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A place for you to create build diaries of the basket cases at the bottom of the garden/driveway.

No fix it part type threads please just cars, build diaries etc.

If you would like old threads from other parts of the forum moved here, feel free to PM a member of the team to get it moved for you.



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PostPosted: Sat Nov 12, 2016 2:59 pm 
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Joined: Mon May 12, 2008 9:11 pm
Posts: 1905
Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
So I recently bought a Dame Edna 9-5 estate
Been doing a host of jobs and putting most of these up in one go as I've got a few hours spare today.

Positives:
I really like the look of the DE estate, just more modern both inside and out. Looks good in Silver too.
Being the Vector Sport it looks 'right'
Never had a diesel in 25 years of driving so thought I'd try it out
Cheap enough to have a punt

Project- more of a maintenance project really

Point 1:

Started off as a motorway project when the intercooler hose popped off and 80% loss in power and black smoke everywhere- when on dual carriage way managed to sus it out and take a jubilee clip off the air filter / maf and us that - got home in the end.....
Thought f me at the time though .....

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Last edited by paolo on Sat Nov 12, 2016 3:39 pm, edited 1 time in total.

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PostPosted: Sat Nov 12, 2016 3:04 pm 
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Joined: Mon May 12, 2008 9:11 pm
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Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Point 2 :
After a few days it was evident that the car wasn't running properly so I set about looking at all the more obvious points. I was lumpy at idle and lacking any real power under 2000revs

Started with airfilter and found this : looks like the K N filter had never been cleaned it was thick with debris too ( this is post brushing it down) clean filter in place


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Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99


Last edited by paolo on Sat Nov 12, 2016 3:09 pm, edited 1 time in total.
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PostPosted: Sat Nov 12, 2016 3:09 pm 
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Joined: Mon May 12, 2008 9:11 pm
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Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
When finding the dirty filter I noticed the interesting Performance mod ( I've already posted about this l, but basically the cut down jobbie was replaced with a proper one....)


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Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99
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PostPosted: Sat Nov 12, 2016 3:16 pm 
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Joined: Mon May 12, 2008 9:11 pm
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Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Running was marginally improved but still not right so I set about looking at the EGR valve- as a sooted up/ sticking one can cause idle and low rev running problems.

I decided on just buying a new one from Neo's

Fairly easy to fit

Old versus new: Not gunk central but dirty dirty and probably sticking


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IMG_4133.JPG [ 104.96 KiB | Viewed 932 times ]

_________________
Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99


Last edited by paolo on Sat Nov 12, 2016 5:50 pm, edited 2 times in total.
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PostPosted: Sat Nov 12, 2016 3:24 pm 
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Joined: Mon May 12, 2008 9:11 pm
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Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Running better but still not right

So decided to splash out on a new manifold pressure sensor - got a proper bosh one. I also cleaned up the throttle butterfly too

As you can see in the picture, the sensor is so gunked up I doubt it could read anything....compare with new


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_________________
Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99
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PostPosted: Sat Nov 12, 2016 3:27 pm 
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Joined: Mon May 12, 2008 9:11 pm
Posts: 1905
Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Car now runs really well. The lumpy idle that lasted a while goes almost instantly and it's like driving a different car below 2000revs. Bags of torque. You had to rev it past 2k before it did anything and now it will happily move from 1.3k in 3rd
Quite a nice engine overall :D

_________________
Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99


Last edited by paolo on Sat Nov 12, 2016 4:00 pm, edited 1 time in total.

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PostPosted: Sat Nov 12, 2016 3:34 pm 
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Joined: Mon May 12, 2008 9:11 pm
Posts: 1905
Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Well 3 of the tyres loose about 15psi over a week - have done since I bought it and it's been a consistent 15psi needed everyweek since.

Fab another issue. Tyres are all almost new (despite chunks out of sidewall- ventus v12 must have softness sidewalls ever...)

I decided to buy some black tyre sealant and have a go at DIY stopping the leaks - which I assumed must be rough ageing edges of the alloy not sealing properly

£12.50 for a pot off Ebay and I begin taking each wheel off, letting air out and with a 'jemmy bar' pushing the tyre rim/seal down and inch by inch pushing/ painting and generally slapping the stuff around the seal.

Looked like a scene from Exxon Valdez but it comes off easily once dry

Result???
A week on and 2 of the 3 tyres have retained their pressure.

I will redo that 3rd one at a later stage-

_________________
Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99


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PostPosted: Sat Nov 12, 2016 3:38 pm 
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Joined: Mon May 12, 2008 9:11 pm
Posts: 1905
Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Handbrake is absolute rubbish- I've posted this already in the workshop. Offside is fine but nearside doesn't work at all. Still need to work this one out- but been too wet to be crawling under car.

It failed mot on this in February according to mot history - not sure what was done to rectify it

Will need to have a think about how this is best fixed

_________________
Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99


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PostPosted: Mon Nov 21, 2016 2:56 pm 
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Joined: Mon May 12, 2008 9:11 pm
Posts: 1905
Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Well I resealed that front tyre again and it's reataiined it's psi- so happy days.

