About time I had a project thread here!

Just installed a brand new Crate Engine in the Silver Sled

My Saab Tech, David Bascomb at Wantirna Auto, down here in Melbourne purchased a brand new 16 valve 900 turbo crate engine (B202 long motor) from Saab Australia in the late 1990s and had been storing it for his own use since then. This is a brand new and a never-ever used engine with 0km (0 miles for those in the USA) on it! Try finding one of these now anywhere… rarer than hens teeth I reckon!

A few years back (around 2006ish) he mentioned to me in passing that if I ever wanted it, I could have first option to buy it from him as it ended up he wasn't going to use it anytime soon.

My 1988 900 Aero's (The Silver Sled) engine was starting to get a bit worn, with oil coming out the dip stick under boost (the one way crank valve was tested and found fine, so crank case was getting overpressurised from worn rings etc.) and the engine had lower compression than it should have. It still went and started up fine but just needed either a rebuild or this crate engine installed. It took me a few years to save up some spare cash to get it done, as I was concentrating on tuning my other Saab at the time: 2002 9-3 Aero. With that all tuned to where I wanted it, it was time to get the crate engine installed!

I left the sled with my tech back in mid-September and said to take as long as you want as I was in no hurry to get it back. That way he wouldn't feel rushed to get it done by a set date.

The crate engine went in and I picked it up (very excited) just before the Saab Club of Australia (Victoria Branch) Concours Show in mid-October but it wasn't running exactly right. Didn't matter totally as I wanted it for the show and was planning to take a look myself and for anything I couldn't do take it back to David to get the little issues fixed.

The issues it had was severe richness on startup, flooding (and subsequent non-starts) when at warm/hot operating temperature. As well as a funny high and wandering idle… at times it was fine then would sit at around 1,500rpm. It was also a real dog under boost and throttle with lack of power.

Testing and steps I took to get issues sorted:

- Replaced AMM with a known second hand working unit

- Replaced the ECU and used my existing JSP Stage 2 ECU chip in the new second hand ECU

- Cleaned and kept same T5 injectors on there

- Kept the 3.0bar FPR on (was going to swap out to a 2.5BAR but the 3.0BAR is only like 12 months old)

- Exhaust checked and no leaks or cracks found

- Checked all vac lines and found a few hidden ones were leaking. Replaced and fixed these.

I also got my tech to replace the NTC sensor (as after testing the old one showed signs of being bad and thus causing the rich issue) when it went back in to get sorted. He also double checked the timing as I have no timing light and set timing at 20˚BTDC for me as requested.

I picked it up again last night and… the result: Everything is now fixed and going as it should. The Sled is a real beast to drive now… the torque amazing. Very different to my 2002 9-3 Aero. The brand new engine feels so tight and I reckon sounds different too (in a good way!)

Now I just got to stay off boost a bit so it can break in properly over the next 1,000km or so.

Damn nice to be able to drive it again without fear of engine breaking down (as was with old engine)… and hopefully this gives the Sled a new lease of life for another 22 years at least! The body and interior is in pristine condition for a 22 year old Saab (yes it won it's class at the concours), so it is great to have such a brand new engine in it!

Thanks to David and George at Wantirna Auto for the great work and the really fair price they charged for the engine and labour to install it. Highly recommend them! So for just a bit more dough than what a second hand rebuilt engine is, I got a brand new crate engine!

They took some shots of the new crate engine being installed, but I don't have them yet. Will share once they send them to me!

Pics below are of the car at our Concours Show and of course the new engine installed!

Can post other performance specs of the Sled up if people are interested?

sab

http://farm6.static.flickr.com/5204/5265165572_9aa697291e_b.jpg

http://farm6.static.flickr.com/5281/5264558327_c7c9ffe170_b.jpg

http://farm6.static.flickr.com/5164/5264558457_65760fe59c_b.jpg

http://farm6.static.flickr.com/5207/5265165306_917c80c828_b.jpg

Wow, what a find

You have by far the best looking Saab on the face of the earth.

Fact.

You have by far the best looking Saab on the face of the earth.

Fact.
I second that.

I second that.

I third that.

Thanks guys! It is much appreciated as she is definitely a labour of love... but I am certain there are other Saabs out there who can wear the same crown!

http://farm4.static.flickr.com/3381/3482781650_8501982bee_z.jpg

Thought I should post some of the specs for the Silver Sled:

Tech Specifications

Engine
Brand new Saab B202 2.0 Litre 16 valve crate engine (installed November 2010)
Rebuilt Bosch distributor
Stock Bosch electronic ignition
SPG9 AID (Advance Ignition Diaphragm) with timing at 20˚BTDC
Bougnicord spark plug leads
NGK BCP7EV plugs
Aquamist 1S water Injection using 0.9mm injector
Aquamist DDD (digital dash display) for water injection output
Crank case ventilation catch can

Exhaust
2.5 inch from cat converter back with hi-flow racing cat
4 inch chrome semi-oval tip
Hi-flow dynomax stainless steel muffler and rear resonator
3 inch JSP stainless steel split down pipe off turbo to cat

