2003 Saab 9-3

To date, ODI is aware of 142 non-duplicative complaints related to the alleged defect.In addition, ODI is aware of 2,626 subject vehicles with one or more warranty claims related to the alleged defect.In total, ODI is aware of 2,714 unique subject vehicles that have experienced one or more front suspension coil spring fractures.ODI is not aware of any crashes or injuries related to the alleged defect.The engineering design and testing data supplied by GM, along with the frequency of consumer complaints and warranty claims related to the alleged defect, tends to support the position that, in general, the coil springs that fractured on many subject vehicles did not achieve the expected service life.However, in regard to the subject vehicles, a front suspension coil spring fracture itself has little safety consequence, as evidenced by the minimal impact on vehicle ride and handling and by the number of drivers who were unaware of the failure condition for some time until alerted by service personnel.The ratio of tire punctures to coil spring fractures appears low and there are no reports of crashes, deaths or injuries related to the alleged defect. A safety-related defect has not been identified at this time and further use of agency resources does not appear to be warranted.Accordingly, this investigation is closed.The closing of this investigation does not constitute a finding by NHTSA that a safety-related defect does not exist.The agency will continue to monitor this issue and will take further action if warranted by the circumstances.See the EA08-026 Engineering Analysis Closing Report for more details.

ON AUGUST 28, 2008, THE OFFICE OF DEFECTS INVESTIGATION (ODI) OPENED A PRELIMINARY EVALUATION (PE08-051) TO INVESTIGATE ALLEGED FRONT SUSPENSION COIL SPRING FRACTURES IN CERTAIN MODEL YEAR (MY) 2003-2004 SAAB 9-3 VEHICLES SOLD OR REGISTERED IN SALT BELT STATES.(NOTE: FOR PURPOSES OF THIS INVESTIGATION, THE SALT BELT INCLUDES CONNECTICUT, DELAWARE, THE DISTRICT OF COLUMBIA, ILLINOIS, INDIANA, IOWA, MAINE, MARYLAND, MASSACHUSETTS, MICHIGAN, MINNESOTA, MISSOURI, NEW HAMPSHIRE, NEW JERSEY, NEW YORK, OHIO, PENNSYLVANIA, RHODE ISLAND, VERMONT, WEST VIRGINIA AND WISCONSIN).SUBSEQUENT ANALYSIS OF DATA PROVIDED BY GENERAL MOTORS CORP. (GM) HAS LED THE AGENCY TO EXPAND THE SCOPE OF THIS INVESTIGATION TO INCLUDE ALL MY 2003-2006 SAAB 9-3 VEHICLES SOLD OR REGISTERED IN SALT BELT STATES. TO DATE, ODI IS AWARE OF 53 NON-DUPLICATIVE COMPLAINTS AND/OR FIELD REPORTS THAT ALLEGE COIL SPRING FRACTURE IN THE SUBJECT VEHICLES, INCLUDING 23 ALLEGING THE FRACTURED SPRING DAMAGED A TIRE, WITH 16 OF THOSE INVOLVING A TIRE PUNCTURE.ANALYSIS OF WARRANTY DATA PROVIDED BY GM IDENTIFIED 1,218 CLAIMS PAID TO REPAIR SUBJECT VEHICLES THAT EXPERIENCED THE ALLEGED DEFECT, OF WHICH 138 VEHICLES ALSO SUFFERED DAMAGE TO THE ADJACENT TIRE AND OF THOSE, 79 VEHICLES EXPERIENCED A TIRE PUNCTURE.ODI IS NOT AWARE OF ANY CRASHES OR INJURIES RELATED TO THE ALLEGED DEFECT. GM MADE SEVERAL DESIGN CHANGES TO THE COIL SPRINGS AND/OR MCPHERSON STRUT ASSEMBLIES USED IN THE SUBJECT VEHICLES IN AN APPARENT EFFORT TO ADDRESS THE ALLEGED DEFECT CONDITION.HOWEVER, GM MAINTAINS THAT THE SUBJECT VEHICLES REMAIN WELL CONTROLLED IN THE EVENT OF TIRE PUNCTURE, THAT THE RATE OF TIRE PUNCTURE INCIDENTS RELATED TO COIL SPRING FRACTURES IS LOW, AND THAT THE ALLEGED DEFECT DOES NOT POSE AN UNREASONABLE RISK TO MOTOR VEHICLE SAFETY.ACCORDINGLY, THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS (EA08-026) TO FURTHER STUDY THE SAFETY CONSEQUENCES OF THE ALLEGED DEFECT.

