UKSaabs

http://www.uksaabs.co.uk/UKS/viewtopic.php?f=12&t=38873

Managed to escape my wife's new kitchen project and start work on a project of my own tonight

The job list so far:

remount near side exhaust pipe - 2 weeks at sea was enough for the rubber mounts
install new nearside exhaust manifold gasket
install UK head lights
install in grill fog lights (this was an optional extra on the 74 car) - managed to find a new set of original saab ones on UK ebay!
install separate side lights and indicators
fix dash lights (rheostat does not work)
adjust/replace boot struts (to avoid severe headaches)

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Saab, better than a mistress.
96 Bullnose
Sonett III

ok first challenge - exhaust is definitely blowing big style in the manifold gasket area, but where?

Position A seems to have a loose gaskety material that scrapes away with a screw driver - you can just about see the remains of it in the photos. Position B seems the more logical place.

Better add leaky rocker box cover to the list.

_________________
Saab, better than a mistress.
96 Bullnose
Sonett III

started work on side light replacement - got my moggy side lights, looks like I will need to drill new screw holes and an extra hole for the side light bulb. Any tips on drilling fibreglass? Side lights have stopped working now I have removed one of the lights but indicators are ok - wonder if the side lights are on some sort of ring?

_________________
Saab, better than a mistress.
96 Bullnose
Sonett III

OK, "A" has been gunged up with firegum or similar material, it shouldn't need any sealant unless the flange between "A" & "B" is corroded, and even then just a thin layer of fire gum will do.

"B" is where the gasket goes, they are a standard size and you really should be able to get from any decent factors or exhaust supplier.

Rocker cover gaskets readily available in sets via eBay and elsewhere, or you could just use blue Hylomar...

If/when you ever have a new exhaust made, get it made with bigger headers than standard, and have those flanges bored out to suit - you can take ~7-10mm out easily, and it really helps gas flow out of the head.

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89 C900 2dr T16S track hack: For sale
9-3 2.8T
9-5 Aero 600Nm
96V4

Your spacer/ flange is incorrectly installed. The bulky flat side should be against the manifold gasket and the cylinder head and the shaped side should be facing the shaped mouth of the exhaust pipe see pic below. I am not surprised it is leaking as shown in your pic.

wow should there be a gasket between those parts too?

_________________
Saab, better than a mistress.
96 Bullnose
Sonett III

Yes, there is a gasket in between the flange and cylinder head manifold. see components below. The tapered side of flange fits into the flare of the exhaust pipe. The gasket slides on the studs then the spacer/flange is placed in position. Draw exhaust pipe against the the taper, using a smear of exhaust paste if you cannot get a good seal. Slide exhaust pipe retainer on to the studs and secure with the nuts tightening evenly.

two gaskets per side?? they look the same....

_________________
Saab, better than a mistress.
96 Bullnose
Sonett III

One gasket per cylinder head.

great pic - that explains it- thanks Woody - I can't believe mine is the wrong way round!! Need to check the other side tomorrow now.

Should I use any gunk with the bid that fits into the exhaust?

_________________
Saab, better than a mistress.
96 Bullnose
Sonett III

[quote]Should I use any gunk with the bid that fits into the exhaust?[/quote]

Not sure what you mean by gunk. Some exhausts have an inner sleeve that slides into the taper of the exhaust. These were deleted in 1973. If you have inserts in the exhaust it is recommended in the Saab W/S manual to discard these.
Try assembling the components dry. check that the spacer surfaces are not pitted. If they are exhaust paste will assist.

to the garage with me......

_________________
Saab, better than a mistress.
96 Bullnose
Sonett III

It might be a good idea to replace the exhaust manifold studs while you are at it. A stud removal tool and heat would make light work of it and it may prevent tears later.

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Sent using a 2nd class stamp.

Where can I find one of those?

_________________
Saab, better than a mistress.
96 Bullnose
Sonett III

Any good tool shop such as Machine Mart, Made by Sykes Pickavant.

That's what was bugging me about the photo...of course, duh! I'm supposed to know about this stuff

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89 C900 2dr T16S track hack: For sale
9-3 2.8T
9-5 Aero 600Nm
96V4

the other side is ok -just this side that is the wrong way round - very strange

_________________
Saab, better than a mistress.
96 Bullnose
Sonett III

Bonnet off ready for some action... still not much room to work!

_________________
Saab, better than a mistress.
96 Bullnose
Sonett III

spent a useful hour fitting new headlights (h4) with RHD spec only to discover one is LHD will be on to the supplier tomorrow. I would like to have a go adjusting my headlights to MOT spec (when I finally get it sorted) - can anyone advise what this is?

In the meantime, removed and refitted the exhaust system - it is pretty rusty but otherwise seems ok - as I was fitting the rear exhaust mounting (this is a rubber cotton reel type mounting that screws and is bolted into the under body through the under boot) - the glass boot lid sliced my head off again and this reminded me that I am on the look out for replacement gas struts for the boot glass lid, suggestions so far:

_________________
Saab, better than a mistress.
96 Bullnose
Sonett III

Park the car about 6 feet away from a wall and get the lights level and evenly spaced..then when you get the car MOT'd pre-warn them that they need adjusting as you hand over a packet of biscuits

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Sent using a 2nd class stamp.