Re: Engine Swap - 92 to 88 - Progress Update - Saab 900 Bulletin Board - Saabnet.com
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Re: Engine Swap - 92 to 88 - Progress Update
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Posted by Calvin [Email] (more from Calvin) on Mon, 6 Mar 2023 05:56:09 Share Post by Email
In Reply to: Engine Swap - 92 to 88, Calvin Morrison, Mon, 27 Feb 2023 07:42:18
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Okay, so here's what I did this weekend.

- Towed the car to me mums house, and got my engine hoist built, all tools laid out and prepared.

- I pulled the engine from my 1990 convertible as the donor car, it didn't have any intake or exhaust, it's been pretty picked over. The only thing I had to do was disconnect the PS system and lift it out.

hint: Here's a hint, if you don't want to deal with disconnecting your power steering - just disconnect the pump from the engine! takes two seconds and that system then stays sealed and intact.

- With my picker, I had to remove the front bumper from the car to pull the engine, probably if I had a longer picker I would not have needed too.

- My A-ARM supports are kinda worn out, so I had to resort to the special tool plus some shims. I only removed the driver side axle on removal.

- The convertible roof makes a nice place to store the hood in the mean time.

- it was a t5 car so I removed the distributor hole seal, the crank sensor, and DIC

- Once the engine was out I gave it a look over. Looked good. I took of the valve cover and double checked the torque on all the cam caps and head bolts. They were correct.

- I sprayed some oil in each of the chambers, and across the cams to lube it up and I cranked the engine over by using a battery to the starter. This worked fine, and was able to get consistent readings from the engine (around 100-120 PSI cold).

And... then I stopped for the day and BBQ'd some Lamb - south african style!

- On the 88, sunday -

setup: I removed bumper and hood. I broke both axle nuts, inserted the a-arm tools and put the car on jack stands and removed both wheels.

I disconnected the main wiring harnesses, and moved them up and out of the way over the fender. I removed the air conditioning lines to make more room. I removed all vacuum lines, throttle cable ground lines and such. I removed the distributor, ignition coil and APC solenoid and lines.

then I drained the coolant and removed the radiator. about 2/3rds made it into the drain bucket.

I removed all the relevant bolts for the motor mounts. I noted 2/3 of the motor mounts were broken. whoopie!

Things moved along nicely from here. I removed the lower wiring harness as well - that is the ones that come in under the manifold - the alternator wire, oil pressure sender wire, knock wire, and got that out of the way.

I removed both oil cooler lines and moved them out of the way.

The only nut that broke - one of the exhaust side studs. I removed the exhaust stud and the elbow connnector on the turbo housing - that way Ididn't need to remove the o2 sensor. I dropped the exhaust off of the transmission bracket so the exhaust side was now free and clear.

I removed the 13mm on the shifter shaft and wiggled the shaft around and it came loose. I didn't use the taper pin because I am changing it over to the newer style bushing anyway.

I removed the fuel return lines and just to avoid damaging anything while lifting, the entire rail.

I removed the passenger side wheel, and loosened up the ball joints. I was then able to remove the axle quite easily.

After that - the engine pretty much pulled free. With it lifted slightly up, I removed the speedo cable covered up the inner drivers with some rubber gloves to keep dirt out

Oops forgot the clutch slave line! did that as well, with the car slightly in the air.


and then I lifted it out - sorry - I am probably forgetting a few minor details.

Once the engine was out I disconnected the turbo - the exhaust manifold and swapped those over.

I then removed the entire intake manifold - piping, hoses, etc and all at the same time, and kept it mostly in once assembled piece. This made installation a LOT simpler.

I installed the new feed lines and the installed the intake manifold. Things are really coming together.

Last piece will be to switch over the new alternator I put on my 88 not long ago, and then the engine should be ready to go back in.


So... all in all not bad. back is kind of sore from pushing around the cars in the garage though lol!


posted by 131.106.22...


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