ON DECEMBER 30, 2003, ODI OPENED A PRELIMINARY EVALUATION (PE03-059) TO INVESTIGATE 16 COMPLAINTS ALLEGING ENGINE STALL WHILE DRIVING IN MODEL YEAR 2003 SAAB 9-3 SPORT SEDANS WITH 2.0L TURBOCHARGED ENGINES.ON JANUARY 15, 2004, GENERAL MOTORS (GM) ADVISED ODI THAT GM AND SAAB HAD DECIDED TO CONDUCT A GLOBAL CUSTOMER SATISFACTION CAMPAIGN TO CORRECT TWO DISTINCT ENGINE MANAGEMENT SOFTWARE CONDITIONS THAT COULD RESULT IN ENGINE STALL IN APPROXIMATELY 12 THOUSAND SAAB 9-3 VEHICLES EQUIPPED WITH AUTOMATIC TRANSMISSIONS.THE REMEDIES FOR BOTH CONDITIONS INVOLVED REPROGRAMMING THE ENGINE MANAGEMENT SOFTWARE. GM HAS STATED THAT NEITHER CONDITION CAN OCCUR DURING VEHICLE ACCELERATION AND IN BOTH CASES THE VEHICLE CAN BE SAFELY CONTROLLED AND IMMEDIATELY RESTARTED AFTER ENGINE STALL. FOR THESE REASONS, AMONG OTHERS, GM BELIEVES THAT THE SUBJECT VEHICLES DO NOT CONTAIN A SAFETY-RELATED DEFECT. TO DATE, ODI HAS NOT RECEIVED ANY REPORTS OF CRASHES ALLEGEDLY DUE TO STALLING OF THE SUBJECT VEHICLES.NEVERTHELESS, ODI BELIEVES THAT THE CIRCUMSTANCES ASSOCIATED WITH THESE STALLING CONDITIONS CAN HAVE A SIGNIFICANT ADVERSE EFFECT ON SAFETY.ODI BELIEVES THAT THE CONDITIONS ADDRESSED BY GM?S CUSTOMER SATISFACTION CAMPAIGN WOULD HAVE BEEN MORE APPROPRIATELY TREATED AS A SAFETY RECALL.HOWEVER, BASED ON THE VERY HIGH COMPLETION RATES FOR THAT CAMPAIGN (83.3 PERCENT OVERALL) AND GM?S LETTER DESCRIBING ITS FUTURE APPROACH TO THE CONSIDERATION OF STALLING ISSUES, ODI HAS DECIDED THAT FURTHER EXPENDITURE OF AGENCY RESOURCES ON THIS INVESTIGATION IS NOT WARRANTED.THEREFORE, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY THE CIRCUMSTANCES.FOR ADDITIONAL INFORMATION SEE THE ATTACHED REPORT.