Turbo
Mitsubishi TE-05 16G: Includes a 16G compressor wheel with 10˚ clipped vanes, upgraded thrust and is rated as a 300HP turbo
Wastegate running 7psi base boost
Stage 2.5 SPG9 APC running to 18psi boost
Jak Stoll Performance Talon high-flow side mount intercooler
8 inch Davies Craig thermo pull fan mounted on reverse side of intercooler with manual switch inside cabin
Saab C900 1990+ aluminium turbo intercooler ducts
Stratmosphere Forge bypass valve
K&N filtercharger
Plastic intercooler top air dam

Fuel System
Bosch 3.0 BAR fuel pressure regulator
Trionic 5 34lb injectors
Jak Stoll Performance Stage 2 ECU chip
Fuel pressure gauge situated in-line on fuel rail

Suspension
Stock Saab Aero springs and shocks
Stock Saab Aero road handling kit including front and rear sway bars
Polyair inflatable air bags inside rear springs

Wheels & Tyres
16" x 6.5" Saab Super Aero rims
Goodyear Revspec Ducaro 205/50/16 tyres

Other
Stock Saab Aero factory whaletail
Saab Aero vent covers (colour coded silver to match duco)
AutoMeter 30"hg to 30psi boost guage
AutoMeter air/fuel ratio guage
Saab factory rear decor panel
SaabSavior short shifter
Saab Momo leather steering wheel
3.5mm blue silicon vacuum hose
Saab Aero original Alpine surround sound 5 speaker stereo
Aero kit colour coded silver to match duco

Output
Estimated 190kW (250hp) at front wheels (need to do another dyno once new crate engine is run in)

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but I am certain there are other Saabs out there who can wear the same crown!
Nope, I'm pretty sure you've got the best one. ;ol;

Nope, I'm pretty sure you've got the best one. ;ol;

This ^

Moar pics plzlol

Good Job Steve ,

Great to here that the Sled ( an icon in Aussie c900's circles ) has a new lease on life and is good for at least another 22 years !
Did you have the gearbox touched or no need ?

We are blessed compared to our freinds in the UK and USA when it comes to the dreaded demise of most of these cars .

Re best on earth ... certainly must be best in Australia . Iron Joe and Mitsus covertibles are also rather large noteables on a world wide scale , also that Pearl white restoration that featured prominently at this site .

I have never dealt with the Wantirna guys but have heard nothing but great things , and always more than happy to pick up C900 and see there stamp in the service history ....

I know the sled is not for sale ... and thats not my intent with this question/comment .

BUT , for the sake of an enthusiasts curiosity , what sort of market value do you believe this car would have ?

This is just my curisosity , I do have a couple of Aeros , not in the same ballpark , but one that is very reasonable . Curious to what someone with your knowledge and experience would believe a car like this to be worth or . what perhaps an Insurance company would Give as an agreed value policy .

Cheers Les

Cheers Les for the kind comments and yes more than chuffed with the new engine!

As far as it's value goes... this is a hard one to put the finger on as to what an exact cost would be! It would be pretty hard to replace as not many decent Aero examples around anymore that haven't been flogged or cared for to a level I would want/expect. I do have it insured at an agreed value of around $10,000. This I think is probably a fairish price considering work and condition. I purchased it back in 1996 for around $20,000 (which was the going rate for them back then) so to lose only half the cost since purchase isn't too bad.

I had no problems getting the agreed value through my insurance at that cost.

EDIT> Gearbox wasn't touched at all. Didn't need it really... all gears are smooth and shift fine. No whine or noise either (touch wood!). The car was originally an auto that got converted to a manual using a 1992 900 Aero gearbox back in about 1999 if I can remember right! I have used REDLINE MTL in it since it went in.

You should come along to some of our vic branch club events some time! Be good to see your Aeros!

Steve

Nice to see this car finally making it to these pages.

What do you think did it for the rings on your old engine? I ask because I had the same thing strike the engine of a Carlsson 3 door, it was a tired engine and had too much boost dialled in, result: smoke trail and a very oily engine bay.;oops:

Oh to find a new engine would be awesome! I found a new speedometer once, so A new engine to go with that would be a perfect world.

Nice find and nice car.

beautiful car, wish more people took care of the oldies like that

Nice to see this car finally making it to these pages.

What do you think did it for the rings on your old engine? I ask because I had the same thing strike the engine of a Carlsson 3 door, it was a tired engine and had too much boost dialled in, result: smoke trail and a very oily engine bay.;oops:

Thanks Phil! Always loved your Convertible and great to see the progress of it over the years too. :)

As far as why the worn rings on the sled... probably (mainly) just due to high boost for so long. I had also done two HG on the old engine, with both times having to ensure the head was flat and planed. This probably changed compression a bit and maybe made it too sensitive to knock... but don't know. I was the third owner of the sled having bought it at 205,000km, so who knows what the previous owners did. It did have a full service logbook history though (and still does :) ).

Anyways... all fixed now for the next 22+ years (fingers crossed)!

Thanks to paul and MaineAero too for the comments.

sab