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Saab Model 99 Bulletin Board
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Re: advice needed on the 16v conversion
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Posted by dan [Email] (#2459) [Profile/Gallery] (more from dan) on Sun, 15 Jan 2006 22:24:06 Share Post by Email
In Reply to: advice needed on the 16v conversion, david, Sun, 15 Jan 2006 17:35:14
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Can't be a stock '91 engine if it is 2.1 and turbo charged.. but no matter. The APC system is an isolated system so you'd be working that on it's own anyway.

You can cut out the metal completely and then redesign it to fit back in for the 16V engine, use a hydraulic press, or a sledge. A combo is my preferred method. The water pump "dimple" is the most visable and with nothing behind the spot, interior side, it is ideal for cut-out. You can take any of the pictures of an '81 99 firewall and figure the right spot. Then cut it out. Make, or have someone make a sheet metal insert that will fill the whole creating a 1 inch (or so) inset. The area for the crank pulley is not seen. That might be where I'd go with the hydraulic press and block of wood. Try not to mess up the area around where the shifter passes through the firewall but be sure to give enough room to change a belt and to allow a bit of engine movement. I'm still curious as to how other's modify the vacuum booster but I have always tapped an indention in the bottom left corner to accomodate the alternator pulley.

Two of the three cars I've done this on had previously been fitted with A/C. Two holes had been cut in the "shelf" by the heater fan motor. I cut out the dividing metal and made one oval. This is where I ran all my wiring for APC and the LH system. On the other car, I used a die to cut an oval in the firewall itself to try and clean the wiring up just a bit more. That oval was made about 6 inches down from the "shelf". (Rowan, often rearing his head on this board, has that car.)

With gas prices as they are, I would possibly reconsider using a 2.1 L engine unless you have lower compression pistons. I have the high compression and HAVE to run the high-end fuel. But if the engine is turbo charged, maybe lower comp. pistons have already been installed.

Good luck. Check other posts on this BB as this has been discussed often. There are also a few sites out there that detail the process.

dan

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