1986 Saab 900 Turbo - White

1986 Saab 900 Turbo - White

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Spinakerr

Original Poster:

1,193 posts

146 months

Saturday 29th January 2022
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A few minutes tinkering today in the dry - luckily rear bulbs were just one blown sidelight bulb and one dodgy contact, freshly sanded.





These lamp covers are never any good... blast...



Following the lead of a fellow PHer, dropped down to a bodyshop today for quotes... this may be an expensive spring for the 900. A good run showed the 900 firing nicely but the brakes need adjustment (again). These front calipers wiht the annoying handbrake attachments (dropped after a few years by Saab) will be the end of me!


Spinakerr

Original Poster:

1,193 posts

146 months

Sunday 30th January 2022
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toastyhamster said:
Just found this great thread!

My Dad had a 900i on a C plate as a company car, as an impressionable young teenager I was blown away with it compared to his previous Cavalier. I was extremely disappointed to test drive a 9000 around 15 years ago and I've always fancied a 900. I always preferred the slightly earlier rear lights on it to yours, but even back then the majority were the later version.

https://en.wikipedia.org/wiki/Saab_900#/media/File...

It was a very nice pale green metallic, either my memory is ropey or it was a rare colour as I can't find an image. Beige interior, heated seats, dashboard like an airplane cockpit layout, economy gauge (wow!), used to love earning my 50p for washing it.

Looking forward to the bodywork.
Ah that would be Acacia Green or Moselle Green metallic - amazing colours that looks fantastic on earlier 99s and 900 GLS with flat front and geometric grill.

You haven't found the right 9000 - if you can find a 9000 2.3 turbo manual or Carlsson early flat front they are incredible to drive!

bolidemichael said:
I've just clocked that the VRN reads 'DIZZERV' -- intentional?
Tis the original plate from registration, but yes I am occasionally referring to it as 'Dizzy'!



Spinakerr

Original Poster:

1,193 posts

146 months

Sunday 13th March 2022
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The Saab had not been out for few weeks, and as the sunlight parted the clouds yesterday we decided to take it on a few afternoon errands.



Scope creep is a common theme in any car related activity, and ten minutes after setting off for some supplies I remembered the two front tyres were looking a little low, so we took advantage of a docile M3 and pulled into Micheldever tyre centre.



Two Goodyear EfficientGrip 195/60/R15s ordered. The fronts had only done 4 years and 20k, but perhaps some of the enthusiastic turbo deployment and braking issues over the years had led to avobe-average wear.



My previous track rod end work and general 'decrusting and lubrication' led to a very easy laser alignment, a far cry form the swearwords deployed four years ago at Micheldever, and once balanced we were on our way.



A recurring theme on this car is the accursed front brake setup, and this instance of 'wheels off' highlighted another deficiency on the nearside that will need further bludgeoning. I may have to find replcement front handbrake calipers, have them refurbed and work out the setup issues myself, as this is just becoming too frequent to rely on others for.



Offside fine.



To cap it off, the temperature sensor decided to stop but it appears to be just a crusty connector rather than the sensor itself.






A few more items for the to do list!

No responses from anyone I bothered to take the car down to for bodywork quotes. It seems a hardworking Saab is not a favoured vehicle amongst the welding community at present.






Spinakerr

Original Poster:

1,193 posts

146 months

Tuesday 15th March 2022
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Thanks for all the comments - yes they need regular fettling and lubrication. Seems to be a realtively troublesome design and hence the move to traditional rear handbrake in later years.

Nelson at NDS fiddlea with these every time it gors in, but I think finding sime replacements, fully refurbing them and then reading all the Saabnerd forum guides on getting factory setup would be a good exercise.

All bodyshop recommendations welvome...I kkow 2stroke2turbo would do a great job but its a fair distance and they are premium pricing....

Spinakerr

Original Poster:

1,193 posts

146 months

Tuesday 15th March 2022
quotequote all
Thanks for all the comments - yes they need regular fettling and lubrication. Seems to be a realtively troublesome design and hence the move to traditional rear handbrake in later years.

Nelson at NDS fiddlea with these every time it gors in, but I think finding sime replacements, fully refurbing them and then reading all the Saabnerd forum guides on getting factory setup would be a good exercise.

