UKSaabs

THE site for UK Saab people!
It is currently Tue Aug 11, 2020 12:46 pm

All times are UTC



Forum rules


The place for you to start a thread about and show us your car.

(Please stick to one thread, rather than starting several threads for the same vehicle).

Your Cars is the place for telling us about your new cars, minor upgrades and mini projects.
Full on restorations & major rebuilds should be posted in Restorations & Major Projects.



Post new topic Reply to topic  [ 20 posts ] 
Author Message
 Post subject: 9-5 Aero resurrection.
PostPosted: Sun Mar 29, 2020 1:21 pm 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
Right here goes.

My dead 2006 (pre March tax hike :D ) which has been sadly sitting on my drive since last August with terminal engine problem. The Flying Scotsman put out less smoke when at maximum puff than the Aero as one of its cylinder just floods with oil and burns it.

I have now purchased, at a nice low cost, a 2007 2.3t Vector (minimum spec), battered and scratched body, and a list of things that need fixing. The good bit is it has less than 60k on the clock and the engine and gearbox run perfectly (just it leaks oil from rocker cover). Tax has just run out (£600 bracket) and my plan is hatched.
Engine out, clean it all up replace consumables, swap all the bits with the Aeros engine (turbo etc) and put it in the Aero.

The biggest project I have ever attempted. Have changed the engine in my wife's Westfield (and had it in and out a few times) which is dead easy lots of room and only a couple of pipes and connections.
The Aero is a much more daunting task and i welcome all advice and help.

This also means there will be a lot of parts available including a very good condition set of seats.

Attachment:
95 Aero.JPG
95 Aero.JPG [ 425.65 KiB | Viewed 1471 times ]


Attachment:
95 23t.JPG
95 23t.JPG [ 475.75 KiB | Viewed 1471 times ]

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Sun Mar 29, 2020 1:24 pm 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
The Aero at the moment:

Attachment:
Aero Engine.JPG
Aero Engine.JPG [ 451.04 KiB | Viewed 1469 times ]


The donor:

Attachment:
23t engine.JPG
23t engine.JPG [ 368.45 KiB | Viewed 1469 times ]

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Mon Apr 06, 2020 2:57 pm 
Offline
Arkwright.
User avatar

Joined: Sat Jan 20, 2007 6:33 pm
Posts: 49999
Location: NETTLEHAM, LINCOLNSHIRE
Car Models: 1984 99GL, 1992 C900 T16, Jaguar XF Sportbrake, FIAT 500 TwinAir
Thread moved to - Your Cars
The place for your car diaries (blogs), letting everyone know about your new cars, mini projects & minor restorations etc...

_________________
When you think you know it all, it's a sure sign you don't.


Top
 Profile  
 
PostPosted: Tue Apr 21, 2020 12:23 pm 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
Up up and away..

Attachment:
edit IMAG3265.jpg
edit IMAG3265.jpg [ 252 KiB | Viewed 1155 times ]

.
Attachment:
edit IMAG3264.jpg
edit IMAG3264.jpg [ 264.75 KiB | Viewed 1155 times ]

.
Attachment:
edit IMAG3266.jpg
edit IMAG3266.jpg [ 325.29 KiB | Viewed 1155 times ]

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Tue Apr 21, 2020 12:28 pm 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
Well that was nearly 3 days of my time of research, reading working things out and slowly removing stuff to the point of lifting the engine out.

Strip of gearbox and start to clean up, next remover turbo and bits......

Attachment:
edit IMAG3295.jpg
edit IMAG3295.jpg [ 345.39 KiB | Viewed 1155 times ]

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Tue Apr 21, 2020 12:33 pm 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
big moment, sump off and see what it looks like..........

Attachment:
edit IMAG3297.jpg
edit IMAG3297.jpg [ 286.23 KiB | Viewed 1155 times ]


Turns out it looks fine which makes me nice and happy, drain the rest of the oil out the bottom and it looks fairly clean, as it should on a 50k car !

Attachment:
edit IMAG3300.jpg
edit IMAG3300.jpg [ 307.08 KiB | Viewed 1155 times ]

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Tue Apr 21, 2020 1:43 pm 
Offline
Saab Nut
User avatar

Joined: Tue Sep 10, 2019 11:14 pm
Posts: 1051
Location: N Yorks
Car Models: 9-5 Aero Estates, 9-5 2.2 TiD estate, 9-5 2.0 Saloon, 9000 Aero
Well done for attempting a rescue.

