not aware of ability to report issue and realize that it is a major defect. please advise. *nm
09/24/20041
 While driving vehicle stalled. consumer was unable to restart vehicle, and had it towed to the dealer for inspection. mechanic informed consumer that the vehicle was placed on a diagnostic machine, and the computer recorded a code referring to the computer system. *ak
ELECTRICAL SYSTEM - FUSES AND CIRCUIT BREAKERS
08/01/2004680003
 Vehicle suddenly loses power when the fuse to the fuel pump blows. *mr the mechanics suggested that nothing was wrong with the vehicle. they did not find anything wrong with the electrical wiring harness. *sc *jb
ELECTRICAL SYSTEM - IGNITION
02/02/2008118356
 Tl*the contact owns a 1999 saab 9-3. the contact attempted to start his vehicle, but was unsuccessful. the vehicle cranked, but he received no spark. he attempted to change the fuel pump, which did not repair the failure. he also removed the spark plug wires and noticed that various parts were cracked underneath the ignition. a junkyard mechanic stated that the ignition was the cause of the malfunction. the contact discovered nhtsa campaign id number 05v399000 (electrical system:ignition:module), which pertained to the 2000-2002 saab 9-3's. the dealer stated that the repair would cost $464. the failure mileage was 118,356.
06/27/2006100788108/13/1999
 Dt*: the contact stated the vehicle stalled while driving 45-50 mph on a snow covered highway. the vehicle was towed to an independent mechanic who determined the recognition cassette module failed. the dealership was not notified. there were no prior problems with the vehicle. the check engine light illuminated at the time of the incident. updated 11/3/2006 - on 11/24/05 the vehicle's direct ignition cassette failed without warning which caused the vehicle to stall while being driven in the snow. after replacement of the direct ignition cassette the repair facility also had to replace two oxygen sensors and the catalytic converter. the technician said it was possible that raw fuel damaged the catalytic converter during the initial failure of the direct ignition cassette. *nm
11/01/2005102000111/01/2004
 Note: this is the exact part and symptom described in nhtsa campaign id number : 05v399000 for 2000-2003 years. 1) i was driving up a hill, and the car stopped driving. 2) once it came to a stop, i could not restart the car. ) the ignition was replaced, and the service center confirmed that it was the same part that is covered in the 2000-2003 recall. *ak
02/26/1999
 Ignition locked. yh
ELECTRICAL SYSTEM - IGNITION - MODULE
09/11/200668618106/28/2002
 While driving at freeway speeds for about 20 minutes, my 1999 saab 9-3 experienced a loss of power and the engine stopped running. there was no warning of a probem until a single clunking noise was detected and then there was no power in 5th or 4th gear. by the time i downshifted to 3rd gear, the engine had stalled and the check engine, battery/alternator, and oil pressure warning lights lit. the car was not able to be resarted. i was able to bring the car to the distress lane and summon help (911). the car needed to be towed for repairs. the local saab dealer determined the ignition discharge module (idm) had failed (burned up). the dealer also informed me of a recent recall (i believe it's 05v-399) for the 2000 - 2002 model years and that perhaps the idm on my car had a similar defect. the dealer installed a new idm (replacement part 55-561-132) and 4 new spark plugs which had been fouled from my repeated efforts to restart the car. i did not receive old parts back.
08/18/200695700104/13/2000
 Direct ignition cassette failed on my 1999 saab 9-3. a recall has been issued for 2000-2002 saab 9-3 and i feel this recall should include the '99 model as well because this part has a less than reasonable life. *jb
07/05/200664830109/18/2000
 The direct ignition failed on my 1999 saab 93. it is not covered under the recall. the service engine soon light came on which alerted us to the problem. my authorized saab mechanic informed me that it was the wisest course to replace this faulty part before it failed completely. the cost to do so $500 out of my own pocket to replace this inherently faulty part. *jb
04/14/200660749102/06/1999
 1999 saab 9-3 ignition cassette failure. *jb
03/28/200615145102/12/2005
 I believe my 1999 saab 9-3 should have been included in recent saab ignition module recalls, my ignition module is no different than the 2000 models, the recent failure of this part involves safety factors same as the 2000 models, replacement cost is over 400.00 and should be reimbursed. *jb
02/19/200672550111/01/1998
 Direct ignition cassette (ignition discharge module) failed. engine would not start after being turned off. car was towed, evaluated, and the ignition discharge module was replaced. the ignition discharge module that failed was identical to the idm that is currently under recall for 2000-2002 model years. i am requesting that the recall be extended to include the 1999 model year. i have retained the failed part. *nm
10/29/2005123000104/01/2003
 Dt: the contact stated vehicle stalled while in a parking lot. he tried to restart it ten minutes later but it would not start. the vehicle was towed to the dealership, and they replaced the direct ignition cassette. there was a recall for later model vehicles and the part was the same unit that was in this vehicle. *ak updated 11/29/05. *jb updated 11/29/2005. *nm
07/15/200550000208/21/1999
 Direct ignition cassette (aka direct ignition module, idm, di, dic) has died on my 1999 9-3 2 times. i have owned the car since new, it now has 66,000 miles. when the di cassette dies the engine immediately shuts down which can result in a dangerous situation if one is driving in traffic. my di cassette first died at 50,000 miles. the car simply would not start, no prior warnings. a brand new di cassette from saab was put in. the 2nd di cassette died at 63,000 miles, while i was driving. there was no prior warning again. the car shut down as i was driving, and i lost power steering. i was able to pull off to the side of the road since i was going slow. di cassette was replaced again, so i am currently on di cassette #3. the part is unchanged, so i fear it could die again at any moment. i've had to pay out of pocket for all of the di cassettes. *jb
08/08/200579660304/15/2003
 In the couple of months previous to this incident, my vehicle's check engine light has come on three times, stayed on for a day or two, and then shut off. each time the light came on (first it blinks, then remains steady until turning itself off) i experienced what i thought was some kind of ignition failure. on the morning of the incident, i was traveling in the passing lane heading north/east on route 365 from verona to rome, ny when i experienced a complete ignition failure. the check engine light came on (first blinking, then steady) and i had complete loss of power. i moved the vehicle to the right lane preparing to coast to a stop on the shoulder, but the vehicle regained power after about 15 seconds and i continued on. the check engine light remained illuminated until it shut itself off later in the day as i was returning home (a two and one half hour trip). i plan to take the vehicle to the dealer where i purchased it to have the problem diagnosed.*jb
09/04/200363000104/15/2001
 While traveling down i-70, the direct ignition cassette failed on my 1999 saab 9-3. the engine stopped immediately which affected the power steering and brakes. fortunately i was able to coast off the highway and onto a side street. the next day i went to the saab parts dealer, bought another for around $375, and was told this is a common problem. my car only had 60,000 miles on it at the time. once the direct ignition cassette was replaced, the problem was solved. *nm
ELECTRICAL SYSTEM - IGNITION - SWITCH
11/18/2005111/15/1998
 Dt: the contact stated vehicle stalled, and had to be towed to the dealership. the ignition cassette was replaced. the vehicle is working properly at this time. *ak
ELECTRICAL SYSTEM - WIRING - INTERIOR/UNDER DASH
05/16/200540000211/15/2002
 Dash information display pixels burn out/disappear. while annoying for time and radio display, this could be a safety issue as this display reports temperature outside (in icy conditions) and mechanical/functional problems with the car. if the display is illegible a driver could misinterpret a problem.