c900 restoration incl. LH2.2 to CU14 injection swap [Archive] - SaabCentral Forums

: c900 restoration incl. LH2.2 to CU14 injection swap


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Shan
10th January 2007, 09:29 AM
The c900 pictured here was purchased less than a year ago. Being a non-runner, the Saab arrived home on a trailer. After several weeks of laying idle, I cranked the engine long enough and managed to get the engine started without knowing the root cause for the mysterious start problems. The car ran fine if started up daily, but starting difficulties persisted if it left to idle. The Saab is a 16V NA, with Bosch LH 2.2 and EZK ignition.

Recently on a cold damp morning, I wasted one full charge on a good battery, cranking up the engine, but failing to get it started. Having 3 Saabs running on Lucas CU14 injection and conventional ignition, the decision was then made to transplant the CU14 injection and front wiring from a donor, including the LPT engine.

Following are some pictures of the car when it was purchased. More info as the project proceeds.

http://www.saabphotos.com/gallery/albums/album496/001_sideview.jpg

Lovely interior :
http://www.saabphotos.com/gallery/albums/album496/002_interior.jpg

http://www.saabphotos.com/gallery/albums/album496/005_16VNA.jpg

Shan
10th January 2007, 09:33 AM
The Saab, when it arrived back home.

http://www.saabphotos.com/gallery/albums/album496/003_arrival.jpg

Shan
10th January 2007, 09:36 AM
With the car finally running, dad had given it a good polish and clean up.
A set of 16" Aero wheels were fitted, and it was starting to look pretty good :)

http://www.saabphotos.com/gallery/albums/album496/004_with16inAero.jpg

Shan
10th January 2007, 09:38 AM
On a dark Saturday night, me and dad decided to pull the engine.

The stuff that Saab nuts do at home.... :lol:

http://www.saabphotos.com/gallery/albums/album496/005_engine_removal.jpg

Shan
10th January 2007, 09:40 AM
The tired 16V lump has definately seen better days.

http://www.saabphotos.com/gallery/albums/album496/006_engine_removal.jpg

Saab-Daniel
10th January 2007, 12:26 PM
Very nice thread, looks like a nice job!
How far along are you?
Daniel.

Si
10th January 2007, 01:46 PM
You've probably been asked before, but there seems to be alot of 4 door saloon c900 in Malaysia, is there any particular reason?

Looks very nice anyway, will be interesting to see it develope:D

ejenner
11th January 2007, 08:03 AM
Is that another auto?

Are you the same chap who has a restored 900 CD with 9000 aero seats or am I thinking of someone else?

Saab-Daniel
12th January 2007, 04:02 AM
Ejenner, you are thinking of someone else... :)
Daniel.

Shan
16th January 2007, 05:32 AM
Very nice thread, looks like a nice job!
How far along are you?
Daniel.
Thanks Daniel ! The shell has already been painted. Progress is very slow at the moment, but I'm not hurrying the job. More pics will follow soon :)

Shan
16th January 2007, 05:36 AM
You've probably been asked before, but there seems to be alot of 4 door saloon c900 in Malaysia, is there any particular reason?

Looks very nice anyway, will be interesting to see it develope:D
Yes, there are more 4 door saloon c900's in Malaysia. From the total 7 c900's in my fleet, there are three 3-doors and four 4-doors. Once this project is over, I'll start rebuilding one of the two strokes, then commence work on a 3-door :)

Shan
16th January 2007, 05:38 AM
Is that another auto?

Are you the same chap who has a restored 900 CD with 9000 aero seats or am I thinking of someone else?
Yes, it is "another" auto. The chap with the 900 CD is a different person who goes by the nickname "Denmaster" on this forum, also another Saab fleet-owner.

Cheers :)

Shan
17th January 2007, 06:20 AM
Me and dad stripped the car at home, then towed it to a nearby paintshop to have it resprayed. Here are some pics with the first undercoat layer sprayed on.

http://www.saabphotos.com/gallery/albums/album496/013_body_undercoat.jpg

http://www.saabphotos.com/gallery/albums/album496/014_body_undercoat.jpg

http://www.saabphotos.com/gallery/albums/album496/015_body_undercoat.jpg

Shan
17th January 2007, 06:28 AM
After looking through various pictures of c900s in the web, dad and me decided to have the Saab painted in "Toyota Forrest Green", code 8266. Pictures of the Saab after the paint job :

http://www.saabphotos.com/gallery/albums/album496/016_painted.jpg

Doors painted, even on the insides. All door seals were removed to allow proper painting. The chap in the yellow shirt is the painter, still doing some work inside.

http://www.saabphotos.com/gallery/albums/album496/017_painted.jpg

VikingSpirit
17th January 2007, 05:39 PM
wow! That's really impressive that you had the car repainted completely inside the doors like that without stripping out the interior, your painter man must be damned good at his job!

how much did that fine looking respray cost you if you don't mind my asking?

Shan
19th January 2007, 06:51 AM
wow! That's really impressive that you had the car repainted completely inside the doors like that without stripping out the interior, your painter man must be damned good at his job!

how much did that fine looking respray cost you if you don't mind my asking?
The interior was partially stripped. The complete respray of the car cost me an equivalent of GBP 300. Not the best paint job, but I am satisfied with the results :)

Here are some pics of the meticulously painted engine bay.

http://www.saabphotos.com/gallery/albums/album496/018_enginebay.jpg

http://www.saabphotos.com/gallery/albums/album496/019_enginebay.jpg

900t
19th January 2007, 02:23 PM
For that much I think I should ship my car to Malaysia and get it painted too :p

woywitka
19th January 2007, 04:27 PM
dude gorgeous! Colour is fantastic!-Clean non rusty car, very very nice. Can't wait to see the finished product.

Shan
20th January 2007, 05:42 AM
dude gorgeous! Colour is fantastic!-Clean non rusty car, very very nice. Can't wait to see the finished product.
Thanks ! There was some rust on the floorboard, but that has been fixed as well before the respray.

For that much I think I should ship my car to Malaysia and get it painted too :p
How much does it cost to paint a c900 in the US / UK ?

Shan
20th January 2007, 05:44 AM
Front cross beam was removed and painted flat black.
Here's a picture of the beam reinstalled.

http://www.saabphotos.com/gallery/albums/album496/020_enginebay.jpg

DanF.
20th January 2007, 08:21 PM
How much does it cost to paint a c900 in the US / UK ?


Way too much. Unless you can do it yourself, or if you have a hook-up of some sort.




Your car is real nice by the way.

Shan
21st January 2007, 05:14 AM
Pics of the interior starting to get stripped. This was done before the body respray.

The earlier type front seat forward mounting beam (shown in arrow) was replaced with a later type beam to fit a set of post '91 front seats, common with the 9000.

http://www.saabphotos.com/gallery/albums/album496/007_interior_removal.jpg

Front seat forward mounting beam removed :

http://www.saabphotos.com/gallery/albums/album496/008_frontseat_crossbeam.jpg

Picture below is with the later type front seat forward mounting beam welded in. The complete floorboard was then painted with a tar like paint.

http://www.saabphotos.com/gallery/albums/album496/009_frontseat_new_crossbeam.jpg

Shan
22nd January 2007, 07:36 AM
Pictures of the donor, which will provide the Lucas CU14 injection, wiring harness and other stuff for the project.

http://www.saabphotos.com/gallery/albums/album496/023_LPT_donor.jpg


Front wiring is superb condition without any mods.

http://www.saabphotos.com/gallery/albums/album496/025_LPT_donor.jpg

Shan
23rd January 2007, 06:13 AM
LPT engine out and looking pretty after a preliminary degrease.

Enjoy the pics :)

http://www.saabphotos.com/gallery/albums/album496/026_LPT_donor.jpg

http://www.saabphotos.com/gallery/albums/album496/027_LPT_donor.jpg

http://www.saabphotos.com/gallery/albums/album496/028_LPT_donor.jpg

ShadowWorks
23rd January 2007, 07:03 AM
Wow that does look clean, I had my engine out and was to lazy to detail and degreeze it like you have.

Great work.

unkleG'sif
23rd January 2007, 08:29 AM
is that a ready made, purpose built, engine and box stand? :cool:
nice
G

Shan
26th January 2007, 08:36 PM
is that a ready made, purpose built, engine and box stand? :cool:
nice
It is a custom made engine stand for the c900, made out of square section steel tubes. My friendly exhaust shop helped me to construct it with a sketch that I prepared. Initially, the rear end was made that the inner driveshaft sat on it (picture below). This may cause stress on the diff bearings due to the weight of the engine + gearbox, I later had it cut off and simply let the rear end of the gearbox sit on the stand with a hole made for the diff drain plug. I've mounted castor wheels at the bottom to move it around easily. Since then, I've had another 4 stands made up for the other spare engines :)

http://www.saabphotos.com/gallery/albums/General_Pics/c900_Engine_Stand.jpg

unkleG'sif
27th January 2007, 11:10 AM
genius :cool:

G




message too short so i have to wite something else.......:roll:

Shan
29th January 2007, 07:31 AM
The block, being given a coat of red :)

http://www.saabphotos.com/gallery/albums/album496/40_engine_painted.jpg

Shan
30th January 2007, 06:12 AM
Picture of the bonnet (front hood) being cleaned before painting.

http://www.saabphotos.com/gallery/albums/album496/011_bonnet.jpg

Bonnet repainted and awaiting installation of the insulation.

http://www.saabphotos.com/gallery/albums/album496/012_bonnet_newpaint.jpg

Insulation refitted and looking pretty good :)

http://www.saabphotos.com/gallery/albums/album496/012_bonnet_insulation.jpg

Shan
7th February 2007, 10:03 AM
More pictures of the LPT engine after some painting activites last weekend.

http://www.saabphotos.com/gallery/albums/album496/40_engine_painted_3.jpg

Shan
7th February 2007, 10:13 AM
My 4-year old son having a go at the LPT :)

http://www.saabphotos.com/gallery/albums/album496/60_wrenching_4.jpg

http://www.saabphotos.com/gallery/albums/album496/60_wrenching_3.jpg

"Inspecting the turbo" :

http://www.saabphotos.com/gallery/albums/album496/60_wrenching_2.jpg

ejenner
7th February 2007, 01:47 PM
hey - he really looks like he knows what he's doing...! when's he getting his first c900 then? ;)

eddiethegreat
7th February 2007, 05:35 PM
Remember me when I was a child, and I put my head into the SAAB while my dad was working on it. I understanded a lot that way.:)
A proud young saaber boy ;)

Congrats for your work :p

Shan
8th February 2007, 06:35 AM
hey - he really looks like he knows what he's doing...! when's he getting his first c900 then? ;)
His favourite car is the 96 stroker. He gets all excited and never misses a ride in it whenever I take it out for a drive.
Favourite tool to play with - the hammer :lol:

Shan
8th February 2007, 06:44 AM
Remember me when I was a child, and I put my head into the SAAB while my dad was working on it. I understanded a lot that way.:)
A proud young saaber boy ;)

Congrats for your work :p
When I was a child, I collected all the spark plugs that my dad changed on his Saab. My dad helped his friends service their cars too (various makes) and I kept those used plugs too until the collection grew to more than 200+ pcs of various makes. Knowing that I collected plugs, one of dad's friends one day handed me a brand new spark plug used in piston engined aircrafts, which became my prized collection. Before going to college, I decided to discard the whole collection, as it was getting difficult to store. Unfortunately, the aircraft plug went with it too, without me realizing.

walawala
8th February 2007, 10:53 PM
Hey shan...i see your son has already started to help you out! :cheesy:

hope to see the forrest green car running with us on our next convoy... ;)

great work...and if you need any help you know who to call... :)

des

jameschong
9th February 2007, 04:38 AM
How much do you charge for tuition, Shan? I'm going to send my 9 and 11-year old over to your place when I next drop them off at their grandparents! Only a stone's throw from your place. They can collect them after shopping at Tescos...

