Buying a SAAB 2.2 TID and the EGR valve - warning light problem

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The Saab 2.2 TID leaves you in no doubt that it has a diesel engine. 'Agricultural' would be an apt description to describe the engine noise.  It's not a problem unless you're really fussy about engine noise.  The 2.2 diesel engine was also used by Vauxhall (in the Omega).  Like all diesels of this ilk, it is a hardy, dependable unit though as usual, much depends on how it has been serviced. 
 With a fully warmed up engine and non stop-start driving at 55mph the car returns 46 mpg without batting an eyelid.  The onboard display has often indicated that at times the car is doing in excess of 52mpg.
Fuel consumption is of course dependent on a number of factors.. speed .. how you actually drive the car ... distance and engine temperature.  From cold, expect the 2.2 TID to indicate around 25 mpg for the first 5 miles.  At around 5 miles the thermostat begins to open and mpg increases.  After 10 miles of driving the thermostat should be fully open and the engine at its operating temperature.  This is when you will achieve the maximum mpg.
The slight niggle with these models is an EGR (Exhaust Gas Recycler) warning light on the dashboard.  The EGR valve allows a limited amount of exhaust gas to be recycled.  A new EGR valve costs in excess of £200 and in 95% of cases there's no need to fit a new one when cleaning the old one will do the trick.
The EGR is located at the front of the engine, connected to the air filter by a tube









It's very easy to remove the EGR housing and clean inside.
Inside the EGR housing/valve you'll find a veritable gunky mess. Unburnt diesel fuel mixes with engine oil and exhaust carbons to form a thick, sticky porridge.  You really do need rubber gloves and lots of rags/cleaning fluid and a blunt screwdriver to scoop it out.  A large can of engine degreaser and brake/clutch cleaner will also be needed to clean the throttle body inside the EGR housing.
Youtube video:

93 or 95, the principle is the same
The throttle body inside .. well .. remember carburettors with a butterfly valve... a round metal disk that turned to control petrol/air mix?
The principle is the same ..  and it is this butterfly valve - the round disk - that needs to be thoroughly cleaned.  It is very 'delicate'/spring loaded ..  and covered with gunky porridge it can't move properly or sticks.  Spray it with engine degreaser, gently clean it with a rag and then spray it with brake/clutch cleaner.
It takes 10 minutes to remove the EGR valve and 30 minutes to clean it.
If your car is 'smoky ' at times and lacks power (or seems to use more fuel than usual) , don't jump to expensive conclusions that it's a turbo at fault.  It's more than likely that the EGR valve needs a clean.  It's an easy job.
You can have the warning light reset but .. it will probably come on again at times.  On a personal note, my wife's 2.2 Saab has had the warning light appearing on .. well ... depends what day of the week it is and what mood the sensor is in.  It has been like that for 4 years.  The car was used for home-helping on short stop-start trips. The EGR has been removed and cleaned twice.
It may be a  quirk of short-trip cars ..
The 2.2 engine has a hell of a reputation for reliability.  Frequent oil changes and 'longer runs' help.



















 
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