2003 Linear Sedan Project
I've dropped a few hints about this project here and there, so I figure it's about time to get a thread going about it. If nothing else, it may provide some sideshow entertainment. Hopefully we end up with a running, driving car at the end :cheesy: . I also have a thread up on GRM if anyone goes to that site. This one will be different in that there will be more Saab specific content to go along with the comedy of errors. My goal is to get a running, driving, bulletproof car for less than $2016, in keeping with the GRM $2016 Challenge rules. We'll see...
I saw this on the local CL, located about 10 minutes from me. The original engine sludged out and spun a rod bearing. The PO had bought a second engine to swap in, but that one turned out to have a balance chain guide failure and was making metal to metal contact. He had a bunch of other projects going, so he decided to dump this one on the first unsuspecting Saab guy to come along.
So, cliff notes version: 03 9-5, ~135k, two dead engines from different causes, neither of which is currently in the car. What could possibly go wrong?
http://saabworld.net/images/imported/2015/12/18.jpg
The PO was kind enough to drag the car over to my house on his tow dolly, while we loaded up long blocks and miscellaneous parts in the family truckster and trailer. Saved us a couple hours, and we got everything packed away before the snow/rain mix arrived.
Here's what two engines worth of internals and ancillaries looks like in the back of an Odyssey:
http://saabworld.net/images/imported/2015/12/19.jpg
Long blocks, human engine hoist, and car in background:
http://saabworld.net/images/imported/2015/12/20.jpg
And everything offloaded into the garage. Sadly, my C900 project, was bumped down the list, and has moved outside for the winter :( . Sad, but no budget for a big enough garage to keep everything inside.
http://saabworld.net/images/imported/2015/12/21.jpg
I borrowed a hoist from a buddy, and got engine #1 up on the stand. I got the 1000lb HF stand using the 20% off coupon.
A week or so later, after finishing the Aero Wagon project, my son had a few other linemen come over to push dead cars around. Then they started a dead lift tournament of blocks, complete long blocks, the hoist, etc. When that got boring, they went inside and ate all the food in the house in roughly 27 seconds :o .
Current parking situation:
http://saabworld.net/images/imported/2015/12/22.jpg
The third bay is the work area. I'll need to spin the car sideways when we go to drop the new engine in place.
So with the car in place, here's the rough project plan:
- Create a workable engine from these two. They both failed in different ways, so there should be enough parts to create one good one. The car came with a new balance chain set, undersized rod and main bearings, new water pump, almost new (Garrett :( ) turbo with no end play, and one of the cranks had been turned down already.
- Do some underhood maintenance things that are nightmarish with the engine in place, or just easier without it in the way.
- Subframe bushings
- Coolant bypass - it's just sitting there out in the open right now!
- Alternator, hopefully just the VR
- Serpentine pulleys - I think we can have them all in place when the engine goes back in, and save a few hours of aggravation
- Rad hoses
- CV boots
- Cosmetic detailing. The body is rust-free, but had been sitting outside under pine trees for awhile. Also, looks like someone used a scotchbrite pad to clean it at some point, so I have an excuse to get a buffer. Interior is in very good shape overall, just dirty.
Let the adventure begin!