Shan
9th February 2007, 10:22 AM
Thanks for the comments guys :)

Something good came about, after the kid had his fun on the B202. Here's him trying to remove one of the exhaust manifold nut.

http://www.saabphotos.com/gallery/albums/album496/60_wrenching_5.jpg

... and off it came !! :o

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_4.jpg.

Apparently, the stud must have cracked previously, which I didn't realise until the kid put some pressure on it. Here's another pic of how it looked after the stud broke. I removed a few other screws as well, preparing to take off the exhaust manifold to extract the broken stud.

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_1.jpg

Squaab99t
9th February 2007, 11:35 AM
That might be the same location mine broke off. Final part off assembly and the stud is twisted off inside the head. I tried an "easy out". Had to pull the head off and gave it to the machine shop to burn it out (EDM) and install a helicoil. What a PIA. Looks like he will be a great wrench turner... On a seperate note: Where you the one who bought a set of adjustable spring for Brad at KC Saab?

Shan
10th February 2007, 04:53 AM
On a seperate note: Where you the one who bought a set of adjustable spring for Brad at KC Saab?
Nope, I believe that is "Bohtak", the chap with the very hot black c900.
He's selling his Trent springs now.

Shan
11th February 2007, 10:12 AM
Attempted to remove the broken stud today. First, I drilled a hole into what's left of the stud (picture below).

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_188.jpg

Fortunately, there was a "screw extractor" in the toolbox which dad bought many years ago to remove a broken manifold screw on the 96 stroker. This went on easily on the broken stud.

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_193.jpg

And the broken stud comes off ! :)

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_197.jpg

Shan
11th February 2007, 10:16 AM
Picture of the screw extractor. Without including the time for removing the exhaust manifold and turbo unit, the broken stud came off in less than 10 minutes using this tool.

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_203.jpg

Shan
11th February 2007, 10:18 AM
I then cleaned the threads with a suitable tap :

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_206.jpg

Shan
11th February 2007, 10:20 AM
And the head, ready to accept a new stud :

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_210.jpg

ShadowWorks
11th February 2007, 11:27 AM
Thats fantastic, I need to get me a stud extractor to do the same job on my spare head.

Shan
12th February 2007, 10:05 AM
Thats fantastic, I need to get me a stud extractor to do the same job on my spare head.
When ya need it, it's worth every penny :)

Btw, does anyone know why are some studs longer than the other, and what does that spacer do ?

KurBads
13th February 2007, 04:41 AM
Hi Shan,

I just remembered that some time you offered LUCAS service info scan via Steve`s place but that was incomplete. I just wonder if it is possible to make it full documentation available or you abandoned it for some good reason? :roll:

Thank`s!

eddiethegreat
13th February 2007, 04:59 AM
Picture of the screw extractor. Without including the time for removing the exhaust manifold and turbo unit, the broken stud came off in less than 10 minutes using this tool.

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_203.jpg

I'm sure McGYVER had one of them! :lol:
Fantastic. I'll remember to look for one...;)

Shan
13th February 2007, 08:25 AM
Hi Shan,

I just remembered that some time you offered LUCAS service info scan via Steve`s place but that was incomplete. I just wonder if it is possible to make it full documentation available or you abandoned it for some good reason? :roll:

Thank`s!
Hi KurBads,

I was considering to open the binder and dump the whole manual into an automatic scanner, as it was getting tiring to scan the pages one at a time with only a handful of Saabers interested in it. Will try to scan the rest of the manual, more than half is done at the moment :)

Cheers.

KurBads
13th February 2007, 09:11 AM
Hi, and thank`s!
I am sure that there are more than that of saabers that wiil find your material usefull. Will be looking forward to full version released!

walawala
16th February 2007, 08:51 AM
Picture of the screw extractor. Without including the time for removing the exhaust manifold and turbo unit, the broken stud came off in less than 10 minutes using this tool.

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_203.jpg

hey shan..does the screw extractor come in various sizes? I think i may need to use it in future. Some of my screws on the doors have been rounded.. ;oops: and i have no way of taking them out...

des

Shan
16th February 2007, 09:56 AM
KurBads, I've finished scanning and uploaded the complete factory Lucas CU14 manual to the following:
http://www.hexfiles.com/shan/Saab_Factory_Manuals/index.html (http://www.hexfiles.com/users/shan/Saab_Factory_Manuals/index.html)

Many thanks to Matthew for letting me upload the stuff to his site :)

Back on topic :

hey shan..does the screw extractor come in various sizes? I think i may need to use it in future. Some of my screws on the doors have been rounded.. ;oops: and i have no way of taking them out...
Des, yes the screw extractor does come in various sizes, as seen in the pic below (tool on the left). The tool on the right is the tap. Come over to my place and we'll get all your rounded screws off :D

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_207.jpg

skilpadda
16th February 2007, 11:45 AM
Thank you very much for that. This is the part missing from the bentley manual. Very helpful. Thanks again:D

Shan
21st February 2007, 11:05 AM
While searching for a stud to replace the broken one, I noticed that it looked very similar to the 8V exhaust manifold studs. So I pulled one out of an old 8V :

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_250.jpg

And it turns out to be exactly the same length as the broken one from the 16V :cool:

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_252.jpg

Shan
21st February 2007, 11:10 AM
The 8V stud goes on the 16V head :

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_259.jpg

And the exhaust manifold is bolted back on, using the 16V spacer on the 8V stud. The spacer from the 16V is split along it's length, while the 8V spacer is a solid tube. Not knowing the reason for the difference, I decided to reuse the 16V spacer.

http://www.saabphotos.com/gallery/albums/album496/61_Broken_Exhaust_Stud_267.jpg

Shan
28th February 2007, 09:15 AM
Pic of the engine wiring being removed from the donor.

http://www.saabphotos.com/gallery/albums/album496/62_Wiring_from_Donor_2.jpg

Shan
28th February 2007, 09:15 AM
Fusebox from the donor :

http://www.saabphotos.com/gallery/albums/album496/62_Wiring_from_Donor_4.jpg

http://www.saabphotos.com/gallery/albums/album496/62_Fusebox.jpg

Shan
28th February 2007, 09:16 AM
Fusebox and wiring removed from the donor :

http://www.saabphotos.com/gallery/albums/album496/62_Engine_Wiring_2.jpg

http://www.saabphotos.com/gallery/albums/album496/62_Engine_Wiring_1.jpg

Shan
28th February 2007, 09:18 AM
Lucas CU14 injection wiring removed from the donor :

http://www.saabphotos.com/gallery/albums/album496/62_Injection_Wiring_1.jpg

Lucas CU14 ECU :

http://www.saabphotos.com/gallery/albums/album496/62_Lucas_ECU.jpg

skilpadda
28th February 2007, 10:39 AM
Lucas CU14 injection wiring removed from the donor :

http://www.saabphotos.com/gallery/albums/album496/62_Injection_Wiring_1.jpg


This is the only wires you will need to convert it from LH2.2 to CU14. I did it the other way round( from CU14 to LH2.2) but converted back to CU14 as I liked it much better. You will have to modify the wires to the fuel cut off(for both relays at the ECU) and also two wires at the 6 pole connector to get AC to work. But the bentley manual schematics makes it pretty clear what to do.

Shan
1st March 2007, 09:22 AM
This is the only wires you will need to convert it from LH2.2 to CU14. I did it the other way round( from CU14 to LH2.2) but converted back to CU14 as I liked it much better. You will have to modify the wires to the fuel cut off(for both relays at the ECU) and also two wires at the 6 pole connector to get AC to work. But the bentley manual schematics makes it pretty clear what to do.
That's interesting to know, thanks.
I've decided to install the complete engine wiring, dash wiring and injection wiring from the Lucas donor, as the previous wiring fitted to the car is in poor condition with unknown mods. Even the air-conditioning wiring is so heavily altered that the low pressure switch and the relay in the fusebox is bypassed , the supply to the AC compressor is wired thru a fuse direct to the AC switch on the dash, then to the compressor ! Not wanting to leave any remanence of the EZK, I've decided to go for a complete wiring swap.

Shan
1st March 2007, 10:19 AM
Pics of the fusebox being installed in the project c900 car :

http://www.saabphotos.com/gallery/albums/album496/62_Wiring_installation_22.jpg

http://www.saabphotos.com/gallery/albums/album496/62_Wiring_installation_27.jpg

Shan
1st March 2007, 10:20 AM
The Lucas CU14 injection wiring being installed in the resprayed engine bay :

http://www.saabphotos.com/gallery/albums/album496/62_Wiring_installation_56.jpg

http://www.saabphotos.com/gallery/albums/album496/62_Wiring_installation_55.jpg

Shan
1st March 2007, 10:21 AM
Lucas CU14 ECU now resides at the place where the Bosch LH 2.2 ECU once sat. The fuel pump relays and base plate for mounting the ECU were also swapped over.

http://www.saabphotos.com/gallery/albums/album496/62_Wiring_installation_43.jpg

jim_mcghee
1st March 2007, 01:33 PM
it does look excellent.. good work

Shan
2nd March 2007, 10:19 AM
it does look excellent.. good work
Thanks :)

Pics of the dashboard in the midst of dissassembly :

http://www.saabphotos.com/gallery/albums/album496/63_Dash_006.jpg

The collapsible section of the steering column removed :

http://www.saabphotos.com/gallery/albums/album496/63_Dash_011.jpg

Shan
2nd March 2007, 10:20 AM
Dash cross beam removed. I plan to discard this beam and install the cross beam from the donor as a complete set with the dash wiring.

http://www.saabphotos.com/gallery/albums/album496/63_Dash_022.jpg

http://www.saabphotos.com/gallery/albums/album496/63_Dash_024.jpg

Shan
2nd March 2007, 10:25 AM
Dash, including wiring and cross beam removed from the donor :

http://www.saabphotos.com/gallery/albums/album496/63_Dash_059.jpg

http://www.saabphotos.com/gallery/albums/album496/63_Dash_061.jpg

Matthew
2nd March 2007, 04:23 PM
Epic work :o And a very clean engine bay! :D

ejenner
2nd March 2007, 04:42 PM
Matthew - you should see my engine bay. No rust anywhere! :lol:

Matthew
2nd March 2007, 04:56 PM
Bah!

