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Discussion Starter #1
Hey everyone. This is my first 9-5 thread. I'm currently working on two other threads on this site.
One for my GTX30 Viggen.
https://www.saabcentral.com/threads/viggen-build.620497/

And another for my Turbo X restoration.
https://www.saabcentral.com/threads/turbo-x-resto.729819/

I have a friend who recently had a motor built for a big turbo project, and it has a low oil pressure issue. From what I'm told, it has maybe 30 miles and a little over an hour of runtime so far. I figured I'd document my findings, and my procedure for diagnosing and finally solution for repair here. The car was trailered almost 600 miles today, and arrived late in the afternoon.



 

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Discussion Starter #2
Made some progress this weekend.





Put the subframe back in so I could get the car in the corner. Good photo op :)





Tore the engine down and we clearly have some damage. Possible crank out of round. Could be machine shop error. You can see the mains wiped, and the pistons were able to make contact with the cylinder walls.

















I'm going to bring everything to the machine shop this week to have it looked at, for confirmation on the cause of the damage.
At this point i would argue the best thing to do is use another engine and start fresh with the bottom end.
 

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Damn the pistons hit the walls too...ouch.

Bleh.
 

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Discussion Starter #4
Very unfortunate considering the circumstances, but I'll get this car straight for the customer. :)
 

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Discussion Starter #7
The 2.5's are known for head gasket problems. I used to have a built 2.5. Cool? Yes, but not much point because you can make a 2.3 make 500whp with 30psi on the stock head with stock bore. :) But now that there are some better head gasket options available I plan on putting it back together. Would be fun, but hard to keep traction even with a diff and sticky tires as it is.
 

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Ya you can buy solid copper head gasket kit which solves the problem. Also, you get way better low end drivability if you are going big turbo. We have started a awd kit and hope to have it for sale some time next year. Can’t talk to much about it thou.
 

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Sick build. Lemme know if he wants to sell it when he's done! Always curious what it costs a shop to build a motor? Like $4-5k? More?
 

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Discussion Starter #10
We have found the issue with the original motor. The oil line from the #3 main to the balance shaft bearing in the rear wasn't plugged properly. Can shine a light right through.

 

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Oh boy...Frank can't be happy with the previous builder.
 

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I know who and he's built so many of these engines. Maybe the block off vibrated out of position.
 

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Discussion Starter #15
Sorry for lack of updates. Been busy with other projects lately. I sourced another engine that is perfect for the build. It's at the machine shop currently. Just waiting on a new set of mains, rods, and piston rings at the moment.
 

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Discussion Starter #16
Got the new bottom end back from the machine shop. Everything checked out perfect and we are able to use standard size bearings. Got the balance shaft delete done, and opted to try out the SAS dummy bearings instead of tapping and using set screws at the bottom of the mains. Rotating assembly looks great! Should be posting updates as I go and will probably be up and running shortly :)





 

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WOW that is some mess. I built a similar motor with forged pistons and balance shaft delete. Got about 60k miles on it and getting about 285HP out of it. AND it is in a RED 2000 Aero wagon!!

Local Los Angeles machine shop did the work Martin Davidson Machine. Martin has done lots of these and was very anal about putting in full bearing with no oil holes to block the oil passages. He also plugged the chain tensioner hole. I do love this motor.

I have a thread on here somewhere will post photos or the project soon.
 

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Discussion Starter #18
Went ahead and assembled the long block.

Pan cleaned





Mains and rods torqued and marked



Chain and guides installed



Inner balance shaft solid bearings installed





Timing cover installed





Pan installed, won't find any glue here ;-)







Cylinder head installed





Lifters cleaned and installed



Cams lubed and engine timed





Oil pump removed, cleaned and re-lubricated



Looking good!



 

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Discussion Starter #19
Got the car running this weekend.















About 18-20 psi with engine temp at 97C. I'd say we're good!
Break in will be done within the first hundred miles, and then we should be good to install the new turbo kit and make some power!
 
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