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Old 04-14-2008, 08:16 PM   #1
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My 99 Turbo Project

As many of you know, I have had a 99 Turbo which is in need of an engine rebuild after a blown headgasket and related damage.

Here's a picture:



The car has never run since I've owned it.

To make a long story short, an acquaintance in our local Saab club and I put together a plan to rehab the motor.

The essential elements of the rehab are:
1. bore the cylinders out two sizes (sadly necessary b/c of damage)
(obviously this entails machining the blocks and new pistons)
2. have the head done
3. fix or replace the cracked exhaust manifold
4. new water pump
5. new fuel injectors
6. new fuel injector lines (you would not believe how fragile the old ones were)
. . . and, the creative part of the project
7. putting a #8 primary gear in the four-speed transmission to make the gearing more tolerable at highway speed (based on an idea Moonracer did on a c900 convertible).

Of note is the fact that the new pistons are spec'd at a compression ratio of 8.5-to-1, instead of the stock 7.2-to-1. We had to go to Europe to get two oversize pistons with the higher compression ratio.

There are some other odds and ends, like a new radiator, involved. (Gee, do you think the car overheated before I got it?)

That's all the interesting stuff. The bad part is that this project has languished for nearly 18 months -- the car has been in my acquaintance's garage or driveway since December 2006. All the parts have been in hand, and all the stuff back from the machine shop, since last summer.

I have been giving a great deal of thought to possibly pulling the car and having someone else finish it. As slow as my acquaintance is, pulling the project and having someone else finish it would take even longer. (This is not speculation - I've called around and checked).

Well, in what must be the slowest project launch in the history of automotive repair, some meaningful work has finally begun.

Some pictures follow. (crosses fingers) The motor and transmission should be put back together and in the car this week.









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Old 04-14-2008, 08:23 PM   #2
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Nice! Its actually in the garage - wow.

Also, seems pretty good that he's painting the block for you!

Hopefully everything is done right
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Old 04-14-2008, 08:23 PM   #3
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Raul red! Good luck with the build.
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Old 04-14-2008, 08:24 PM   #4
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Is your acquaintance Raul? The tip off was the red block

edit: too slow to the punch thanks to spelling acquaintance 5x to get it right :P
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Old 04-14-2008, 08:25 PM   #5
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ohhh, chevrolet Orange! Good Choice. Good luck getting it all back together. I know all about LOOOONNNGGG projects like this. I have a 9-5 in my driveway that has never run since I got it, and is waiting for a new engine. I bought it a few months before my second child was born, she'll be 1 yr old in May!!!

It will be worth it in the end is what I tell myself!
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Old 04-14-2008, 08:25 PM   #6
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Raul Red? Thats got to be chevrolet orange, or a very bad camera!

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Old 04-14-2008, 08:27 PM   #7
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The camera is my iPhone. It's red in real life.
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Old 04-14-2008, 08:28 PM   #8
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Hopefully Mr. L knows how to put an engine together.
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Old 04-14-2008, 09:01 PM   #9
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One of these days it would be nice to see one of your classics done. Yeah just one!
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Old 04-14-2008, 09:14 PM   #10
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that's probably my favorite car/color/wheel combo in history. hope she gets running soon.
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Old 04-15-2008, 05:09 AM   #11
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Most excellent, Greg. I remember you telling me about the car and it's current state at SOC... Glad to see some progress is being made.
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Old 04-15-2008, 06:12 AM   #12
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Awesome car Greg. Should move pretty good with those higher compression pistons.
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Old 04-15-2008, 06:49 AM   #13
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Fantastic. I miss my 99
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Old 05-08-2008, 09:13 AM   #14
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I love the F&*^ outta the 99 turbo...sorry, just had to share
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Old 05-08-2008, 09:47 AM   #15
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Yeah, Greg, how's the progress on this one? Is it last Noember yet?
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Old 05-23-2008, 02:52 PM   #16
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Yo, any chance you could get me a shot of the flywheel end of the engine. Thanks.
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