I don't need encouragement!! :lol: It'll be a miracle if that car's on the road for Sweden... and that's three months away! :evil: :p

Put that Carlsson back together yet? :p You must have lost most of the bits by now :p ;)

misu
2nd March 2007, 06:10 PM
Dash cross beam removed. I plan to discard this beam and install the cross beam from the donor as a complete set with the dash wiring.

http://www.saabphotos.com/gallery/albums/album496/63_Dash_022.jpg

http://www.saabphotos.com/gallery/albums/album496/63_Dash_024.jpg

As I see, You have an automatic transmission. I have a very big dilema: What kind of transmission use in my convertible? Manual, or auto? I have 9000 with auto, and I love it. But Iīve heard, that auto in clasic 900 isnīt a good choice - bad shifting points, three gears only, etc... Can You tell me Your opinion and experiences with auto in 900? I will use this car mainly in town driving (70%), sometimes highway and open roads (30%), but with open top You cannot drive more than 110km/hr. On normal roads we have a speed limit just 90 km/hr, so I suppose this car will not move faster than 130 km/hr (speed limit for our highways).
Thank You for Your reply.

Shan
2nd March 2007, 07:35 PM
As I see, You have an automatic transmission. I have a very big dilema: What kind of transmission use in my convertible? Manual, or auto? I have 9000 with auto, and I love it. But Iīve heard, that auto in clasic 900 isnīt a good choice - bad shifting points, three gears only, etc... Can You tell me Your opinion and experiences with auto in 900? I will use this car mainly in town driving (70%), sometimes highway and open roads (30%), but with open top You cannot drive more than 110km/hr. On normal roads we have a speed limit just 90 km/hr, so I suppose this car will not move faster than 130 km/hr (speed limit for our highways).
Thank You for Your reply.
Choosing between an auto or manual is really a personal preference. I have 3 manuals and 4 auto c900s and enjoy driving all of them equally as much :D . For the daily 100 km commute to work, the auto provides easy effortless driving. On a hard drive through windy country roads, nothing beats an FPT manual. The auto surprisingly provides loads of torque under acceleration. Contrary to it being sluggish, I've out-accelerated many hot hatches from a standstill with the LPT auto. Frequent oil changes is a must, I replace them every 10k - 15k kms depending on driving stlye and have never had a transmission failure. On highways, you'll feel that something is missing on the auto -> a 4th gear !! Noise level is lower on the manual when cruising even at 110 km/hr due to the lower engine rpms. When there is an urge to have some fun, the manual can be floored all the way without hesitation. On the auto, you'll be thinking if some long term damage is being done.

Cheers.

Shan
2nd March 2007, 07:41 PM
Put that Carlsson back together yet? :p You must have lost most of the bits by now :p ;)
:lol: , that was what I was feeling yesterday searching for the cam cover bolts. Removed them more than a month ago and couldn't remember where I had left them.... had to remove a few from the old NA engine.

jameschong
2nd March 2007, 10:24 PM
Contrary to it being sluggish, I've out-accelerated many hot hatches from a standstill with the LPT auto.

I get surprised looks myself, especially from boy-racer types. The pull from 2.5k rpm onwards is surprising, for what some think is an old car. And it's only doing 0.5bar...

ejenner
3rd March 2007, 01:28 AM
I used to have an FPT auto and that would beat loads of other stuff. the long gearing works really well when combined with a turbocharged 16 valve engine.

Scandia
8th March 2007, 08:53 PM
Familiar with the lh injection. what & where did the lucas system come from ? what are the benefit's of it over the LH ?


Thanks, Dave

TheRedBaron
9th March 2007, 12:30 AM
Familiar with the lh injection. what & where did the lucas system come from ? what are the benefit's of it over the LH ?


Thanks, Dave
Lucas is the [in]famous british company - the cars over there had it for a bit at least. Don't know much about it, although I have heard you can take the fuel a little higher with stock equiptment...

...when those guys wake up they'll tell us all about it (hopefully!)

skilpadda
9th March 2007, 02:22 AM
The Lucas cu14 is a license built LH2.4 with a few alterations. Injectors are running different voltage so a ballast resistor is fitted, it also has an improved AMM design which is less restrictive to airflow. It runs a 3 bar FPR compared to the LHs 2.5 and 2.8 bar. I have so far only come across two types of injectors to choose from, but stock injectors should cope with up to 250hp.

Matthew
9th March 2007, 05:09 AM
Lucas CU14 was fitted to 900s from MY89 up (may have been MY90).

The Lucas injectors are 27lb/hr compared to LH2.2's 21lb/hr.

Scandia
9th March 2007, 12:52 PM
Does anybody offer to sell the setup ? I'd be interested in one just to try out. depending on the price of course. If anybody's willing to aquire all the parts in the system I'd really be interested in hearing from you.
Over here 89 is the worst year to have. . . . if your going to hop it up that is. I took the system from an 89 when I did my conversion . . . . when you'd jump into the boost the car would cut off. . . . in 89 they wired a fuel cut off through the AMM. So as soon as it detected you trying to cram more air through it, it cut out. back dated my injection wiring to an 86 non turbo wiring harness & just ran the turbo ECU. . . . work's great. it'll break the tire loose in 4th get'n on the freeway if it's even the slightest bit damp.

..............Dave

Shan
11th March 2007, 11:18 AM
Familiar with the lh injection. what & where did the lucas system come from ? what are the benefit's of it over the LH ?
I believe there are several versions of the LH 2.2. On my 16V NA, the main disadvantages are :
1. no fault codes to pull on the LH 2.2 (my biggest frustration when the car would not start).
2. no O2 sensor fitted.
3. no AIC fitted, just a simple idle up valve like on the 8V.

LH 2.4 has all of the above.

Shan
11th March 2007, 11:32 AM
Complete dash including cross beam from the Lucas LPT installed in the project c900. I'm gonna have a lot of fun reconnecting the wiring :)

http://www.saabphotos.com/gallery/albums/album496/63_Dash_089.jpg

Scandia
11th March 2007, 01:05 PM
Thanks Shan, here our's come w/ an 02 sensor & I believe a AIC, atleast anything that ran a 16V. I'll double check that. . . . .Thanks again for the info

..........Dave

Shan
12th March 2007, 10:40 AM
Together with the dash, the fresh air inlet from the donor is installed on the project car. I put on a thick layer of Sikaflex black silicone on the surrounding of the air inlet where it contacts the firewall from the inside of the car.

http://www.saabphotos.com/gallery/albums/album496/63_Dash_125.jpg

http://www.saabphotos.com/gallery/albums/album496/63_Dash_132.jpg

Shan
14th March 2007, 10:23 AM
Before the exhaust manifold was removed to replace the broken stud, I replaced a water jacket plug beneath the manifold which was showing traces of a leak.

First I drilled a hole into the old plug, then chiseled it until I could get a pry bar in and it popped off in a matter of minutes :)

http://www.saabphotos.com/gallery/albums/album496/64_Waterjacketplug_083.jpg

Shan
14th March 2007, 10:24 AM
On the left is the new plug, which I managed to source easily from the local parts shop. The "41" denotes that the outer diameter of the plug is 41 mm.

http://www.saabphotos.com/gallery/albums/album496/64_Waterjacketplug_137.jpg

http://www.saabphotos.com/gallery/albums/album496/64_Waterjacketplug_135.jpg

Shan
14th March 2007, 10:26 AM
The new plug is fitted on the block with a lavish application of Permatex Ultra Grey on the new plug, as well as the cylinder block. I've been told that this is mandatory, as the Saab block is porous and a dry fitted plug would quickly develop a leak.

http://www.saabphotos.com/gallery/albums/album496/64_Waterjacketplug_138.jpg

http://www.saabphotos.com/gallery/albums/album496/64_Waterjacketplug_133.jpg

Another view of the plug installed.

http://www.saabphotos.com/gallery/albums/album496/64_Waterjacketplug_140.jpg

ShadowWorks
14th March 2007, 10:34 AM
Wow your cars in such amazing condition. No rust on the engine bay, not even in the drive shaft tunnels:o

What else is on your to do list?

Shan
14th March 2007, 10:56 AM
Wow your cars in such amazing condition. No rust on the engine bay, not even in the drive shaft tunnels:o

What else is on your to do list?
Thanks ! There was such a huge oil leakage on the old NA engine that it probably helped to save the engine bay from rotting.

To do list : Engine has to go in, the interior, rest of the dash, door panels, etc, etc. Biggest challenge will be connecting up the interior wiring. The donor has the interior wiring chopped off just after the gear shift housing and I don't have a complete interior wiring from a Lucas CU14 car. I will have to somehow mate up the donor's chopped wiring with the old interior wiring at this point....

Shan
15th March 2007, 07:50 AM
Pictures of the old wiring that was removed from the car prior to painting.

Fusebox, EZK control unit, ignition coil and engine wiring :

http://www.saabphotos.com/gallery/albums/album496/65_OldWiring_05.jpg

LH 2.2 wiring used on the NA engine, minus the LH 2.2 ECU. The relays for the fuel pump is still attached to the loom.

http://www.saabphotos.com/gallery/albums/album496/65_OldWiring_02.jpg

Dashboard wiring and vacuum hoses. Looks quite a mess, doesn't it ;)

http://www.saabphotos.com/gallery/albums/album496/65_OldWiring_04.jpg

ShadowWorks
15th March 2007, 09:37 PM
There really is not much to the wiring loom on a c900, I hate wiring diagrams but I love wires:lol:, wiring diagrams make some sense and wires make alot of sense:cheesy:

Its a good idea to check the connectors for lose wires.

Shan
16th March 2007, 11:12 AM
Cut out the old NA exhaust today with an angle grinder. I was surprised how quickly it came off, the total job took no longer than 10 minutes.

Following are some pics of the removed NA exhaust beside the LPT exhaust that I will be installing.

http://www.saabphotos.com/gallery/albums/album496/66_Exhaust_051.jpg

http://www.saabphotos.com/gallery/albums/album496/66_Exhaust_058.jpg

Shan
17th March 2007, 09:08 AM
There really is not much to the wiring loom on a c900, I hate wiring diagrams but I love wires:lol:, wiring diagrams make some sense and wires make alot of sense:cheesy:

Its a good idea to check the connectors for lose wires.
That wiring loom is excluding the one from the fusebox to the gearshift and to the rear-end of the car. I'm re-using a portion of the old wiring to the rear, as I don't have the complete loom from the donor. Can't wait to start connecting them all up :)

Shan
18th March 2007, 10:39 AM
Installed the trans oil cooler from the LPT today. It previously had an inline cooler, using the engine's cooling water to cool down the trans oil.