Lots of stuff will be compatible, however one question. Does the 2.3t of that age have the nimonic valves, are you going to swap heads or leave as is.

Timing chain to do while the engine is out as well, or leave well alone as it's still low mileage. You can at least measure the extension ;)


Top
 Profile  
 
PostPosted: Tue Apr 21, 2020 3:41 pm 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
carrera wrote:
Well done for attempting a rescue.

Lots of stuff will be compatible, however one question. Does the 2.3t of that age have the nimonic valves, are you going to swap heads or leave as is.

Timing chain to do while the engine is out as well, or leave well alone as it's still low mileage. You can at least measure the extension ;)



I am thinking leave the base engine well alone for a 2 main reasons:
1. It was a perfectly running engine with 50k on the clock when i started
2. I am stretched in my knowledge and capabilities as it is with this swap so for that reason 1 above makes even more sense.

I have had a discussion on the engine comparability on this thread : viewtopic.php?f=2&t=196948 and the gas filled valves on the Aero is the only difference.

Of course a check on the timing chain and changing pipes gaskets and other things is on the card.

I welcome any advice on other things that it is wise to change while it is out the car.

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Mon May 11, 2020 5:20 pm 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
Well that is now two engines removed!

Attachment:
P1020872s.JPG
P1020872s.JPG [ 605.79 KiB | Viewed 997 times ]



Attachment:
P1020858s.JPG
P1020858s.JPG [ 491.54 KiB | Viewed 997 times ]



Looks like the passenger side of the subframe will need a bit of tlc but it is only surface rust so clean up and give it a covering.

Attachment:
P1020860s.JPG
P1020860s.JPG [ 570.69 KiB | Viewed 997 times ]

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Wed May 13, 2020 5:22 am 
Offline
Saab Nut
User avatar

Joined: Sat Oct 03, 2009 3:05 pm
Posts: 1689
Location: Crewe, Cheshire
Car Models: 2002 Saab 9-5 Aero Estate
I would keep the alternator from the new one on the engine if I were you as it is an absolute pig to get to afterwards, the old one might do as a spare if the bearings are OK. Obviously anything else on the back of the engine is a no brainer to attend to now that the engine is out.

I recommend Bilt Hamber Hydrate 80 for the de-rusting, you can paint it on and leave it for 6 hours to work it's magic (4 hours if you are in a hurry), it's then paintable with topcoat, no primer required. For it to work properly you do need to get rid of the worst of the rust and oil, it won't penetrate an oily surface.

Good luck

_________________
'02' 9-5 Aero wagon
'98' 9-5 SE 2.3LPT
'98' 9000 CSE 2.0LPT
'01' 9-5 2.0L LPT
'97' Merc SL500 (oops)


Top
 Profile  
 
PostPosted: Wed May 13, 2020 3:08 pm 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
masonmjs wrote:
I would keep the alternator from the new one on the engine if I were you as it is an absolute pig to get to afterwards, the old one might do as a spare if the bearings are OK. Obviously anything else on the back of the engine is a no brainer to attend to now that the engine is out.

I recommend Bilt Hamber Hydrate 80 for the de-rusting, you can paint it on and leave it for 6 hours to work it's magic (4 hours if you are in a hurry), it's then paintable with topcoat, no primer required. For it to work properly you do need to get rid of the worst of the rust and oil, it won't penetrate an oily surface.

Good luck


My plan is to keep the best parts of the two. there is only a years difference between them but the donor car has 80k less miles so parts from that will mostly be used. Strangely the donor car is in much worse condition with rust etc so a lot of the actual; metal bits will stay with mine.

I already have Hydrate 80 as i have i used it on my wife's Westfield chassis.

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Mon May 18, 2020 11:47 am 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
Engine clean up time and start to add all the bits.