All bodyshop recommendations welvome...I kkow 2stroke2turbo would do a great job but its a fair distance and they are premium pricing....

Spinakerr

Original Poster:

1,193 posts

146 months

Tuesday 15th March 2022
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We're in SW London, but willing to travel for someone with Saab experience and able to keep it realistically priced. We have other cars so no rush on timing, just want it to be underway as its just at a crucial rot turning point, and want ut undersealed and solid before the end of the year.

Spinakerr

Original Poster:

1,193 posts

146 months

Tuesday 15th March 2022
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Thanks, much appreciated.

I knew of Mark in Kingston but he wasn't interested in tackling the repair work, only painting sadly.

I will give them a call - thanks!

Edited by Spinakerr on Tuesday 15th March 12:49

Spinakerr

Original Poster:

1,193 posts

146 months

Monday 18th April 2022
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Hope everyone is enjoying an Easter drive or tinker - the Saab ticks over 202k and I had a few hours spare so decided to fit some new alternator bushes.



A common issue with the 900 is an excitable little jumping alternator, gleefully kicking like a spring lamb in the engine bay. I had ignored it long enough!






The alternator sits against the firewall, as the 900 engine is 180 degrees from where you would expect it to be mounted, so I had been warned that the relatively routine jobs attending to ancilliaries and belts can be a little fiddly.

This was not a bad job, but over 3 hours, including tea breaks and a few pauses to clean up areas that had been neglected in years past. The most strenous part is taking the alternator out of the car once fully loosened - you can start wiht moving the expansion tank, but I decided not to. I probably would in future.

Our little voltage generator was bouncing a fair amount at idle, and this is often due to cracked or solidified rubber bushes on the main mounting 'hinge' and also on a support arm for the tensioner. Skandix sell a cheap kit, and I also ordered a voltage regulator as I thought while the item is off the engine, best to replace what I can.

As there is not enough room to remove the giant hinge bolt setup and bushes with it on the car, the Saab collective knowledge ether suggests removing the entire hinge, which is three M8 bolts with hex heads, plus the tensioner arm.

Tensioner off first - one 17mm bolt at the top and a 13mm on the engine attachment, with its own two bushes to be replaced. The two belts can then be nudged gently off the pulley.

On the back of the unit the starter exciter wire, ground leads and a plug all needed to be carefully detached... tiny nuts and washers must not be dropped into the engine bowels...



The M8 bolts were doused in PlusGas and I assembled a daisy chain of TengTool 1/4 drive attachments & allen keys to best attack the bolts.



This was the hardest bit of the job, as there were exceptionally tight and access miserable.



After the top two were out, I tied the alternator up on the hinge to access the lower one... and success, it was off.



Lifting the alternator out required careful manipulation of the coolant hoses (scuse me), the brake booster hose (removed at one end), vacuum lines (I'll just push you over here), and the throttle cable (please, please don't bend...). Everything has to be rotated '90 degrees or somersaulted out gracefully.



Off. And out. Once on the floor, 17mm sockets took care of the hinge bolt, and the old bushes removed. Terminal bushes on the support arm too, rock solid and crumbly.



I changed the regulator over - some life left in the old one so added it to my parts draw, but happy this was swapped out give the age related degradation.



The new bushes went into the arm with some silicone spray and poetry, the alternator ones though.... goodness. Very tight fight, and as they have metal inserts some slipperiness, power ballads and actual hammering were required. Very tight but once in, its not going anywhere!





Quite a fiddle to get it all back in, many hands requried to get the bolts in without crossthreding and support arm/belts on in the correct order. Fortunately no casualties, and now it is steady as a rock. Success!



Here's the Saab in a rainbow for getting this far:






Spinakerr

Original Poster:

1,193 posts

146 months

Wednesday 1st June 2022
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Cambs_Stuart said:
Always good to see an update. What's spares support like for the Saab vs the Alfa? Just wondering as there are quite a few parts for my clio the Renault no longer support.
Thanks - more specialists in the UK, plus healthy club support. The problem is Saab changed bits every year. Between engines, trim levels, body styles and other nonsensical changes to wiring layouts and sensors it can make hunting down correct T16 bits a chore. But way better than the Alfa 164! I seem to have the last bits of the 164.