Here are some pics of the new installation:

http://www.saabphotos.com/gallery/albums/album496/67_OilCoolerInstalled_71.jpg

http://www.saabphotos.com/gallery/albums/album496/67_OilCoolerInstalled_74.jpg

Shan
18th March 2007, 10:42 AM
Here are some pics of the trans oil cooler pipes laid up in the front of the engine bay.

http://www.saabphotos.com/gallery/albums/album496/67_OilCoolerInstalled_68.jpg

http://www.saabphotos.com/gallery/albums/album496/67_OilCoolerInstalled_65.jpg

Shan
20th March 2007, 09:49 AM
I decided to clean out the Mitsubishi TE05-12B turbo unit before reattaching it to the engine, after the exhaust manifold stud job.

Pic of the turbo unit before cleaning. Dirty compressor wheel and housing :

http://www.saabphotos.com/gallery/albums/album553/68_TurboBefore_13.jpg

Dirty exhaust housing :

http://www.saabphotos.com/gallery/albums/album553/68_TurboBefore_15.jpg

Shan
20th March 2007, 09:50 AM
Exhaust casing removed :

http://www.saabphotos.com/gallery/albums/album553/68_TurboBefore_24.jpg

Shan
20th March 2007, 09:52 AM
Compressor wheel and housing looking clean, after cleaning up with gasoline and a brush :

http://www.saabphotos.com/gallery/albums/album553/68_TurboAfter_22.jpg

Shan
20th March 2007, 09:54 AM
Compressor housing re-attached, showing the cleaned compressor wheel :

http://www.saabphotos.com/gallery/albums/album553/68_TurboAfter_50.jpg

Exhaust housing and turbine wheel, after a similar cleanup :

http://www.saabphotos.com/gallery/albums/album553/68_TurboAfter_52.jpg

ShadowWorks
20th March 2007, 12:57 PM
http://www.saabphotos.com/gallery/albums/album553/68_TurboAfter_22.jpg

Shan do you know where I can get the compressor wheel for the TE05-12B?

Mines is shattered and I can't find a replacement, can you measure the top of the inducer, thats where mines is damage and I think its 40mm and the bottom exducer is 58mm?

Shan
21st March 2007, 10:34 AM
Shan do you know where I can get the compressor wheel for the TE05-12B?

Mines is shattered and I can't find a replacement, can you measure the top of the inducer, thats where mines is damage and I think its 40mm and the bottom exducer is 58mm?
Hey Shadow,

Not really sure where you could get a compressor wheel in the UK, I pulled one out today and measured it up. You're right, it is 40 mm and 58 mm.

http://www.saabphotos.com/gallery/albums/Turbo-Comparison/TE05_12B_Dimensions_44.jpg

http://www.saabphotos.com/gallery/albums/Turbo-Comparison/TE05_12B_Dimensions_45.jpg

Cheers, :)

ShadowWorks
21st March 2007, 11:31 AM
Thank you for checking Shan:D very decent of you to do that;)

I just can't believe the condition of your engine bay, its looks like it came off the factory floor:o

how come it has no rust or any signs of dirt!

Shan
22nd March 2007, 07:14 AM
I just can't believe the condition of your engine bay, its looks like it came off the factory floor:o

how come it has no rust or any signs of dirt!
Having had bad experiences with previous rusty Saabs, this shell looked pretty decent and I thought it would be a good candidate for a restoration job. The old NA engine had considerable amount of oil leaks, which I suspect is the reason why the body was so well protected. The previous owner had also taken extra care to ensure that all the door hinges were oiled and greased, I could not find any wear on them despite the car having done more than 240k kms. With the engine out, it was easy to de-grease the entire engine bay before the paint job. I'm thinking of removing the engine on my other Saabs and have the engine bay similarly painted :)

Shan
23rd March 2007, 10:09 AM
Having installed the left side bodywork strips after the paint job, I got down to installing the right side strips today. Here's some pics of the strip being installed using a thread and sticky tape as a guide.

http://www.saabphotos.com/gallery/albums/album292/70_SideStrips_03.jpg

http://www.saabphotos.com/gallery/albums/album292/70_SideStrips_04.jpg

Left side showing the painted wheel arch. Bald tyres are only temporary to move the car around :)

http://www.saabphotos.com/gallery/albums/album292/70_SideStrips_05.jpg

Matthew
23rd March 2007, 06:59 PM
I like the idea of using the thread to fit the strips :cool:

Coming along nicely! :D

Shan
24th March 2007, 11:25 AM
I like the idea of using the thread to fit the strips :cool:

Coming along nicely! :D
I tried using a piece of string, but it sagged in the middle and was difficult to get a straight line. The thread worked perfectly :)

Shan
24th March 2007, 11:27 AM
When I got the LPT engine, the fuel rail was bent (picture below). I presume something heavy was placed on it during transport.

http://www.saabphotos.com/gallery/albums/album539/71_BentFuelRail_32.jpg

Fortunately, the fuel rail is identical to the one from my old 16V NA engine with Bosch injectors :)

http://www.saabphotos.com/gallery/albums/album539/71_BentFuelRail_114.jpg

http://www.saabphotos.com/gallery/albums/album539/71_BentFuelRail_112.jpg

Shan
24th March 2007, 11:28 AM
Some pics of the Lucas and Bosch injectors after they were seperated from the fuel rail. Bosch injector on the left, Lucas on the right.

http://www.saabphotos.com/gallery/albums/album539/72_BoschLucas_injectors_121.jpg

http://www.saabphotos.com/gallery/albums/album539/72_BoschLucas_injectors_120.jpg

http://www.saabphotos.com/gallery/albums/album539/72_BoschLucas_injectors_118.jpg

Shan
24th March 2007, 11:31 AM
Pics of the Lucas injectors mounted on the fuel rail from my old 16V NA.

http://www.saabphotos.com/gallery/albums/album539/73_LucasInjectors_125.jpg

http://www.saabphotos.com/gallery/albums/album539/73_LucasInjectors_123.jpg

ShadowWorks
24th March 2007, 09:17 PM
Its looks stunning, your so lucky to have found such an amaing condition 900;)

Shan I like your floor tles as well, they look to nice to have car parts on like your exhaust, does your wife not mind:lol:

Shan
25th March 2007, 08:08 AM
Its looks stunning, your so lucky to have found such an amaing condition 900;)

Shan I like your floor tles as well, they look to nice to have car parts on like your exhaust, does your wife not mind:lol:
Thanks ! LOL. The floor is cleaned after every DIY session. Dad does most of the cleaning work including the parts as well, while I do the disassembly and reassembly works. It's nice to work on the Saab when the floor, workbench and tools are clean before every DIY session :)

Most of the Saabs here are rust free, due to the tropical warm weather and no salts on the roads. Maintaining the bodywork requires minimum effort with just an occational wash and waxing.

Glad you're enjoying this thread.
Cheers.

Matthew
25th March 2007, 12:19 PM
Trying to keep a classic car clean in the UK is a real headache. I think I'm actually glad the 900 hasn't been on the road this Winter!

Shan
26th March 2007, 10:40 AM
Trying to keep a classic car clean in the UK is a real headache. I think I'm actually glad the 900 hasn't been on the road this Winter!
Is the winter over yet ? I heard that it's still snowing... :roll:

Shan
26th March 2007, 11:04 AM
Power steering pump gets an external clean-up before being reinstalled on the engine.

http://www.saabphotos.com/gallery/albums/album202/74_PowerSteeringPump_31.jpg

http://www.saabphotos.com/gallery/albums/album202/74_PowerSteeringPump_32.jpg

http://www.saabphotos.com/gallery/albums/album202/74_PowerSteeringPump_29.jpg

Shan
27th March 2007, 10:09 AM
The starter motor on the LPT engine was looking rather dirty. I had a spare one handy, which I had previously dismantled, cleaned and lubricated. I decided to plonk in the spare unit and service the one which came with the engine at a later stage.

Pics of the old starter removed, beside the serviced unit :

http://www.saabphotos.com/gallery/albums/album567/75_ReplacingStarterMotor_127.jpg

http://www.saabphotos.com/gallery/albums/album567/75_ReplacingStarterMotor_128.jpg

Serviced starter motor installed on the LPT engine :

http://www.saabphotos.com/gallery/albums/album567/75_ReplacingStarterMotor_163.jpg

Matthew
27th March 2007, 03:58 PM
Why is the plate on the end of the throttle spindle different to every other 900 I have seen? They normally have a cam, but yours doesn't!

Breakin5speeds
27th March 2007, 07:39 PM
because it is an automatic....

Matthew
28th March 2007, 08:55 AM
But why would an automatic car not have the throttle cam?

Shan
28th March 2007, 10:00 AM
But why would an automatic car not have the throttle cam?
Not really sure, but all the automatics I've seen doesn't have the throttle cam.
Perhaps it interferes with the kick-down cable on wide open throttle ?

Shan
29th March 2007, 10:55 AM
Got a pair of new hydraulic mounts from eurocarparts.com.
I should have cleaned them before installation, it looks rather dusty in these pics...

http://www.saabphotos.com/gallery/albums/album568/76_HydraulicEngineMount_82.jpg

http://www.saabphotos.com/gallery/albums/album568/76_HydraulicEngineMount_79.jpg

http://www.saabphotos.com/gallery/albums/album568/76_HydraulicEngineMount_95.jpg

Shan
29th March 2007, 11:04 AM
A new front mount from PartsforSaabs.com installed at the front of the autobox.

http://www.saabphotos.com/gallery/albums/album568/76_FrontMount_130.jpg

http://www.saabphotos.com/gallery/albums/album568/76_FrontMount_131.jpg

Shan
2nd April 2007, 11:24 AM
Finally installed the engine over the weekend :) Here are some preliminary pics.

The project c900, ready to accept the engine :

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_127.jpg

Engine hoist being prepared to lift the engine :

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_128.jpg

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_129.jpg

4 year old son posing beside the engine :

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_134.jpg

ejenner
2nd April 2007, 04:18 PM
aurr, aint that lovely! interesting choice of colour for the turbo heat shield. Is there a reason why it's yolk-yellow?

ShadowWorks
2nd April 2007, 05:21 PM
Orangy Yellow because its hot!;)

I would have painted the turbo exhaust elbow for sure, I hate brown metal it makes my teeth hurt when I think about it:lol:

You have a cute wee boy Shan, I can't believe he has glasses at such a young age, my nephew is only 3 and he needs glasses as well:roll: crazy

Shan
3rd April 2007, 10:58 AM
aurr, aint that lovely! interesting choice of colour for the turbo heat shield. Is there a reason why it's yolk-yellow?
The engine was looking rather bland, I had some yellow paint laying around and thought I'd make it a little more colourful by painting it yellow :lol:
It does liven up the pics, doesn't it ? :cool:

Shan
3rd April 2007, 11:08 AM
Orangy Yellow because its hot!;)

I would have painted the turbo exhaust elbow for sure, I hate brown metal it makes my teeth hurt when I think about it:lol:

You have a cute wee boy Shan, I can't believe he has glasses at such a young age, my nephew is only 3 and he needs glasses as well:roll: crazy
The kid unfortunately has astigmatism, I suppose he took this on from me (including the interest in Saab) as I was using glasses at the age of 10.