THE SUBJECT VEHICLES ARE EQUIPPED WITH AUTOMATIC TRANSMISSIONS AND TURBOCHARGED ENGINES WITH TWO DIFFERENT POWER OUTPUTS, 175 HP AND 210 HP.SAAB HAS MODIFIED THE ELECTONIC CONTROL MODULE (ECM) SOFTWARE IN THE SUBJECT VEHICLES TO CORRECT PROBLEMS THAT COULD RESULT IN ENGINE STALL IN BOTH ENGINES. IN JANUARY 2003, SAAB DISABLED THE DUAL MASS FLYWHEEL (DMF) PROTECTION (INTENDED ONLY FOR MANUAL TRANSMISSION VEHICLES) IN SUBJECT VEHICLES WITH 175 HP ENGINES.ACCORDING TO SAAB, DMF PROTECTION IN A VEHICLE WITH AUTOMATIC TRANMSSION MAY CAUSE THE ENGINE TO STALL WHEN RELEASING THE ACCELERATOR PEDAL WHEN COMING TO A STOP OR WHEN THE VEHICLE IS COASTING. IN AUGUST 2003, SAAB REVISED THE ECM SOFTWARE IN THE 210 HP ENGINES TO ADDRESS A CONCERN WITH ENGINE STALL DURING ABORTED TAKE-OFF MANUEVERS.ACCORDING TO SAAB, ABORTED TAKE-OFF STALLS OCCUR WHEN THE VEHICLE IS STATIONARY AND IN DRIVE GEAR, THE ENGINE IS IDLING, AND THE ACCELERATOR PEDAL IS PULSED (PRESSED QUICKLY AND RELEASED IN LESS THAN 1 SECOND). THERE HAVE BEEN 553 NON-DUPLICATIVE COMPLAINTS TO ODI AND SAAB ALLEGING ENGINE STALL IN THE SUBJECT VEHICLES.THERE IS ONE REPORTED CRASH AND NO INJURIES.SAAB INITIATED A CUSTOMER SATISFACTION PROGRAM IN EARLY FEBRUARY TO REPROGRAM THE ECM'S.SAAB REPORTED THAT 36% OF THE VEHICLES HAD BEEN SERVICED IN THE PROGRAM AS OF MARCH 9, 2004.THIS INVESTIGATION HAS BEEN UPGRADED TO AN ENGINEERING ANALYSIS TO FURTHER ASSESS THE ALLEGED DEFECT IN THE SUBJECT VEHICLES AND SAAB'S ACTIONS TO ADDRESS THE PROBLEMS.

I WAS DRIVING MY 2003 SAAB 9-3 SE CONVERTIBLE TO THE NEARBY PUBLIX SUPERMARKET. THE CAR HAS NEVER BEEN IN AN ACCIDENT OR HIT. I PARKED IT IN THE LOT WITH THE TOP DOWN AND WENT INTO THE STORE FOR APPROXIMATELY 10 MINUTES. IT WAS A WARM DRY DAY IN FLORIDA ABOUT 85 DEGREES. I CAME OUT AND PUT THE KEY IN THE IGNITION AND TURNED IT TO START THE CAR, AND THE PASSENGER SIDE AIRBAG EXPLODED FOR NO KNOWN REASON. I CALLED GM, THEY TOOK THE CAR TO A GM FACILITY AND INSPECTED IT, AND THEN CAME BACK A WEEK LATER AND SAID THE UNEXPLAINED DEPLOYMENT OF THE AIRBAG WAS NOT A MANUFACTURERS DEFECT AND THEY WOULD NOT REPAIR IT. I FIND THAT DIFFICULT TO BELIEVE. THE AIRBAG SHOULD NOT DEPLOY ARBITRARILY WHEN THE IGNITION KEY IS TURNED.

NHTSA ID

11389024

Incident

Nov 20, 2020

Mileage

130,000 mi

TL* THE CONTACT OWNS A 2003 SAAB 9-3. THE CONTACT STATED THAT WITH THE KEY FOB IN THE IGNITION, THE POWER STEERING WHEEL LOCK MALFUNCTION WARNING LIGHT ILLUMINATED. THE CONTACT MANUALLY TURNED THE IGNITION KEY TO THE LEFT TO RIGHT IN ORDER TO HAVE THE VEHICLE STARTED. THE VEHICLE WAS TAKEN TO FLIKKEMA SAAB (2424 176TH ST, LANSING, IL 60438 (708) 474-19330) TO BE DIAGNOSED. THE CONTACT WAS INFORMED THAT THE COLUMN INTEGRATED MODULE (CIM) NEEDED TO BE REPROGRAMMED. THE VEHICLE WAS REPAIRED HOWEVER, THE FAILURE RECURRED SEVERAL TIMES. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE APPROXIMATE FAILURE MILEAGE WAS 130,000.