I'm sure the Clio is relatively well served by the enthusiasts - once you find that bloke that stored a few away its all a bit easier to sort out.

The 900 continues to be our secondary car as the Alfa is awaiting calipers. In sympathy for its stablemate, the Saab has deciding to renew its brake squeaking. These front handbrake calipers are a real pain - I need to source another par and refurbish them & set them up correctly. Tweaking these old ones is not working!

Recent jaunt to help a friend have his exhaust fitted on the only Toyta Crown wagon in the country:




The turbo/apc gauge just stopped working - suspected loose hose; the temperature sensor finally gave up - new one ordered and the front right speaker is dead. So that's a little list for the summer. We also visited a friend who is aiming to take on the sill repair and sunroof/roof repair in July/August. Phew.

Spinakerr

Original Poster:

1,193 posts

146 months

Sunday 12th June 2022
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Always tempted but never the time or space. I need a sabbatical to tackle things like that!

A couple of satisfying Saab fixes this weekend - the dash speaker, temperature sensor and boost gauge.

Both required removal of the dash speakers, so out they came. A previous owner had nicely upgraded the original paper cones Saab items with some Sony units. However loose wiring and poor fitting resulted in a terrible sound.



Yes, they really were just 'lounging about under the cover, as the plastic fitting threads appear to have broken off with age.




In my spares pile there lurked and original pair of speakers and their covers, so I repurposed the original spare 'gaskets' and the four metal clips for each corner. Result! Correctly located speakers using the OEM fittings. A clean of the wires and everything was working nicely.







The boost gauge I suspected a vacuum line cracking or popping off - it transpired both had occured, not at the cluster but at some shorter lengths in the spaghetti of vacuum hoses under the passenger dash.

Bottom black hose here:



Some of these I had mistakenly left as they 'looked ok'. Mistake. All were cracked or split, and I spent a good hour upside down with my feet out the sunroof, cutting silicone hoses to fit.



These excellent photos I took with my nose, so feel free to cackle.

The long hose from the overboost switch to the gauge I fed through after joining old to new...



Success.



And just like that, normal operation resumed. I also untagled and repositioned a few lines with kinks in them - the car seems to be much happier - even at idle! Very strange, but I'll take it as placating the Swedish Trollhatten deities.



The temperature sensor was also not workign so I replaced the engine block sensor.





It moves the needle, but doesn't work correctly. I'm now doubtful whether I bought the right sensor, but as the fan correctly kicks in when hot (see previous pages for all that work), I'll leave it for the time being.

202k and going strong.

Rust removal dates going in!





Spinakerr

Original Poster:

1,193 posts

146 months

Sunday 12th June 2022
quotequote all
harrykul said:
Loving your work, thanks for documenting!

Here's a gratuitous of BOJ, our 92 Carlsson. About to hit 230k, but the PO had it rebuilt about 15k ago.

Wow and wow again - that is our goal! If we can get it to 230k and being the yin to that yang colour wise I will be happy.

Thansk for the note and happy turboing.

darkyoung1000 said:
Good to see an update, I really don't envy you tracking down more leaks and perished pipes in seemingly miles of hose!
Great that it now idles and goes better though!

On the MIG welding, basic patches for structural stuff like sills aren't too bad to pick up. Neat, tidy and complicated stuff however is another level....

Good luck with the rust treatment!
Thanks, yes I really want to - its just time, cost and all the normal 'excuses'. I just need a week or two to have it as a specific goal... more ot follow.

Safe journey back from LeMans!


Spinakerr

Original Poster:

1,193 posts

146 months

Friday 15th July 2022
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Cambs_Stuart said:
I'm still up for a group booking at somewhere that welds patches!
Always good to see an update and a reminder of what it takes to keep a modern classic usable every day.
I wonder if in 30 years time there will be a thread of someone doing the same to a fiesta ST (or pick any other current hot hatch)?
I hope so....
If I ever get a ridiculous amount of cash I'm committed to setting up a car repair shop and getting some apprentice schemes going - though in the meantime perhaps a few days with a master fabricator? We need to ensure those STs are preserved in the future!