You're absolutely right with the turbo elbow, the corroded colour makes the engine look "aged". I snapped the following pic of a 8V engine at a local Saab meet last weekend. The painted look of the whole exhaust manifold and turbo looked so lovely, I wish I had done more work on mine before the engine went in....

http://www.saabphotos.com/gallery/albums/album573/IMG_0221.sized.jpg

Matthew
3rd April 2007, 11:57 AM
The problem is finding a proper high-temp paint that won't have flaked off after a few heat cycles.

The exhaust manifold from my 900 will be zinc metal sprayed, and then I'll paint it with Factory Manifold. Wish I'd had the turbo elbow zinc'd too. I'll probably give that and the turbine housing a coat of Factory Manifold, and see how they fare.

Shan
4th April 2007, 10:15 AM
The problem is finding a proper high-temp paint that won't have flaked off after a few heat cycles.

The exhaust manifold from my 900 will be zinc metal sprayed, and then I'll paint it with Factory Manifold. Wish I'd had the turbo elbow zinc'd too. I'll probably give that and the turbine housing a coat of Factory Manifold, and see how they fare.
Is there a website with info on 'Factory Manifold' ?

Shan
4th April 2007, 10:16 AM
Pic of the engine being lifted :

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_139.jpg

Ready to return where it belongs :)

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_140.jpg

Shan
4th April 2007, 10:17 AM
In she goes :)

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_148.jpg

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_152.jpg

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_155.jpg

Shan
4th April 2007, 10:20 AM
B202 LPT in position.

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_156.jpg

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_157.jpg

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_159.jpg

Shan
4th April 2007, 10:20 AM
The 4-year old again joining in the fun !


http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_160.jpg

Shan
4th April 2007, 10:22 AM
More pics of the installed engine with the hoist removed.

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_002.jpg

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_010.jpg

Shan
10th April 2007, 10:37 AM
View of the installed engine from the top.

http://www.saabphotos.com/gallery/albums/album569/77_EngineReinstallation_008.jpg

Shan
10th April 2007, 10:49 AM
I inserted these pieces of rubber in the front trans mount, hoping that it would help lengthen the life of the new mount. Has anyone done the same and any ill effects from doing it ?

http://www.saabphotos.com/gallery/albums/album568/79_FrontMount_021.jpg

http://www.saabphotos.com/gallery/albums/album568/79_FrontMount_019.jpg

Saab-Daniel
10th April 2007, 11:09 AM
Hi shan.
I haven't tried it, but I changed that engine-mount a few months back, the old one was at least 10 years old (my guestimate, and the car has always been in the family, can't remeber it being changed) and it wasn't that badly worn! Unfortunatly, really, as I hoped it was that causing a bit of wobling, hehe :)
Daniel.

Shan
13th April 2007, 10:12 AM
Installed the engine oil cooler today. The shroud for the cooler that I removed from the donor was completely rusted (pic below). The project c900 originally did not have an engine oil cooler, being fitted with an NA engine originally. Fortunately I had a spare shroud laying around and installed that together with the cooler from the donor into the project c900 :)

Spare shroud and the rusted one from the donor :
http://www.saabphotos.com/gallery/albums/album215/80_Oil_Cooler_061.jpg

Engine oil cooler installed :
http://www.saabphotos.com/gallery/albums/album215/80_Oil_Cooler_033.jpg

Shan
29th April 2007, 10:51 AM
Installed a new gasket for the camcover, Saab part no.8822041. The original gasket had hardened and the previous owner had resorted to using red RTV unsuccessfully. I installed the new gasket without any additional sealant.

http://www.saabphotos.com/gallery/albums/album591/81_CamcoverGasket_41.jpg

ShadowWorks
29th April 2007, 11:23 AM
You won't need silicone if you torque up the cam cover in series, like pinching down the head gasket, I know its not a requirement but it seems to help, I have changed these gasket twices and never had a leaky cam cover like some people talk about, I think its because the cam cover is thin and can twist with to much torque all at once, no harm in being nice right;)

ejenner
29th April 2007, 11:29 AM
Mine leaked because it was a Scantech gasket. That gasket you have there seems much more substaintial. The Scantech one is half the thickness and needs lots of Loctite 518 to seal it up.

Shan
30th April 2007, 11:20 AM
Mine leaked because it was a Scantech gasket. That gasket you have there seems much more substaintial. The Scantech one is half the thickness and needs lots of Loctite 518 to seal it up.
Thanks for that information. I was planning on ordering a couple of Scantech ones for spares. Anyone else experienced the same with the Scantech gasket ?

Btw, I was pleasantly surprised when I looked up the part number in my EPC 2003 and it showed that the same part is used in the 2003 9-5 :cool:

Shan
1st May 2007, 11:55 AM
Some pics of the engine with the cam cover removed.

http://www.saabphotos.com/gallery/albums/album591/81_CamcoverGasket_45.jpg

http://www.saabphotos.com/gallery/albums/album591/81_CamcoverGasket_50.jpg

http://www.saabphotos.com/gallery/albums/album591/81_CamcoverGasket_47.jpg

Shan
1st May 2007, 11:55 AM
A front shot :)

http://www.saabphotos.com/gallery/albums/album569/77_External_66_001.jpg

philb
1st May 2007, 12:19 PM
well, mine is a genuine saab gasket. It was ok until I had to remove it to retorque the head bolts, obviously my retorque on the head was better than that on the gasket, it is leaking copious amounts of oil. I'd say I've warped the cam cover, will give it another shot though.

Aussiebob
1st May 2007, 06:09 PM
Shan - you are a great inspiration to us all. I have a black 900 Aero sitting in my back yard I would love to strip and do the job you have. Possibly after our winter (a few days in July - cannot understand all the forum talk about snow!!) I will begin.

My family is a little older than yours, 17 and 13, but they both have the SAAB bug and are pretty good on the spanners.

Shan
2nd May 2007, 10:13 AM
Shan - you are a great inspiration to us all. I have a black 900 Aero sitting in my back yard I would love to strip and do the job you have. Possibly after our winter (a few days in July - cannot understand all the forum talk about snow!!) I will begin.
Thanks Aussiebob :). This project is taking longer than what I had planned, but I'm in no hurry and taking it one step at a time. Keeping my fingers crossed that all will turn out well.

Aussiebob
2nd May 2007, 05:54 PM
Shan - do you have a drawing of the engine stand you made. If so can you post it so we can download.

Shan
3rd May 2007, 09:19 AM
Shan - do you have a drawing of the engine stand you made. If so can you post it so we can download.
I'll have it measured up the weekend after next, all the stands are presently stored at my dad's place.

Cheers,
Shan

Shan
28th May 2007, 10:55 AM
Got some work done during the weekend, after being away for a while. I decided to swap out the complete gearshift housing with the later style knob (left in the pic below), as I had a complete matching set of good door locks to go along with it.

http://www.saabphotos.com/gallery/albums/album828/82_GearshiftInstallation_60.jpg

To my surprise, I found the gear stick bent (picture below). I can't imagine how this happened, fortunately I had another stick laying around and could swap it into the housing without difficulty. Unfortunately, I did not take pics during dismantling of the gear stick from the housing.

http://www.saabphotos.com/gallery/albums/album828/82_GearshiftInstallation_64.jpg

Shan
28th May 2007, 10:57 AM
Picture before reinstallation of the gearshift housing. Remanence of old welding where the previous front seat cross bar resided can be seen in this pic.

http://www.saabphotos.com/gallery/albums/album828/82_GearshiftInstallation_13.jpg

Gearshift housing installed in position :

http://www.saabphotos.com/gallery/albums/album828/82_GearshiftInstallation_16.jpg

Shan
28th May 2007, 10:58 AM
Dad made this "special tool" from a 10 mm deep socket to tighten the 3 mounting nuts.
Worked perfectly ! :)

http://www.saabphotos.com/gallery/albums/album828/82_GearshiftInstallationTool_53.jpg

ejenner
28th May 2007, 12:13 PM
I've got one of those 'special' tools as well!

Shan
31st May 2007, 10:51 AM
Installed the rest of the ancillaries in the engine bay including the radiator, fans, Lucas air mass meter, ignition distributor, air and water plumbing, charcoal canister, etc. etc.

http://www.saabphotos.com/gallery/albums/album569/78_EngineReinstallation_43.jpg

http://www.saabphotos.com/gallery/albums/album569/78_EngineReinstallation_35.jpg

http://www.saabphotos.com/gallery/albums/album569/78_EngineReinstallation_42.jpg

Shan
31st May 2007, 10:52 AM
More pics :

http://www.saabphotos.com/gallery/albums/album569/78_EngineReinstallation_36.jpg

http://www.saabphotos.com/gallery/albums/album569/78_EngineReinstallation_45.jpg

Shan
30th June 2007, 10:57 AM
Lots of work done on the project c900. With fresh oil in the engine and autobox, and a new oil filter installed, I cranked the engine with the spark plugs and fuel pump fuse removed to allow lubrication to flow in the block, and the engine to ease up.

With all the bits reassembled, a few cranks to fill up the fuel lines and the engine spluttered to life ! It settled down at an idle speed of 1400 rpm and refused to drop further. Out came the AIC valve, which was filled with hardened sludge. A quick clean with degreaser and a toothbrush, and the idle speed dropped to the normal 850 - 900 rpm.

Driveshafts were reinstalled and took the car out for a short drive. The engine felt pretty solid :) However I noticed traces of water on the engine block beneath the exhaust manifold. I had replaced the water jacket plug previously, the one closer to the turbo. Now the second plug towards the rear of the engine started developing a leak! So off came the exhaust manifold for the second time, not as easy as previously with the engine now installed in the car. I managed to avoid removing the turbo unit and tied it with a piece of string (picture below) and installed a new plug.

http://www.saabphotos.com/gallery/albums/album627/83_WaterJacketPlug2_56.jpg


http://www.saabphotos.com/gallery/albums/album627/83_WaterJacketPlug2_55.jpg


Picture taken from the bottom after the new plug was installed :

http://www.saabphotos.com/gallery/albums/album627/83_WaterJacketPlug2_60.jpg

ejenner
30th June 2007, 01:33 PM
to get the manifold in and out whilst the engine is in the engine bay sometimes it helps to open the nut on the top of the rear engine mount on that side of the car. Then just raise the engine up an inch. It gives you a bit more clearance. Easier to remove the manifold than it is to put it back.

Aussiebob
30th June 2007, 08:13 PM
Shan - did you do anything to the auto box?

One of mine is a 1988 Aero with auto box and I was interested in your earlier comments regarding upgrading the auto to handle greater power, possibly better than the manual.

Shan
1st July 2007, 11:10 AM
to get the manifold in and out whilst the engine is in the engine bay sometimes it helps to open the nut on the top of the rear engine mount on that side of the car. Then just raise the engine up an inch. It gives you a bit more clearance. Easier to remove the manifold than it is to put it back.
You're absolutely right. After removing the manifold, I had great difficulty to put it on back again. In the end, I jacked the bottom of the diff casing, then removed the bracket completely (shown in the pic below) and the exhaust manifold went back on pretty easily :)

http://www.saabphotos.com/gallery/albums/album627/83_WaterJacketPlug2_159.jpg

Shan - did you do anything to the auto box?

