Archive for the ‘ SAAB Insanity ’ Category

Finally, signs of spring

   Looking warmer out on the street. 

  No snow to be seen. 

Except for the north face… 

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Jenny Not Allowing the Winter to Get Us Down

Jenny and Mellis, neither of them down.

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Louvers for a c900

I got a good deal on some louvers for my ’84 900T winter warrior but there was one catch: they were missing the lower mounting hardware. How hard could it be to fabricate that?

I found this photo on one of the SAAB forums. Mine needed the lower ones.

I found this photo on one of the SAAB forums. Mine needed the lower ones.

Good use for a Guinness box and a 1950's ice cube tray.

Good use for a Guinness box and a 1950’s ice cube tray.

 

Well that kinda fits

Well that kinda fits

These allen bolts fit the receivers perfectly. Deep socket over the top- a few taps with a hammer.

These allen bolts fit the receivers perfectly. Deep socket over the top- a few taps with a hammer.

Unfortunately the aluminum split a little but it gave me a great idea- fill the recesses with epoxy. This also served to shield the glass from the bolt head.

Unfortunately the aluminum split a little but it gave me a great idea- fill the recesses with epoxy. This also served to shield the glass from the bolt head.

Mounted with a liberal amount of 3M weatherstrip adhesive. Looking very Nordic after a light snow.

Mounted with a liberal amount of 3M weatherstrip adhesive. Looking very Nordic after a light snow.

SAAB c900 Alternator Replacement

It’s bad enough that the engine is in backwards, but alternator access is especially tough because the master cylinder, AC, hose, and heater hoses are in the way. Zack from the Peoples Wheels had a hard time with his and it had been a while since I’d done one so I decided to take my time and document the process.

First step, AC belt tensioner.

First step, AC belt tensioner. Not too bad- just loosen the small nut and bolt

In my case I wanted to replace the pully/bearing unit so off it came

In my case I wanted to replace the pully/bearing unit so off it came

New one is short $ from eEuroparts.com

New one is short $ from eEuroparts.com

My 2-arm puller came in handy

My 2-arm puller came in handy

Make sure you have the rounded hub side in

Make sure you have the rounded hub side in (old one is flipped over, new one oriented correctly)

New one tapped right on using a socket and brass hammer

New one tapped right on using a socket and brass hammer

PS pump next- loosen the base 17mm bolt in the back

PS pump next- loosen the base 17mm bolt in the back- you can see it there to the right of the hard line

And loosen the adjuster bolt behind the pulley

And loosen the adjuster bolt behind the pulley

 

Alternator is next- I took a quick snap to document electrical lead placement, particularly the # of grounds

Alternator is next- I took quick snaps to document electrical lead placement, particularly the # of grounds. Note that the oil filter is off.

A better one of the leads

A better one of the leads. That green wire will get a new connector.

I removed the whole top bracket to make room and to refresh the bushings. eEuroparts makes a nifty kit.

I removed the whole top bracket to make room and to refresh the bushings. eEuroparts makes a nifty kit.

After lots of wriggling while having an assistant hold the AC hose out of the way, I have an empty space

After lots of wriggling while having an assistant hold the AC hose out of the way, I have an empty space.

Only to realize that I got the wrong alternator. There were two kinds in 1984, and mine has two big ears rather than one big and one small.

Only to realize that I got the wrong alternator. Apparently there were two kinds in 1984, and mine has two big ears rather than one big and one small. Bosch AL35X is incorrect.

Another angle.

Another angle.

Well that was a bummer- off it went back to eEuroparts. I poked around and learned that Bosch PN AL69X works if you turn the clock position 180 degrees so I ordered one of those- it was even on clearance for $83, such a deal!

At least I have the right belts

At least I have the right belts

Here's where it's going- note how the top of the bracket slips under the AC bracket

Here’s where it’s going (before necessary cleaning)- note how the top of the bracket slips under the AC bracket

Nice and clean, ready for new bushings

Nice and clean, ready for new bushings

Here's the angle for installation

Here’s the angle for installation

Fitting the correct alternator...

Fitting the correct alternator…just enough room!

I found this setup to be key for the left and bottom 6mm hex alternator bracket bolts

I found this setup to be key for the left and bottom 6mm hex alternator bracket bolts

Install and adjust belts and done. I found the new alternator belts to be a bit of a pain to put back on but not terrible.

 

Lonely 900

In the ODV Garage

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SAAB Fuel Pump Refresher

It’s a long story, probably one best told over beer, but to make it short: never let anyone borrow your car.

This is generally a rule of mine since the GT got injured, but this isn’t my fault because Ryan technically stole it. Anyway while it was in his possession the drivers window motor burnt out, the alternator went flaky, and the fuel pump ceased to function.

One AAA tow later it was back at the ranch being diagnosed.

One AAA tow later it was back at the ranch being diagnosed.

At least the pump is easy to get to. Big hatch=pump. small hatch=gauge sender.

At least the pump is easy to get to. Big hatch=pump. small hatch=gauge sender. Note trunk rust work in progress.

Lid and clamp screw access plug off.

Lid and clamp screw access plug off.

The doctor is in.

The doctor is in.

With a fresh battery the car started right up but the fuel pump was really noisy. At first the charging seemed fine but then the battery light started to come on. The next day after everything cooled off and more gas in the talk the noise was considerably less but it still didn’t sound healthy and it was really hot. A fluctuating whirr with occasional clicks, here amplified with my mechanics’ stethoscope. Time to order parts.

That's not it!

That’s not it!

I ordered an alternator, alternator bushing kit, main pump, pre-pump, and strainer from Eeuroparts. The universal high-pressure pump they sent, a Walbro GSL392, came with no documentation. I poked around and determined that it would have to be patched in outside the tank. Some material I read indicated that while it was a great high-performance pump for many applications, it wouldn’t be up for the high base pressure of a K-Jet. Eeuroparts is great for returns so back it went along with the strainer (which was for the stock main pump). More reading reminded me of how crucial the pre-pump is in this setup so I decided to install just that and see how it went.

Main pump and pre-pump live happily together under a toadstool.

Main pump and pre-pump live happily together under a toadstool.

It’s actually a clever setup- the pre-pump (the shiny silver cylinder) feeds a steady stream of fuel into the black plastic reservoir containing the main pump. Two small screws and the pre-pump comes off.

Uh-oh. Dropped a screw into a full tank of gas. Magnet-on-a-stick to the rescue.

Uh-oh. Dropped a screw into a full tank of gas. Magnet-on-a-stick to the rescue.

Rain, rain, go away.

Rain, rain, go away.

It went back together quickly and the fluctuation and clicking are gone. Just a nice, steady whirr and cool. A very successful day at the ODV garage. I even got my new sunroof in:

Sweden! Or, "how to be That Guy without driving around with your shirt off."

Sweden! Or, “how to be That Guy without driving around with your shirt off.”

I wouldn’t normally go for something like this but the original sunroof cover was damaged. My friend Mike got me one from Conn-tech, a local SAAB specialist, as a gift. Thanks Mike! It was rose quartz metallic so…

Two spray bombs and five coats of clear. Tasteless.

Two spray bombs and five coats of clear. Tasteless.

Barely noticeable

Barely noticeable

 

 

 

 

 

 

 

 

 

 

 

 

SAAB C900 ebrake cable boots

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Looking for two of these.