The working music system is providing a significant increase to driving enjoyment. The car definitely needs improved insulation and a headlining, but we'll get there once some of this pesky rust is sorted out.



Recent run to the New Forest...



One item that had bothered me was the tatty turbo heatshield for the distributor. After prodding various sources Abbott racing provided a solid stainless replacement for £19. Two 13mm turns later, it was on and improves the underbonnet look a nice amount.












Spinakerr

Original Poster:

1,193 posts

146 months

Saturday 23rd July 2022
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Smitters said:
I have complaints.

I got up at 5am to do some important work. It's now 6.53 and all I have to show for my trouble is a finger sander on order and a pile of work I'm yet to start.

Dammit. Love a Saab.
Ha! Sorry to impact productivity - though I am convinced that a finger sander is as necessary as a 10mm ratchet spanner and am happy to hear of another conversion to this church.

Spinakerr

Original Poster:

1,193 posts

146 months

Sunday 7th August 2022
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bolidemichael said:
Saw this and thought of you -- not sure if you've kitted yourself out as of yet.



Starts from 7th August at Aldi
Thanks - I will go and take a look, but sent it on to my freind who welds for a living and he advised...er... second hand instead... awaiting his pick to further examination.

The Saab, happily, ticked off another MOT after only a mild bulb change and general checkover.



This is the first time I think its not requried any actual work prior to the test or had a handful of advisories. Must have been a busy day.

...and yes, long term readers, the horn worked...!



Edited by Spinakerr on Sunday 7th August 21:44

Spinakerr

Original Poster:

1,193 posts

146 months

Friday 23rd December 2022
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Good luck with it - they are fun cars to work on - quirky, a little counterintuitive at times but lots of great help and experience in the community.

Saab pressed into regular daily use. Saab did Saab things in the frostwave. Saab never stopped or appeared to care about snow.


Spinakerr

Original Poster:

1,193 posts

146 months

Saturday 31st December 2022
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Last little trip for the Saab this year was to TR Autos in Yeovil.



We have been looking for a specialist to take care of the underbody crustiness, check timing, the coolant system and generally give it a good once over for a priority list.

I couldn't recommend TR Autos enough - this was really a trip to see what would be recommended, and Tommy took an hour to produce a highly comprehensive report. The overiding response of 'it's actually all ok, just some items to keep on top of' was what my wife was hoping for.

First up, the timing and general high idle/ignition worries were within spec, and apparantly about normal for this age and mileage. Just something to keep an eye on. Turbo system and all the parts of the system are in good order and performance is 'good'. Phew.

Second, the coolant system is operating correctly, the gauge in the cabin on T16s are prone to bad readings, so our 'low' needle is normal and can be rectified maybe if the dash comes out for some other work. The keen eye of Tommy picked up a bulge in the top radiator hose, one to be replaced, and also the two heater hoses that go into the bulkhead were the wrong way round. Not a concern but I'm amazed he spotted that.





Rust - we are now booked in for May to tackle the front sills, wheel arch patches and a hole in the front valance. All known about but picked up by TR as the priority and needed for the MOT. May gives us time to save up and sort out some other service items.

Overall, a great experience with a some great tips, and no pressure. It seems we have found our new expert for when my tools and experience fail the Saab...

Right, I'm off to order a hose, some bulbs and perhaps two new tyres for the rear.




Spinakerr

Original Poster:

1,193 posts

146 months

Saturday 28th January 2023
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Cambs_Stuart said:
Are TR doing the welding or have you found someone closer to home?
Always good when the professionals don't find too much wrong...
Yep they're doing it, and then depending on what else is uncovered it will be going off for a lick of paint on the current main eyesore panels.

mercedeslimos said:
It's always nice to have another professional cast their eye over a car before the test. I did a load of work to the underneath of her daily driver last week and took it over to my mate's garage for tyres, alignment (which I'd set up by eye, counting threads) and headlight adjustment.
Once I find a garage I can trust, absolutely. I am lucky to have Phil from Alfacraft nearby for the 164, but sadly Tony in Taunton retired for the Saab, and NDS are too busy to ever really check it through thoroughly. Tommy and the team at TR got the nod from my wife, so as its her car it'll be with them for the major jobs I can't do.

nismo48 said:
biglaugh
They're speedholes, don't worry.