One of mine is a 1988 Aero with auto box and I was interested in your earlier comments regarding upgrading the auto to handle greater power, possibly better than the manual.
No, nothing done on the auto box, except for new oil in the trans and diff. I don't think it was me who commented about upgrading the autobox...

Shan
2nd July 2007, 11:46 AM
With the engine now functioning properly and gearbox shifting smoothly, it was time to install the rest of the external bits and pieces. Here are some pics of the front bumper and headlights being refitted.

http://www.saabphotos.com/gallery/albums/album630/85_HeadlightBumper_06.jpg

http://www.saabphotos.com/gallery/albums/album630/85_HeadlightBumper_11.jpg

http://www.saabphotos.com/gallery/albums/album630/85_HeadlightBumper_12.jpg

http://www.saabphotos.com/gallery/albums/album630/85_HeadlightBumper_09.jpg

Shan
2nd July 2007, 11:47 AM
Front grille and license plate refitted, so that I can drive the car legally to test it out. The front spoiler has not been fitted, I plan to remove the front bumper at a later stage to install the air conditioning. The front lip will be installed at that stage.

http://www.saabphotos.com/gallery/albums/album630/85_HeadlightBumper_14.jpg

http://www.saabphotos.com/gallery/albums/album630/85_HeadlightBumper_13.jpg

Matthew
2nd July 2007, 04:28 PM
Nice work :D

It must feel great to see everything coming back together after all your hard work :D

Shan
3rd July 2007, 11:29 AM
Nice work :D

It must feel great to see everything coming back together after all your hard work :D
Thanks :). Yes, I am very pleased with the way the car is turning out.

After starting up the engine, the 'check engine' lamp came on after a few minutes on idle. After that, I could not start the engine anymore, unless I disconnected the battery momentarily which somehow reset the ECU.

I pulled the error codes from the ECU and it gave me a 13225 -> Lambda sensor faulty signal! In the Lucas CU14 manual, one of the first items to check is fuse no.1. This supplies power to the Lambda sensor preheater. Sure enough, there was no fuse at that location !!! Instead, there was a fuse at location no.2, which is unused and doesn't have any terminals to it. When I installed the fusebox from the donor, I hadn't checked that all the required fuses were present. I swapped the fuse from location no.2 to no.1 (fuse rating correct), cleared the fault codes and started up the engine. No more 'check engine' alarms :cool:

Looking back during the dashboard swap from the donor, there was no bulb at the instrument panel for the check engine lamp. I suspect the previous owner must have junked the Saab as the check engine lamp kept on appearing due to the missing fuse no.1. He must have then removed the check engine bulb, but with the engine having difficulty starting up, he must have junked the whole car. What a pity, as the engine and gearbox runs so smoothly.

I still had the original spark plugs from the donor installed which are the wrong resistor type plugs, and decided to replace them with a fresh set of NGK BCP6ES plugs. From an engine that had only run a few hours after being swapped into the project car, I was amazed that the old plugs looked clean (pic below), indicating good combustion. I replaced the plugs anyway, as there were corona marks on the insulator.

http://www.saabphotos.com/gallery/albums/album631/86_SparkPlugs_116.jpg

Matthew
3rd July 2007, 12:11 PM
What causes those corona marks? Plug overheating?

Shan
4th July 2007, 11:24 AM
What causes those corona marks? Plug overheating?
I'm not really sure, it could just be a leak at the internal seal of the spark plug, causing exhaust gases to escape. Below is another pic of the discarded plug.

http://www.saabphotos.com/gallery/albums/album631/86_SparkPlugs_02.jpg

Shan
4th July 2007, 11:44 AM
Pics of the rear bumper and side trim being refitted.

http://www.saabphotos.com/gallery/albums/album630/85_RearBumper_71.jpg

http://www.saabphotos.com/gallery/albums/album630/85_RearBumper_05.jpg

Shan
8th July 2007, 11:32 AM
Some pics of the interior wiring, relays, etc. being installed. As the donor wiring was only from the front right up to the gearshift housing, I had to join all the wiring that goes to the rear at this point. All wires were soldered to create solid joints.

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_015.jpg

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_028.jpg

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_017.jpg

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_019.jpg

Shan
8th July 2007, 11:33 AM
Working at night with a lamp :

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_018.jpg

View of the instrument cluster from the top :

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_027.jpg

Shan
8th July 2007, 11:34 AM
Some pics taken during the day :

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_042.jpg

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_040.jpg

Shan
8th July 2007, 11:45 AM
Managed to find this rear fusebox from the local scrapyard :)

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_036.jpg

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_037.jpg

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_039.jpg

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_038.jpg

Shan
8th July 2007, 11:47 AM
Rear fusebox being wired up to fit the existing rear wiring, and the fusebox bracket installed in position (top right in the pic).

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_044.jpg

Shan
8th July 2007, 11:49 AM
Rear fusebox installed in position below the rear seat.

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_056.jpg

View from the top :

http://www.saabphotos.com/gallery/albums/album668/86_Wiring_055.jpg

ejenner
8th July 2007, 12:28 PM
I sometimes work outside in the dark and use a lamp the same way you do. Sometimes you just need to spend that 'extra' hour on something and it's better to keep going rather than leaving it. Although in my case, I'm often preparing the 99 for a track day, trip to Sweden or rolling-road day the night before it's due to happen. I don't do that on purpose, it just happens sometimes!

It's looking good. Keep up the good work.

walawala
9th July 2007, 06:36 AM
shan...
nice work there man...would like to lend a hand in my rear fuse box wiring project? :cheesy: :cheesy:

des

Matthew
9th July 2007, 07:31 AM
That wiring looks like a nightmare made real :o You're a brave man! :cheesy:

Shan
9th July 2007, 10:45 AM
It's looking good. Keep up the good work.
nice work there man...would like to lend a hand in my rear fuse box wiring project?
That wiring looks like a nightmare made real :o You're a brave man! :cheesy:
Thanks for the encouragement chaps. The wiring is the most difficult part of the whole project, with limited parts available. Thankfully, Saab wiring diagrams are informative and well laid out. I've re-created the complete wiring for the power windows to the later type control module just from the diagrams :)

Shan
9th July 2007, 11:20 AM
Dashboard panel being prepared for reinstallation.

http://www.saabphotos.com/gallery/albums/album676/87_DashboardPanel_052.jpg

http://www.saabphotos.com/gallery/albums/album676/87_DashboardPanel_050.jpg

Shan
9th July 2007, 11:22 AM
Pics of the dashboard panel installed.

http://www.saabphotos.com/gallery/albums/album676/87_DashboardPanel_061.jpg

http://www.saabphotos.com/gallery/albums/album676/87_DashboardPanel_062.jpg

Shan
9th July 2007, 11:24 AM
With the dashboard lining installed, I temporarily fitted the front seats so that I can shift the car in the house compound :)

http://www.saabphotos.com/gallery/albums/album676/87_DashboardPanel_067.jpg

Shan
10th July 2007, 10:45 AM
Pics of the dash lower air duct installed. This allowed the dash wiring to be tidied up considerably and the central locking control module mounted at it's original location.

http://www.saabphotos.com/gallery/albums/album676/87_DashboardLowerAirDuct_202.jpg

http://www.saabphotos.com/gallery/albums/album676/87_DashboardLowerAirDuct_203.jpg

http://www.saabphotos.com/gallery/albums/album676/87_DashboardLowerAirDuct_204.jpg

Albert Trout
10th July 2007, 11:10 AM
I wish I had a tenth of your patience Shan. You're doing a cracking job there :cheesy:

Shan
10th July 2007, 11:20 AM
I wish I had a tenth of your patience Shan. You're doing a cracking job there :cheesy:
Thanks ! :)
Looking back, it's more than 6 months since the project started. I'm more motivated to complete it now, since I know that the mechanical bits (engine, gearbox, turbo unit) are pretty solid :)

Shan
10th July 2007, 11:20 AM
Door bottom rubber strip being prepared for reinstallation, a nice break after the tedious wiring work.

http://www.saabphotos.com/gallery/albums/album679/88_DoorBottomStrip_081.jpg

http://www.saabphotos.com/gallery/albums/album679/88_DoorBottomStrip_086.jpg

Shan
10th July 2007, 11:21 AM
Door bottom rubber strip being riveted back in place.

http://www.saabphotos.com/gallery/albums/album679/88_DoorBottomStrip_090.jpg

http://www.saabphotos.com/gallery/albums/album679/88_DoorBottomStrip_093.jpg

http://www.saabphotos.com/gallery/albums/album679/88_DoorBottomStrip_094.jpg

bohtak
10th July 2007, 01:25 PM
shan! great work there!!

its nice to have a big house! :cheesy:

TooMany2cvs
10th July 2007, 05:18 PM
KurBads, I've finished scanning and uploaded the complete factory Lucas CU14 manual to the following:
http://www.hexfiles.com/shan/Saab_Factory_Manuals/index.html (http://www.hexfiles.com/users/shan/Saab_Factory_Manuals/index.html)

Shan,

Having just bought a Lucas 900, I want to say a big thank you for doing the manual. I *hope* I don't need it - having it should be good insurance against having injection probs... <grin>

Shan
11th July 2007, 11:35 AM
shan! great work there!!

its nice to have a big house! :cheesy:
Thanks Bohtak. This project has been an exciting adventure for me, reconstructing a car from an empty shell. The extra space in the house is helpful :)
Having just bought a Lucas 900, I want to say a big thank you for doing the manual. I *hope* I don't need it - having it should be good insurance against having injection probs... <grin>
You're most welcome :). Wish I had the time to scan the rest of the manuals.

Shan
11th July 2007, 11:39 AM
Fitted the sound insulation on the front floor, then the air duct. Only then did I realise that the front carpet had to be installed first before the air duct :o Fortunately the air duct is easy to remove and reinstall. Here's a pic of my error :

http://www.saabphotos.com/gallery/albums/album683/89_SoundInsulation_001.jpg

Shan
11th July 2007, 11:41 AM
Fitting the door trims :

http://www.saabphotos.com/gallery/albums/album683/89_DoorTrim_006.jpg

Shan
11th July 2007, 11:49 AM
With the air duct off, the front carpet could be installed. Unfortunately I could not obtain the correct rear carpet, so the original blue carpet had to go back in. I had to cut holes in the carpet for the rear mounts of the front seats as these were moved backwards to fit the later type front seats.

http://www.saabphotos.com/gallery/albums/album683/89_CarpetInstallation_015.jpg

Shan
11th July 2007, 11:58 AM
Sourced a lovely set of leather seats from the local scrapyard :)
The leather is soft, supple and feels almost new. Here's a pic of one of the front seat.

http://www.saabphotos.com/gallery/albums/album683/89_FrontSeat_002.jpg

http://www.saabphotos.com/gallery/albums/album683/89_FrontSeat_003.jpg

http://www.saabphotos.com/gallery/albums/album683/89_FrontSeat_005.jpg

Matthew
11th July 2007, 12:08 PM
Get some Glyptone cleaner and then conditioner on those seats... they'll be even better! :D

Nice front carpet... new old stock or cleaned? Is cleaned, do you have any tips?

