Re: Engine Swap - Progress Update 2 - Saab 900 Bulletin Board - Saabnet.com
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Re: Engine Swap - Progress Update 2
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Posted by Calvin [Email] (more from Calvin) on Mon, 27 Mar 2023 07:06:34 Share Post by Email
In Reply to: Re: Engine Swap - 92 to 88, Calvin Morrison, Tue, 21 Mar 2023 10:27:24
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Saturdays are really my day to just do car stuff and zone out. The only down side is it's only once a week.

So - this week, stopped at the bakery in doylestown (Crossroads Bakery) and got my title sorted out for my 1968. After like 4 years of not having it titled, it's now totes legal.

Then went to work on the car.

Shifter alignemnt proved to be impossible. Couldn't get it in 5th or reverse. Not a new issue for the car, it was always kinda crappy, but now i couldnt get it in at all.

Even with following the instructions, even pinning 3rd and the transmission in 3rd. The issue? the shift shaft bushing was worn out significantly, as well as internally it had big wear marks. Tried with the new shift shaft, and it was kinda better, but not totally. I put another shifter housing, shifter assembly (new style seems more robust anyway, all metal versus the nylon). and it aligned immediately! wohoo!

drove the car around and have a few issues to sort:

1. alt/wp belt was kinda whining, the belt was a bit to tight. Loosened it up a tad and it seems fine.

2. I have a small coolant drip. still can't find it but I put a cardboard box under neath while it sits for a week and hopefully that'll help me pinpoint it.

3. my timing is off, and my trusty timing gun finally bit the dust! very sad, I was attached to it, but I'll go get a new one at HF, they're like 20 bucks.

4. forgot to hookup the BPV vacuum line, which is a PITA to get to. Hoses off and got some room and got that fixed. Now idle is muuch better.

5. PS hose is a bit leaky. The return line with the hard crimp is leaking at the crimp. I think I'm just going to take off the crimp and put some hose clamps over the barbs. That worked well for my oil cooler (4 yrs and going strong.

6. The new shifter housing was pulled previously because the key/ignition was all messed up. I have a new key, but this car is push start anyway. When I put all the wires in for the ignition, the key was in the off position but it still had power to everything, whatever, gonna do a flip switch and mount it next to my starter button.

6a. My starter button is a ground wire that runs to a relay that sits near the starter It provides power to the solenoid when grounded instead of going all the way into the ignition area for starter power. I think there was a tsb for adding a starter relay, I did this with a push button.

7. Exhaust woes - my exhaust was lined up before, but 'before' was a broken motor mount bracket, a bad motor mount on the other side, and a bent up transmission exhaust hanger. Muffler was sitting too far back so with it all lined up it was very off kilter. Wasn't able to get the intermediate pipe and muffler separated, did the dirty deed and just cut a few inches from both sides with a sawzall and put about 4 inches of flex over pipe in between. This let me adjust it in/out to get the muffler lined up right. Really wish the exhaust sytems had a flex pipe or other thing on them tbh, the run is long enough that a motor mount being off or a hanger off there causes the whole thing to crap out. Look I don't love flex pipe, it's kinda ghetto, but you gotta do what you gotta do - now it doesn't leak and it doesn't bang around.

---

So after all of that, car starts and runs. Spun it around the block and besides the terrible alignment, the car is working.

Right now the following issues are:

1. timing is off. Engines humming great, it just has little power.

2. I unhooked my apc knock light by accident when changing the steering column. With that hooked back up i should see what the APC is thinking. Not sure why it's at base boost otherwise but will run checks next week.

3. Otherwise - all is good, gotta put in a flip switch to replace the key (or just put a new key and barrel in,I have one somewhere).

4. my alternator didn't seem very excited. I looked and the exciter wire blade was kinda lose. Hoping that will solve with a bit of tightening.

Anyway cheerio.

posted by 131.106.22...


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