A quick oil change at nearly 207k, 10w40 Millers in, new filter from Saabits. I almost rounded off the sump plug so need to order another for next time. it seems to be worn to a roughly 12.5mm, so next time could be a lovely round of sweary bachache to get right.



Changeing oil on the Saab is typically counterintuitive in task difficult - the drain plug and oil can be accessed without jacking up or even kneeling down:



The oil filter, while a spin on variety and small, is nestled in a very awkward position thanks to a the ongoing evolution of turbos, cooling systems, vacuum hoses and the like fromt he original design. I use my slimmest oil filter grabber and get about 15mm of cercumferal movement at a time, then towel everything off to get purchase with a rubber glove.





3.8 litres back in and the 900 is set for the first half of 2023.




Spinakerr

Original Poster:

1,193 posts

146 months

Sunday 5th February 2023
quotequote all
The 900 continues to turbo its way around the country, and I am working my way through the list of advisories from TR Autos as parts and time turn up.

Rear brake pads were 'close to minimum', which is annoying as NDS had only replaced.... 4 years ago. Oh well, maybe I should take a look.



Fortunately Nelson's previous ministrations meant things were not seized.





Uh oh. That looks more like a recalcitrant caliper with commitment issues than enthusiastic use.



I think this points to a caliper rebuild. Entirely expected, given occasional screeching noises and all the front handbrake adjustments, but one to add to the list. The calipers didn't demonstrate any real issues as the new TRW pads went in...



Other side was fine - plenty of meat on the pads on both sides, but I replaced them anyway.



The wash/wipe function was getting intermittent according to the owner - pump was fine, just the stalk that looked to be acting up. A few torx bits later...



Check out the gold dust.... 206k of steering action....! "All my life I have been in love with its colour, Mr. Bond..."



A reseating of connectors and slight lubrication seemed to restore proper operation. Fluid topped off and jets realigned. All set.





Spinakerr

Original Poster:

1,193 posts

146 months

Friday 5th May 2023
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Last week it was our five year wedding anniversary, and decided there are two things we always enjoy - a road trip and a swim in Cornwall. Last minute accommodation booked, there was only one choice of vehicle for late night, long distance adventure: the wedding present.



The 900 has been pressed into daily service after our Rover 75 was hit by a van while aprked outside our house (see other thread), and continues to be the reliable, if tatty, chariot of choice. My wife has put on roughly 30k, and after all the work in this thread its mechanically fit and cosmetically miserable.

Still, the whistling of the turbo and 3rd gear acceleration on the A303 dual carraigeways is addictive. It has never been an overly sharp car, but grippy tyres on the 15inch Super Incas, light weight and predictable suspension creates a 'firmly floating' experience. Learn to expect certain roll, throw in revs to plan turbo kick-in and the 900 is a superb A road blaster. The wooden Ital Volanti wheel is a joy to operated and the green instrument backlight gives a truly unique night driving experience.



As the 6 hour drive down reached the fresh air and narrower roads of ST Ives, our playlist from Miami Vice reached a neon zenith and we stepped out without an ache.

We slightly fought for the keys on the way back too.





Brakes are squealing a little, as always - the thought of the front handbrake and 4 caliper rebuild makes me want to weep so I'll work on the wipers and other normal service items while we plot a more involved rust surgery session at TR Autos, now delayed monetarily and temporally by the green 99's carb rebuild.

Good to give the car a decent run!

Spinakerr

Original Poster:

1,193 posts

146 months

Friday 5th May 2023
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bolidemichael said:
How was the swimming?
Actually not bad at all, but we have wetsuits! The best part was the last night (Sunday) that my wife booked over breakfast on Saturday - Carbis Bay Hotel - it had a heated outdoor pool.



It was the hotel used for the G7 summit a few prime ministers ago - highly recommended on the off season - cheap deals including a decent dinner, near empty when we went and an upgrade from the bog standard room to a suite.



We don't usually get that lucky with accomodation, but the fact we had the place really to ourselves was, naturally, the highlight.



Looks like some customers might be able to afford the sunny season too...!



In other news, the seat really deteriorated today.