At the Festival, I bought a brand new in the bag rear carpet for a 900 :cheesy: I really wanted a front carpet, only rears were available.

RWElphinstone
11th July 2007, 02:29 PM
:o

Wow. Everything looks just so ... wow.

I have absolutely no hope in coming anywhere close to the quality of the work that you have done here. (I'm sure this thought is echoed in many people here, too.)

I just re-read every post in this thread, from the beginning, and it was extremely inspirational! (I have to stifle my thought of, "hurry up!", as I'm really excited to see the final result!)

I can't wait. Thank you, thank you, thank you for posting so many fantastic pictures!

Again, WOW!

:o

TooMany2cvs
11th July 2007, 03:26 PM
Get some Glyptone cleaner and then conditioner on those seats... they'll be even better!

Let's hope so - my bottles were delivered today...

Wow. Everything looks just so ... wow.

I have absolutely no hope in coming anywhere close to the quality of the work that you have done here. (I'm sure this thought is echoed in many people here, too.)

I don't remember my mother's '86 900i 5-dr looking that good... and that was brand spankin' new...

SteveTheFolkie
11th July 2007, 04:14 PM
spectacular restoration - wish I had the time and space to take my '85 down to her bare shell (well, given the tin-worm repairs maybe not - it might be traumatic!) and restore her -

Shan
12th July 2007, 11:46 AM
Thanks guys for all your encouraging words, I'm really glad that you are enjoying this thread :D

Nice front carpet... new old stock or cleaned? Is cleaned, do you have any tips?
It is a used carpet from the donor c900. I soaked the carpet with water and brushed it down with clothes detergent and a soft brush. The saab carpet is very durable and resistant to water damage. Afther washing all the detergent off, I hung it over the fence to dry. It dries pretty quickly in a couple of hours and comes up bright and fluffy.

Shan
12th July 2007, 12:06 PM
Bought some chrome stripes for the bumpers. These are made for a locally produced car, but fits the c900 perfectly. For RM18 (equivalent to GBP 3) per roll, I thought it was a good bargain. One roll is sufficient to fit the complete rear bumper including rear side panels.

Pic of the chrome strip with a portion cut off for the rear bumpers.

http://www.saabphotos.com/gallery/albums/album630/85_RearBumperStrip_06.jpg

http://www.saabphotos.com/gallery/albums/album630/85_RearBumperStrip_05.jpg

Shan
12th July 2007, 12:08 PM
Rear bumper before fitting the chrome strip :

http://www.saabphotos.com/gallery/albums/album630/85_RearBumper_71.jpg

Rear side panels and chrome strip fitted :

http://www.saabphotos.com/gallery/albums/album630/85_RearBumper_05.jpg

Matthew
12th July 2007, 07:56 PM
That trim looks good. How wide is it? Is it self-adhesive or are you using the original spring clips?

Shan
13th July 2007, 11:03 AM
That trim looks good. How wide is it? Is it self-adhesive or are you using the original spring clips?
The new trim is self adhesive. I've discarded the original springs. Width is equal to the original Saab trim. Below is a closer shot of the new trim. There is a plastic protective layer on top of the trim, once that is removed, it really shines :)

http://www.saabphotos.com/gallery/albums/album630/85_BumperStrip_17.jpg

Shan
13th July 2007, 11:18 AM
Another view of the front carpet :

http://www.saabphotos.com/gallery/albums/album683/87_InteriorReinstallation_016.jpg

Pic of the centre console and power window control module installed. I really should source for the correct rear carpet...

http://www.saabphotos.com/gallery/albums/album683/87_InteriorReinstallation_026.jpg

Shan
13th July 2007, 11:19 AM
A closer pic showing the repositioned seat mount to fit the later type front seats.

http://www.saabphotos.com/gallery/albums/album683/87_InteriorReinstallation_034.jpg

Shan
13th July 2007, 11:29 AM
Pictures of both front seats installed. Most of the interior pictures did not turn out as well as I had hoped for as the work was done during the night. It does looks better in reality :)

http://www.saabphotos.com/gallery/albums/album683/89_FrontSeat_043.jpg

http://www.saabphotos.com/gallery/albums/album683/89_FrontSeat_044.jpg

Shan
13th July 2007, 11:41 AM
AC compressor installed. Still oustanding is the evaporator unit (see the empty hole in the top left of the pic), condenser, reservoir/filter and the rest of the bits and pieces.

http://www.saabphotos.com/gallery/albums/album682/90_AirCond_004.jpg

Shan
14th July 2007, 10:37 AM
Another view of the chrome bumper trim, and now with rear badges stuck on.

http://www.saabphotos.com/gallery/albums/album630/85_BumperStrip_371.jpg

Shan
14th July 2007, 10:54 AM
I decided to replace the front cross member back to the original unit, as I couldn't get the correct gap between the bonnet and headlamps / front grill. When the car was repainted, I had swapped the front member with a spare unit and this somehow caused the bonnet to sit high up. After a few hours playing with the two adjustment screws without success, I decided to disassemble the front again and install the cross member that came with the car.

http://www.saabphotos.com/gallery/albums/album630/85_HeadlightBumper_14b.jpg

Something's not right with this front cross member, probably bent in the middle :

http://www.saabphotos.com/gallery/albums/album682/91_FrontMemberReplacement_010.jpg

Cross member removed.

http://www.saabphotos.com/gallery/albums/album682/91_FrontMemberReplacement_032.jpg

Shan
14th July 2007, 11:01 AM
The original front cross member reinstalled. Fortunately I had that repainted together with the replacement front cross member when I had the car painted. The AC condenser can be seen being prepared for installation in the following pic.

http://www.saabphotos.com/gallery/albums/album682/90_AirCond_037.jpg

Shan
14th July 2007, 11:17 AM
AC condenser installed :

http://www.saabphotos.com/gallery/albums/album682/90_AirCond_044.jpg

AC reservoir/filter unit being prepared for reinstallation :
http://www.saabphotos.com/gallery/albums/album682/90_AirCond_052.jpg

AC reservoir/filter unit and inlet & outlet pipes to the condenser reconnected :

http://www.saabphotos.com/gallery/albums/album682/90_AirCond_055.jpg

Shan
14th July 2007, 11:20 AM
There is a cover/guard to protect the inlet and outlet pipes of the AC condenser. I fitted this next.

http://www.saabphotos.com/gallery/albums/album682/90_AirCond_059.jpg

http://www.saabphotos.com/gallery/albums/album682/90_AirCond_063.jpg

Shan
14th July 2007, 11:30 AM
Installing the AC cooler unit was not so easy. I had to remove the cam cover again to create enough clearance for the cooler unit to slide in place.

Cam cover comes off (again :o) :

http://www.saabphotos.com/gallery/albums/album682/90_AirCond_008.jpg

AC cooler unit touches the camshaft sprocket as it goes in :

http://www.saabphotos.com/gallery/albums/album682/90_AirCond_023.jpg

http://www.saabphotos.com/gallery/albums/album682/90_AirCond_022.jpg

Shan
14th July 2007, 11:36 AM
AC cooler unit in place :

http://www.saabphotos.com/gallery/albums/album682/90_AirCond_031.jpg

Cover for the AC cooler unit installed and hoses connected :

http://www.saabphotos.com/gallery/albums/album682/90_AirCond_110.jpg

Shan
14th July 2007, 12:02 PM
Front bumper and side panels being installed, now with a perfect gap between the bonnet and front lamps :D

http://www.saabphotos.com/gallery/albums/album630/85_HeadlightBumper_076.jpg

Matthew
14th July 2007, 03:18 PM
Nice panel gap :D Much better than with the other crossmember.

Didn't know the cam cover had to be removed to fit the evaporator!

I think your rate of work is staggering. You're really on a misson to finish this car!

Shan
15th July 2007, 11:03 AM
Guess what I scored at the local breakers... a wooden dashboard facia with a Sony radio :D

http://www.saabphotos.com/gallery/albums/album676/91_NewDashFacia_070.jpg

Shan
15th July 2007, 11:04 AM
Some repairs with super glue needed to secure the guide sleeves in place behind the facia.

http://www.saabphotos.com/gallery/albums/album676/91_NewDashFacia_084.jpg

http://www.saabphotos.com/gallery/albums/album676/91_NewDashFacia_096.jpg

Shan
15th July 2007, 11:05 AM
Steering and panel switches removed, the facia being disassembled (again :o) to replace it with the wooden facia.

http://www.saabphotos.com/gallery/albums/album676/91_NewDashFacia_067.jpg

http://www.saabphotos.com/gallery/albums/album676/91_NewDashFacia_097.jpg

Shan
15th July 2007, 11:06 AM
Pics of the Wooden facia being installed. It really transforms the looks of the interior :)

http://www.saabphotos.com/gallery/albums/album676/91_NewDashFacia_101.jpg

http://www.saabphotos.com/gallery/albums/album676/91_NewDashFacia_105.jpg

Squaab99t
15th July 2007, 11:45 AM
Nice panel gap :D Much better than with the other crossmember.

Didn't know the cam cover had to be removed to fit the evaporator!

I think your rate of work is staggering. You're really on a misson to finish this car!

To remove mine (with the cam cover in place) I removed the vacuum actuator for the recirc flapper. Still a tight fit, but no chance of a leaky cam cover. I guess there is always more than one way to skin a cat.

ShadowWorks
15th July 2007, 07:13 PM
I have a similar gap between my bonnet and side light that I have not been able to correct with the bonnet bolts as well, crazy you switched the the whole frame over, you have so much motivation is amazing!

philb
15th July 2007, 07:45 PM
Shad, I think part of that is the crappy fit of the clear corners. Mine angle downwards from the line of the wing, the originals did not do that.

Shan
16th July 2007, 10:48 AM
To remove mine (with the cam cover in place) I removed the vacuum actuator for the recirc flapper. Still a tight fit, but no chance of a leaky cam cover. I guess there is always more than one way to skin a cat.
Thanks for that tip :). I've been told that it is possible to fit it without removing the cam cover, but I just could not get mine in. Removing the vacuum actuator is probably the trick.

Shan
16th July 2007, 10:52 AM
I have a similar gap between my bonnet and side light that I have not been able to correct with the bonnet bolts as well, crazy you switched the the whole frame over, you have so much motivation is amazing!
I was quite demotivated seeing that big gap after all that work. It took some time to convince myself to pick up the tools and swap that front member. Having only recently assembled everything, all the nuts and bolts came out fairly easily and the front member was out in less than an hour.

