Saturday 23rd October 2004

Introduction

As the rain poured down outside the Saab Flight workshops we were all pleased to be inside in the warm and dry. Having a well-equipped workshop makes all the difference when tackling a project like this and we soon found having the workshop of a Saab specialist is even better!

This was to be the first time we had been able to get a good look over the car since we had collected it from Bury St Edmonds, late on a Sunday evening. We were all keen to get the car up on a ramp and give the car a proper inspection. We have big plans for the car, but the first job of any project such as this is to ensure the basic mechanical soundness of the vehicle.

An inspection of the car with David Greenwood, Saab Flights owner, quickly revealed a few minor areas of concern that would need to be addressed before the car set eyes on a track.

1. The characteristic bright red colour of power steering fluid could be seen on the bottom of the sump. A quick inspection of the power steering pump revealed a few suspect unions.
2. A few areas of minor rust where apparent on the rear of the sills and these will require a treatment of rust killer to prevent further deterioration.
3. The rear over-axle brake pipes around the fuel tank area were quite rusty in places, so were marked for replacement the next time the brake circuits are apart.
4. The fuel tank retaining straps were also showing signs of rust and would need to be checked. This we would tackle at the same time as replacing the rear brake pipes which run between the fuel tank and the car body.
5. The pin was absent from the wastegate actuator rod. A very common minor problem on Saab 9000s.
6. The front crankshaft oil-seal was showing some seepage, as was the oil pressure switch and the head gasket.

Having made a long list of future jobs, we started on the days planned tasks. The first of these was an engine service.

We started with an oil and filter change. We have chosen Motul 300V competition 15W50 100% synthetic oil - slightly thicker than Saab's specified oil, but this should maintain better viscosity at the higher running temperatures found on the track, probably at the cost of some economy; it has been suggested that we can expect to lose 3-4MPG with the thicker oil, but we won't be using the car for commuting, so hopefully this won't break the bank.

The sparkplugs were changed with the standard specification NGK BPR7ES plugs, gapped to 1.1mm. Due to the sensitivity of the Direct Ignition system, the use of different plugs can adversely affect performance and the longevity of the DI cartridge.

We added a flushing agent to the coolant reservoir, which will need to run in the system for a short time to give it time to clear any unwanted deposits from the cooling system - this will then be changed at a later date.

We didn't change the air filter at this time as we are still considering which set-up to use - a modified air box with replacement paper filter or a full induction kit.

One fault with the car when we picked it up was that the speedometer wasn't working. This was due to the electric sender unit being missing! With the car on a lift, it was a simple job to screw on a second hand unit and wire it up - now the speedometer works fine.

With the routine servicing complete we begun stripping the unnecessary interior items out of the car: We started in the boot and worked forward, taking out anything that would not be needed on the track! This included:

Ø Boot carpet lining
Ø Wooden boot floor
Ø Spare wheel and tools
Ø Rear seats
Ø Front Seats
Ø Sill trim plates
Ø Carpets
Ø Overmats
Ø Rubber sound deadening
Ø Bags of fibreglass sound-deadening from voids.
Ø Hardboard panels under the sound proofing
Ø Parcel shelf cover
Ø Steel parcel shelf
Ø All pillar covers
Ø Rear seatbelts
Ø Front passenger seatbelt
Ø Rear door cards
Ø Rear door central locking motors
Ø Glove Box
Ø Speakers
Ø Stereo

This amassed a sizable pile of parts, so must have afforded a worthwhile reduction in weight. We will be weighing the completed car to find out the overall weight reduction.

We fitted a temporary driver's seat, and left the driver's seatbelt to leave the car in a useable state.

The centre console was left, as the window switches need to be re-located before it can be removed. The front door cards were left so that the doors could be opened, and to cover any sharp edges on the doorframe.

The day was considered a great success, as we now have a clear set of plans for future workdays, and feel that the project is now well and truly underway.

Photos of the day