You really do need to jemmy the tyre down off the bead as much as you can, slowly inch by inch working your way around

_________________
Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99


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PostPosted: Sat Nov 26, 2016 5:47 pm 
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Joined: Mon May 12, 2008 9:11 pm
Posts: 1905
Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Started to do a ' do for now rust halting' on the rear arches, so they don't drop off come next summer.

Going to do in 4 simple stages for now
Stage 1 outside clean, rub down and clean
Stage 2 paint up the outside
Stage 3 inner arch, clean and rub down
Stage 4 spray with waxoil black or the like

As always, what the eye can see ends up being twice as bad in reality.....


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Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99
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PostPosted: Fri Dec 23, 2016 3:28 pm 
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Joined: Mon May 12, 2008 9:11 pm
Posts: 1905
Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Stripped the rear brakes today- all working fine
The handbrake cable is goosed so I've ordered a new one- the nearside one just does not move so it's broken or jammed.

I'm 100% that a new cable will fix it.

The inner arch is rusted to hell though...... never seen such a rusty 9-5. :wall:

Did a quick rust 'proofing' job for now to try and slow it down. It's like an old c900 looks ok until you crawl underneath and take parts off.....


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Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99
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PostPosted: Fri Dec 23, 2016 7:59 pm 
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Joined: Wed Jan 13, 2010 5:05 pm
Posts: 1635
Location: Wirral
Car Model: GM900
Great work.

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PostPosted: Sat Dec 31, 2016 5:22 pm 
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Joined: Mon May 12, 2008 9:11 pm
Posts: 1905
Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Ok - old handbrake cable off. The nearside cable was jammed solid, the plastic sheath around the cable had broken up and got jammed into the metal rings that were rusted up inside the protective outer rubber.

New cable all fitted apart from the rear hub connection- I'll do that tomorrow and hopefully will have a working cable!

_________________
Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99


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PostPosted: Mon Jan 02, 2017 11:43 am 
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Joined: Mon May 12, 2008 9:11 pm
Posts: 1905
Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Rusty now has a working handbrake on both sides- success. It was driving the wife mad on hill starts so she will be happy now.

Treated a bit more rust on the underside too.

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Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99


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PostPosted: Sat Jan 07, 2017 3:55 pm 
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Joined: Mon May 12, 2008 9:11 pm
Posts: 1905
Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Fitting new handbrake return springs that arrived very promptly from SAABits.
One was missing and the other broke as it was rusty.


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Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99
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PostPosted: Sat Jan 07, 2017 3:58 pm 
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Joined: Mon May 12, 2008 9:11 pm
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Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
Also - decided that I will try and clean the map sensor weekly if I can.

It gets dirty so quickly on these diesels and really is a two minute job to remove and squirt some electrical cleaner on it.

_________________
Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99


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PostPosted: Sat Jan 07, 2017 6:58 pm 
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Joined: Wed May 12, 2004 9:46 pm
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Location: Mulbarton,Norfolk
Car Model: TTid's only now :-(
paolo wrote:
Also - decided that I will try and clean the map sensor weekly if I can.

It gets dirty so quickly on these diesels and really is a two minute job to remove and squirt some electrical cleaner on it.


It would stay much cleaner without the EGR...

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PostPosted: Sat Jan 07, 2017 8:09 pm 
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Location: Down Sarf'
Car Model: 93ss V6 Maptun St3 + 9-5 Dame
wrighar wrote:
paolo wrote:
Also - decided that I will try and clean the map sensor weekly if I can.

It gets dirty so quickly on these diesels and really is a two minute job to remove and squirt some electrical cleaner on it.


It would stay much cleaner without the EGR...


Yes you're right, the egr idea sounds mad to me, dump a load of diesel soot into the intake...
However, that would require a remap would it not?
If I just go blanking it off wouldn't it run bad and throw a cel?

_________________
Ex:9-5 Aero Stg3,9-5 Hirsch Aero,9-5 Aero,9-5 Airflow Stg1,9-5 2.0 Stg5, 9-3 HOT, c900 Aero, '71 99


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PostPosted: Sat Jan 07, 2017 8:23 pm 
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Joined: Wed May 12, 2004 9:46 pm
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Location: Mulbarton,Norfolk
Car Model: TTid's only now :-(
paolo wrote:
wrighar wrote:
paolo wrote:
Also - decided that I will try and clean the map sensor weekly if I can.

It gets dirty so quickly on these diesels and really is a two minute job to remove and squirt some electrical cleaner on it.


It would stay much cleaner without the EGR...


Yes you're right, the egr idea sounds mad to me, dump a load of diesel soot into the intake...
However, that would require a remap would it not?
If I just go blanking it off wouldn't it run bad and throw a cel?


Mine (1.9) has run well with it's CEL for 4 yrs now :-)

Hopefully the intake is nearly clean

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PostPosted: Mon Jan 09, 2017 12:42 pm 
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Joined: Tue Aug 06, 2013 4:26 pm
Posts: 632
Car Model: 9-5 Aero (2002, manual, saloon
Great to see it's not just my 9-5 diesel clogging up the Project section :)

I ended up getting my EGR disabled or blanked (not sure which) as part of a remap package with Angel Tuning (see my project thread).

What sort of MPG are you getting Paolo?


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