Shan
16th July 2007, 10:57 AM
I think your rate of work is staggering. You're really on a misson to finish this car!
Reason to quickly finish this car now is another 16v c900 in the fleet requires an engine change (suspected piston ring failure). This project car needs to become a daily driver asap :)

Shan
16th July 2007, 10:59 AM
Steering and knee pad installed, the centre console in the midst of being reinstalled :

http://www.saabphotos.com/gallery/albums/album683/93_Interior_007.jpg

http://www.saabphotos.com/gallery/albums/album683/93_Interior_010.jpg

http://www.saabphotos.com/gallery/albums/album683/93_Interior_011.jpg

Shan
16th July 2007, 11:00 AM
Interior reinstallation completed :)

http://www.saabphotos.com/gallery/albums/album683/93_Interior_351.jpg

http://www.saabphotos.com/gallery/albums/album683/93_Interior_345.jpg

http://www.saabphotos.com/gallery/albums/album683/93_Interior_343.jpg

VikingSpirit
16th July 2007, 12:11 PM
Beautiful car and awesome work Shan, but tell me do you actually have a job?! :lol:

Seriously what do you do that gives you with so much spare time during the day to restore saabs (and obviously the money to do it as well)?

I'm very jealous of course, it sucks only having rainy evenings and weekends and salary of shiny glass beads to worth with:p

Shan
17th July 2007, 10:16 AM
Beautiful car and awesome work Shan, but tell me do you actually have a job?! :lol:

Seriously what do you do that gives you with so much spare time during the day to restore saabs (and obviously the money to do it as well)?

I'm very jealous of course, it sucks only having rainy evenings and weekends and salary of shiny glass beads to worth with:p
Thanks :D Yes, I do have a full time job, and very little time to spend on the Saab. The rebuild has taken more than 6 months now, and far longer than I had estimated. A professional workshop would probably be able to do the same job in 2 weeks or less. Most of the work is done during the weekends, the lighter ones in the evenings or during the nights. I have about one hour of sunlight after work to get the important stuff done, working with the handlamp in the dark isn't really enjoyable.

The cost of the rebuild was actually quite low. All replacement parts were purchased from various local breakers. The only new parts on the car are the spark plugs, engine mounts, water jacket plugs and bumper trim.

Shan
17th July 2007, 10:40 AM
Some exterior pics :)

http://www.saabphotos.com/gallery/albums/album680/95_Exterior_112.jpg

http://www.saabphotos.com/gallery/albums/album680/95_Exterior_107.jpg

http://www.saabphotos.com/gallery/albums/album680/95_Exterior_118.jpg

http://www.saabphotos.com/gallery/albums/album680/95_Exterior_109.jpg

Shan
17th July 2007, 10:56 AM
Coming close to the end of the project, I do hope that this thread has been entertaining and provides some inspiration for those who would like to undertake your own restoration. Updating this thread in Saabcentral was in itself something I looked forward to every time a little work was done on the project Saab. The journey started with a desire to build a low-budget reliable daily driver and it has turned out beyond my expectations.

Hope you enjoyed this restoration as much as I did.

Cheers :)
Shan

VikingSpirit
17th July 2007, 11:28 AM
Thanks :D Yes, I do have a full time job, and very little time to spend on the Saab. The rebuild has taken more than 6 months now, and far longer than I had estimated. A professional workshop would probably be able to do the same job in 2 weeks or less. Most of the work is done during the weekends, the lighter ones in the evenings or during the nights. I have about one hour of sunlight after work to get the important stuff done, working with the handlamp in the dark isn't really enjoyable.

The cost of the rebuild was actually quite low. All replacement parts were purchased from various local breakers. The only new parts on the car are the spark plugs, engine mounts, water jacket plugs and bumper trim.

That Just makes the project even more impressive! Considering the limited spare time and low budget the results are amazing, also 6 months is a hell of a quick time for an engine out AND respray job!

The work is top notch considering you have to work by handlight! (I hate working in the evenings and then coming back to my work in the daylight the next day and realising it looks rubbish! :roll: )

You really are to be congratulated, the car looks truly beautiful, especially on those wheels and the choice of colour really works as well.

My hat goes off to you sir!:cool:

Saab-Daniel
17th July 2007, 11:40 AM
That Just makes the project even more impressive! Considering the limited spare time and low budget the results are amazing, also 6 months is a hell of a quick time for an engine out AND respray job!

The work is top notch considering you have to work by handlight! (I hate working in the evenings and then coming back to my work in the daylight the next day and realising it looks rubbish! :roll: )

You really are to be congratulated, the car looks truly beautiful, especially on those wheels and the choice of colour really works as well.

My hat goes off to you sir!:cool:

Yeah man, what he said...
Daniel. :)

Albert Trout
17th July 2007, 11:44 AM
I don't believe you've restored it at all Shan. I reckon those last pictures were taken in 1990 ;)

Shan
20th July 2007, 10:55 AM
Thanks for your comments guys :)

Got a little more work done today. When the car was purchased, the complete toolkit was missing.

http://www.saabphotos.com/gallery/albums/album691/94_Toolbox_083.jpg

Dad found this lovely tool set including toolbox and all mounting straps at the nearby scrapyard and bought it for an equivalent of GBP3.

http://www.saabphotos.com/gallery/albums/album691/94_Toolbox_089.jpg

Shan
20th July 2007, 10:56 AM
The toolbox being mounted :

http://www.saabphotos.com/gallery/albums/album691/94_Toolbox_091.jpg

Toolbox installation complete with original Saab tools :)

http://www.saabphotos.com/gallery/albums/album691/94_Toolbox_099.jpg

RickyS
21st July 2007, 07:02 AM
I have just read this project and have to congratulate you on such a well done restoration.

Did you replace any of the door and window seals or did you reinstall existing ones? These tend to disintegrate and leak over time - at least they do in the UK.

You were going to post diagrams/plans of your engine stand - did you post them?

Shan
21st July 2007, 09:29 AM
I have just read this project and have to congratulate you on such a well done restoration.

Did you replace any of the door and window seals or did you reinstall existing ones? These tend to disintegrate and leak over time - at least they do in the UK.

You were going to post diagrams/plans of your engine stand - did you post them?
Thank you :D
The door and window seals were still in good condition and I decided not to replace them. I have a set spare from the donor and will fit them when mine starts to disintegrate.

I haven't posted dimensions of the engine stand yet, my only free angine stand is at the exhaust shop having another 4 made up. Will post dimensions once I have it back at home.

RickyS
21st July 2007, 10:50 AM
I found it difficult to remove the clips on the door seals without damaging the seal and/or the clips.

Have you a special removal tool? How did you manage to remove the door seal without damaging the clips or splitting the seal?

VikingSpirit
21st July 2007, 07:00 PM
Ricky, if you are talking about the little hammer-head clips that hold the rubber seal round the edge of the door, I popped them all off with an old fork (the kind you eat with)! Just get two of the prongs behind the head of each clip in turn, slide it all the way to the base and then pull the fork handle towards you to lever them off! (much like you'd use a claw hammer to remove a nail from a piece of wood)

This makes the clips pop out of the door itself rather than ripping the rubber off the clips (which ruins the seal and makes it loads harder to put back on)

Hope that helps!:cool:

RickyS
22nd July 2007, 01:00 AM
A kitchen fork. What a good idea. I'll try that next time.

I made up a tool with a 'V' shaped head - but it was not entirely successful.

Shan
22nd July 2007, 11:19 AM
I found it difficult to remove the clips on the door seals without damaging the seal and/or the clips.

Have you a special removal tool? How did you manage to remove the door seal without damaging the clips or splitting the seal?
My painter had a wide head flat screwdriver modified into a V shaped head. I could remove all the hammer head clips with it, although it was not easy.

The difficult part was refitting the top section of the rubber seals where there are no hammer head clips and held on in a groove instead. It took me 2 days just to refit all the door seals.

walawala
25th July 2007, 11:08 PM
shan...

can i send my car in to your house for a restoration too?

:cheesy: :cheesy: :cheesy: :cheesy: :cheesy:

des

Shan
30th July 2007, 10:52 AM
shan...

can i send my car in to your house for a restoration too?
Sure if you're willing to let this kid have some fun on your c900 :

http://www.saabphotos.com/gallery/albums/album601/100_Kid_0046.jpg

:cheesy:

Shan
1st September 2007, 11:12 AM
The following pic taken a few weeks ago when the project car reached a milestone point of 111111 kms :cool:

The Saab has since done 2000 trouble free kilometres since completing the project.

http://www.saabphotos.com/gallery/albums/album601/111111_kms.jpg

TooMany2cvs
1st September 2007, 11:14 AM
Sure if you're willing to let this kid have some fun on your c900 :

http://www.saabphotos.com/gallery/albums/album601/100_Kid_0046.jpg

:cheesy:

I think you might have gone a bit far with polishing that tyre up... You seem to have polished all the tread off it.

Shan
1st September 2007, 11:22 AM
I think you might have gone a bit far with polishing that tyre up... You seem to have polished all the tread off it.
Those were some old wheels and tyres fitted to move the car around during the course of the project :lol:

Here's a recent pic with the currently fitted wheels. Tyres are now Michelin at the front and Yokohama at the rear.

http://www.saabphotos.com/gallery/albums/album601/IMG_1727.jpg

http://www.saabphotos.com/gallery/albums/album601/IMG_1725.jpg

Breakin5speeds
1st September 2007, 11:31 AM
Sure if you're willing to let this kid have some fun on your c900 :

http://www.saabphotos.com/gallery/albums/album601/100_Kid_0046.jpg

:cheesy:

Sure! send him this way I have a garage full of Saab-Ness he can play with, I'll adopt the little Wrench...as long as he doesn't mind living off Cheap Hot Dogs and Expensive Beer :cheesy:

Cute Kid BTW

walawala
18th September 2007, 07:17 AM
The following pic taken a few weeks ago when the project car reached a milestone point of 111111 kms :cool:

The Saab has since done 2000 trouble free kilometres since completing the project.

http://www.saabphotos.com/gallery/albums/album601/111111_kms.jpg

hey shan..

i had some fun with your pic...you should have taken the pic at this speed! :lol:

http://i8.photobucket.com/albums/a16/dezmomo/etc/111111_kms.jpg

des

Shan
18th September 2007, 10:09 AM
hey shan..

i had some fun with your pic...you should have taken the pic at this speed! :lol:
I wish the rpms were really that low :lol:

rawill
31st December 2008, 07:25 PM
I have just read through this whole project. I have no suitable words to congratulate you with Shan. Lots of people have commented so positively on your project. All of their comments are thoroughly deserved. The work you have done on this car, along with the documentation is simply amazing. If you wanted I am sure that in the right place you could get a fulltime job restoring cars. I also must disagree with you, no proffessional could have done this job in two weeks, it would have been absolutely impossible. If cars can be a work of art this one is. I only had 2 questions as I read through, someone asked one, that was if you actually had a job because this looked like fulltime work to me. The other, and I am being niggly, After you found the first leaking plug, I didn't know why didn't replace all the plugs when you had the engine out.

Simply fantastic job, and yes those aircon radiators are not easy to get in out at all.