2004 Saab 9-5 2.2L Diesel · SP04 DXG

Corrosion is the defining theme of this 2004 SAAB 9-5's test history, and it has already cost the car two failures. In May 2021 the vehicle failed on excessively corroded brake pipes at the offside front and both rear positions, with the near side front pipe also flagged as corroded and grease-covered; these were evidently renewed or repaired, as the car passed the following day, though ferrule corrosion on both front brake hoses persisted as advisories. Alongside this, the 2022 test recorded corrosion in the nearside front integral body structure in the engine compartment area, described as not significantly reducing structural rigidity, plus slight corrosion to the bonnet lid and a deteriorated front number plate. The most recent test in October 2023 was a pass, but only after a same-day failure for an illuminated engine malfunction indicator lamp and a parking brake lever with excessive movement, and the pass carried advisories for worn rear shock absorber bushes on both sides and a worn nearside rear suspension arm bush. The overall trend is one of recurring age-related deterioration being addressed reactively rather than a clean record. At 151,743 miles over roughly 22 years, the car has averaged around 6,900 miles annually, a typical accumulation for its age. The test dates themselves reveal an irregular usage pattern: tests in March 2019, June 2020, May 2021, September 2022 and October 2023 show the MOT being allowed to lapse by several weeks to months on multiple occasions, which points to periods where the car was likely off the road or used sparingly between certificates. Moderate annual mileage on a car of this era is consistent with the wear items recorded: front and rear brake discs noted as worn, pitted or scored in 2020, front pads wearing thin at the same test, and an offside rear brake binding slightly, a classic symptom of a caliper that sees intermittent use. The 2020 advisory for a corroded rear exhaust back box also fits a car that has spent time standing. A prospective buyer should prioritise the braking system and the structural corrosion. Although the failed brake pipes were rectified in 2021, the hose ferrule corrosion advisories continued, so the flexible hoses and remaining hard lines should be inspected closely for renewed surface rust, particularly along the rear axle run where pipes are exposed. On a test drive, feel for any pulling under braking or a dragging sensation from the offside rear, which would suggest the previously noted binding caliper has worsened, and check the handbrake holds firmly on a gradient given the 2023 parking brake adjustment failure. The engine compartment corrosion near the nearside front structure warrants a careful look with a torch, probing for any spread since 2022, as this area was only one step below a structural concern. The rear suspension bushes flagged in 2023 on both shock absorbers and the nearside suspension arm should be assessed by listening for knocks or clonks over uneven surfaces and checking for rear-end vagueness through corners; worn bushes of this type typically progress from advisory to failure within a year or two. The recurring engine management light, noted in both 2022 and 2023, should be interrogated with a diagnostic reader before purchase to establish whether it reflects a minor sensor fault or something more involved, and the frayed offside front seat belt webbing and previously defective centre rear belt should be checked for proper operation and replacement where needed. The discoloured rear indicators are trivial, but the cumulative picture is of a car that will need ongoing expenditure on corrosion-related and suspension items rather than one that can be bought and forgotten.