12.05.2006: Powertrain - photo.platonoff.com

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12.05.2006: Powertrain

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Powertrain rebuild on the 1995 Saab 900 turbo convertible.

A few notes regarding the 2.3 engine swap. It has to be of the same generation, e.g. for NG900 you need a 2.3 turbo engine from a 1994-1998 9000 (B234E, B234L or B234R).

The head and the block are exactly the same. The timing and balancing gear is also the same. The end plate is identical. The only internal difference is the crankshaft with pistons (longer stroke), so you can either find a good 9000 engine and drop it straight in or rebuild your 2.0 with a crankshaft/rod/piston combo from a 2.3 turbo. The 2.3 N/A has the same crankshaft, but weaker pistons.

Further differences: the 9000 uses a different oil pan, timing cover, pumps, manifolds, mounts and other accessories. You will have to reuse all those parts from your original engine. The block will have the provisions for all configurations, but because the accessories are mounted differently, some bolt holes might be exposed to rust and need their threads refreshed.

The 9000 ECU is reported not to work correctly in NG900. A stock NG900 ECU will start and run with a 2.3, but it's certainly better if you can source a custom tune.

	12.05.2006 Headlights and grille The headlights and the grille go first. The broom is retired as a hood prop rod, and replaced with an old 9-5 sway bar.		12.05.2006 Bumper and airbox The lower protective shields and the bumper come off to allow the access to the intercooler. The airbox is now in the open, so that gets removed too.
	12.05.2006 Intercooler and pipes Next, the old intercooler and pipes. Since all of this will go to another car (which then gets sold), I've removed the turbo silencer while it's exposed. The new owner should thank me for it ;].		13.05.2006 Exhaust system The stock exhaust system: downpipe with catalitic converter, flex pipe, middle section with resonator, and rear muffler.
	15.05.2006 Engine support Engine support installed. Time to disconnect the rear engine mount, detach the shifter linkage, unbolt and lower the front subframe.		15.05.2006 Transmission The transmission is drained of oil and removed from the car. [more...]
	20.05.2006 Engine out The engine being removed out of the car. [more...]		20.05.2006 On the stand Engine out, secured on a stand.
	21.05.2006 Throttle body inlet pipe A ported throttle body inlet pipe: before and after.		22.05.2006 B234R A replacement 2.3L turbo engine from a 1996 Saab 9000 Aero.
	25.05.2006 Engine stripped The old engine is stripped of all accessories, oil pan cracked open.		28.05.2006 Timing cover off The 2.0 with timing cover and end plate removed. On its way into storage.
	28.05.2006 Out of the trunk The 2.3 is out of the trunk, the accessories will come off shortly.		28.05.2006 Ready for disassembly The replacement engine is stripped and mounted on a stand. Ready for final disassembly.
	01.06.2006 Camshafts Valve cover off, no sludge, everything looks nice and clean.		01.06.2006 Crankshaft Crankshaft and piston removal. The paper towel pieces are wrapped around the bolts on the piston rod to prevent them from scratching the crankshaft.
	02.06.2006 Out to rebuilder The engine on the way to the rebuilder to have everything cleaned and polished.		07.06.2006 Engine parts rebuilt Back from the rebuilder. Parts cleaned, cylinders honed, head polished.
	08.06.2006 Manifold cleaning Abrasive Dremel buffing wheels make it easy to clean manifold flanges. Unfortunately, they wear out too fast.		08.06.2006 Firewall cut Another use for your favourite rotary tool: cutting a hole in the firewall for the hydraulic clutch.
	16.06.2006 Parts A big parts order from eEuroparts just landed at my door in two large boxes.		18.06.2006 Cylinder head The head is assembled with new seals and refreshed valves. [more...]
	21.06.2006 Engine block Crankshaft and pistons are in with new rings and bearings. [more...]		04.07.2006 Engine This starts to look like an engine again now. [more...]
	09.07.2006 Engine assembled The engine is assembled and ready to go in. [more...]		10.07.2006 Installation Engine installation in progress. [more...]
	10.07.2006 Transmission A low mileage gearbox from a 1999 Saab 9-3 -- stronger, smoother, easier to shift.		10.07.2006 SPEC clutch A kevlar stage2 clutch from SPEC and a Viggen pressure plate to hold the power.
	15.07.2006 Engine in Installed and running.		18.07.2006 Delivery pipe One of MP Performance leftover delivery pipes. The fit was problematic, but all worked out in the end.

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