NHTSA ID

11297754

Incident

Nov 20, 2019

Mileage

130,000 mi

TL* THE CONTACT OWNS A 2003 SAAB 9-3. WHEN THE VEHICLE DECELERATED, IT SHUT OFF WITHOUT WARNING AT WILL. THE CONTACT ALSO STATED THAT THE VEHICLE DECELERATED WHEN DRIVING UP A HILL. THE DEALER AND MANUFACTURER WERE NOT NOTIFIED. THE VEHICLE WAS NOT DIAGNOSED OR REPAIRED. THE FAILURE MILEAGE WAS 102,000.

NHTSA ID

11208331

Incident

May 17, 2019

Mileage

102,000 mi

ECU IN CAR BECOMES COMPLETELY FRIED BECAUSE OF THE LOCATION IT IS MOUNTED FROM THE FACTORY BECAUSE OF HEAT SOAK

NHTSA ID

11156781

Incident

Oct 15, 2018

Mileage

99,989 mi

I AM RECEIVING AN ONSTAR NOT AVAILABLE ERROR - THERE WAS A RECALL 08089-B PART # 10027804 - I WANT MY ONSTAR DISABLED. WHO DO I CONTACT?

NHTSA ID

11128082

Incident

Sep 3, 2018

Mileage

85,000 mi

TAKATA RECALL. DRIVER'S SEAT AIRBAG DEPLOYED WHILE WAITING AT A RED LIGHT THIS MORNING.

NHTSA ID

11103343

Incident

Jun 22, 2018

Mileage

168,000 mi

2003 SAAB. CONSUMER WRITES IN REGARDS TO AIRBAG INFLATOR SAFETY RECALL. *LD THE CONSUMER STATED THE MANUFACTURER EXCEEDED A REASONABLE AMOUNT OF TIME COMPLETING THE RECALL REPAIR. *JS

NHTSA ID

11054310

Incident

Mar 1, 2016

I WAS DRIVING AT ABOUT 15 - 20 MPH TRYING TO ENTER HWY I-75. UPON ROUTINE BRAKING,THE AIRBAG DEPLOYED, CAUSING AN ACCIDENT.AFTER I HIT THE CAR IN FRONT OF ME,THE SECOND AIRBAG DEPLOYED. I AM HURT. THE VEHICLE WAS DEEMED TOTALLED BECAUSE THE AIRBAGS DEPLOYED, AND TAKEN AWAY.

NHTSA ID

10995688

Incident

May 28, 2017

Mileage

180,000 mi

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

This Preliminary Information communication provides information to the technician about changing the tire and wheel size on vehicles. General Motors will only support a tire calibration for tires that have been sized, tested and designed for the vehicle in question and its applications. Technician should not use the information that is provided by the antilock braking system tire size selection.

Vehicle Wide Programming (VWP) is a new process to update software on GM Vehicles. It provides the ability via a single selection within Techline Connect to first identify which modules need updating and then proceed to updating affected modules (with some exceptions). The updating of modules is completed in parallel instead of the technician needing to update one module at a time. This allows a more streamlined approach for dealers and customers.

This service bulletin advises of a new fuel injection cleaner kit used for decarbonizing the intake valves to correct conditions of rough idle, Crank no start, extended crank or misfire, MIL with DTCs, and explains how Top Tier fuels should be used to reduce carbon build-up.

This bulletin provides information for use on a Product Assistance Claim (PAC), which is formerly known as a Product Allegation Resolution (PAR) claim.

This service bulletin provides information for dealers/technicians on Service Programming System (SPS) Error Codes E4398, E4399, E4401, E4403, M4404, M4413, M6954, M6955, E4414, E4423, E4491, E4492, or E6961 and resolution information.