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I called an ASE-certified mechanic. He charged some $60 for the visit and $60 diagnosis and really he didn't quite spot on anything. Left me where I was - work-wise , diagnosis-wise and knowledge-wise. So I am reaching out to hopefully a more "pundit" community here.

I was driving up hill and suddenly at 2000 RPM , I got a CEL due to P1549 (Expanded to BOOST CONTROL VALVE).

I checked all the vacuum hoses. They were okay this time too.. they've now been checked a total of three times. And all three occasions were related to excessive power for uphill or whenever I sought extra speed by going beyond 3000 RPM. Typically, it will happen after about 150 miles of driving. I will clear it and continue to drive.

The turbo bypass valve is actually the forge kind of valve which has 2 rings or washers and a spring in it. The washers do not remain in the center but will fall down towards the inlet for the vacuum hose. I am not sure how they're supposed to be positioned in there and what their presence will make in terms of power.

Why am I getting this error and what should I do to fix it?

BOMK also - the wastegate is built into the turbo.
This is a SAAB 9-5 5 Speed 2000 2.3t wagon

user1874594
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P1549 (Trionic 7) is "Charge Air, Malfunction". (You don't say what year your 9-5 is, but T7 is pretty common.) Since you checked the vacuum hoses going to the charge-air control valve, then it's "basic engine and turbo" to check; but it seems to work below the critical speed. Then, change the charge-air control valve. This is not the same thing as your Forge turbo bypass valve, but this thing or its equivalent for your model year, so double-check the fitment: https://www.esaabparts.com/saab/parts/55557331

If your car is more than about 10 years old, I'd replace that 3-hose assembly that feeds this solenoid valve, as well. They may look OK but they all rot sooner or later. Item 17 on this page, with a couple of variants by engine number, so be careful: https://www.esaabparts.com/viewparts.php?searchpart=1&section=311045036

jxh
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