Attachment:
IMAG3470s.jpg
IMAG3470s.jpg [ 294.76 KiB | Viewed 825 times ]


Attachment:
IMAG3466s.jpg
IMAG3466s.jpg [ 373.93 KiB | Viewed 825 times ]

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Mon May 18, 2020 11:49 am 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
Attachment:
IMAG3468s.jpg
IMAG3468s.jpg [ 200.19 KiB | Viewed 825 times ]


Attachment:
IMAG3469s.jpg
IMAG3469s.jpg [ 210.48 KiB | Viewed 825 times ]

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Mon May 25, 2020 12:04 pm 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
Attachment:
P1040026s.JPG
P1040026s.JPG [ 519.9 KiB | Viewed 712 times ]




Attachment:
P1040045s2.JPG
P1040045s2.JPG [ 344.11 KiB | Viewed 712 times ]

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Tue Jun 16, 2020 8:27 am 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
Well it has now moved on and the engine is in!
.
Attachment:
P1040115s.JPG
P1040115s.JPG [ 594.25 KiB | Viewed 505 times ]

.
Attachment:
P1040116s.JPG
P1040116s.JPG [ 543.73 KiB | Viewed 505 times ]

.
Attachment:
P1040118s.JPG
P1040118s.JPG [ 338.87 KiB | Viewed 505 times ]

.

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Tue Jun 16, 2020 8:30 am 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
Lots of connecting up.
.
.
Attachment:
P1040135s.JPG
P1040135s.JPG [ 345.96 KiB | Viewed 503 times ]

.
Attachment:
P1040136s.JPG
P1040136s.JPG [ 529.33 KiB | Viewed 503 times ]

.
Drive shafts back in and suspension back together, all ready for inner arches and wheels
.
Attachment:
P1040138s.JPG
P1040138s.JPG [ 477.75 KiB | Viewed 503 times ]

.

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Sat Jun 20, 2020 4:59 pm 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
She runs..................... :D :D :D :D :D

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Sat Jun 20, 2020 9:17 pm 
Offline
UKS Encyclopædia G-M
User avatar

Joined: Sun Aug 15, 2004 9:39 am
Posts: 41878
Location: SW Herts
Car Models: 2007 9-5 Aero est. 300hp Hirsch. 9-3 2010 9-3 Carlsson
:) :)

_________________
.
.
.
.
Everything will be OK in the end. If it's not OK, it's not the end...


Top
 Profile  
 
PostPosted: Sun Jun 21, 2020 8:07 am 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
Small oil leak on one of the turbo pipes to sort, as that is the only thing i am happy.
Now wheels and bodywork back on and all ready for the MOT at the end of next week.
.
Attachment:
P1040152s.JPG
P1040152s.JPG [ 532.03 KiB | Viewed 416 times ]

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
PostPosted: Sat Aug 01, 2020 3:48 pm 
Offline
Light Pressure Turbo
User avatar

Joined: Thu Sep 29, 2005 7:42 pm
Posts: 544
Location: Bishops Waltham
Car Models: 2006 9-5 Aero Est
All back together!

Next problem rear arches!

Attachment:
P1040205s.JPG
P1040205s.JPG [ 527.63 KiB | Viewed 153 times ]


So both arches now repaired fully and all sealed and car back together with full MOT.

Goes like a rocket again.

135K with a 50K engine so many more years of smiles.

:D

_________________
In our Garage but not all mine;
9-5 Aero
Westfield SEi
Mini Cooper S
Z4 Msport
ZX9R
ZX6R
ZXR400


Top
 Profile  
 
Display posts from previous:  Sort by  
Post new topic Reply to topic  [ 20 posts ] 

All times are UTC


Who is online

Users browsing this forum: No registered users and 6 guests


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum
You cannot post attachments in this forum

Search for:
Jump to:  
Powered by phpBB® Forum Software © phpBB Group

follow UKSaabs on Twitter



UKSaabs silhouette logo images by Mark Green www.greenphotos.com
"subsilver2" slightly bodged by UKSaabs for our own use.

:: Disclaimer ::
Comments posted here are the views of their individual authors and are not necessarily shared by the owners of this Web site.
Authors assume all responsibility for comments posted here.

UKSaabs The biggest and best privately owned UK based independent Saab forum for all SAAB enthusiasts.
Whilst we encourage our users to support our advertisers the site wishes to remain independent and therefore does not endorse any particular advertiser(s)
UKSaabs is not affiliated with Saab Cars UK or Saab Automobile AB