SAAB V4 ENGINE--REALLY SCREWED UP!

 

You are looking at a very screwed up Saab/Ford V4 engine block. I took this one apart to do a complete overhaul. The piston in the photo IS at top dead center. I rigged the dial indicator to measure how far the crown of the piston is below "deck height" [top surface of the block]. The drill is to get a starting point, so I set the dial indicator at some number greater than the estimated depth of the piston below deck height. I also know the thickness of the steel strap.

 Next is to remove the strap and take a measurent at the piston crown.  I subtract this measurement [plus the amount of the strap thickness] from the first reading. The result was 0.247".  This is a 1698cc V4. We all know [don't we?] that the pistons in the stock 1698cc V4 do not come up to deck height BUT they certainly are not a quarter inch below it! ZOUNDS! Some metally challenged mechanic really did a number on this little engine.

But wait! There's more! It's hard to see in this photo but the cylinder walls are a mess. There is about six jillion tiny hammer marks, all evenly spaced in that shiny area above the piston. What the hell caused that? I am not sure. Perhaps a worn out boring bar [the engine was bored .5mm (0.020") oversize] or an equally worn out hone of some sort.  So what does this have to do with the deck height problem?   Well, sports fans, when I got the sucker all apart I find that the super smart "wrench" who did this work managed to fit [new] pistons for a 1698cc engine onto a 1498cc crankshaft, resulting in the 0.247" under deck height measurement.
This same genius had the crankshaft turned 0.010" undersize on the main bearing journals, and 0.020" undersize on the connecting rod journals, BUT then installed bearings that were ALL 0.010" oversize. That sucker must have rattled quite a lot had had about as much power as an old two stroke Saab with one plug wire pulled off! 

Proving once again that these little V4's are pretty special and require some special knowedge--like factory manuals and 40+ years of Saab experience-- in order to rebuild them correctly. A hack mechanic who once overhauled a Chevy pickup engine has absolutely no business getting within a city block of a Saab V4. This particular rocket scientist managed to make the Saab owner pay TWICE to get his engine overhauled correctly.

SAAB V4 TRANSMISSION DIP STICK

 SAAB, in their infinite wisdom, made the transmission for the 95/96/97 models VERY unhandy when it came to checking the transmission oil level. The drill is to remove the check plug [see drawing above] and if oil runs out, the oil level is good.  If no oil runs out, take out the fill plug and add oil until it does run out, then replace the check plug.  Some Saab owners don't even know where the check plug IS, and has even less inclination to go through this drill.  So a dip stick is a real good idea, and can prove to be a transmission saver since the owner MIGHT actually check the transmission oil level on occasion.

 I built a construction fixture [red item at the bottom in the photo above and top red item in the photo below] that exactly matched an original SAAB trans dip stick, so when the stock of dip sticks have been sold, I whip out the fixture, and make up some more of them.

This photo shows seven [of a dozen] freshly completed dip sticks plus the original Saab dip stick [red, top next to the fixture]. I add the "MIN" and "MAX" notches, as per the original. Now, y'see, all you have to do is remove the fill plug with a 3/8" drive extension, dip the dip stick into the trans, pull it out, read the oil level, add if necessary, put the fill plug back into the transmission case, wipe off the dip stick, and if you're  a neatnick, you didn't even get oil on your hands. PLUS, your transmission stays properly oiled and happy. By the way--SAAB used to offer these dip sticks through their dealers. Since that is no longer an option to the vintage Saab owner, I thought it would be a good idea if I made the little buggers available.  Good stuff, huh?

SPEAKING SPEEDOMETER

VDO speedometers are pretty trouble-free, for the most part. However the ODOMETER portion gets tired after while and in order put them into good fettle once again, they have to come apart. This isn't a real easy thing to do, assuming you don't want that nice chrome bezel all boogered up.

This is the anti-booger tool that I designed and built. It clamps the speedo just right, and the handle [with a wedge tool attached to the speedo end] peels the chrome bezel off, slick as a whistle, without damaging the bezel. SLICK!

I have to take off the speedo needle in order to get the number face off, in order to take the speedo apart to get to the odometer bits that go South. The needle is fragile. I'm using a little puller tool that I built--to pull the needle without doing a booger job on it, either. Gentle is the name of the game when working with speedometers!

Voila! the face is off and I have the front half of the speedo in my left hand. I've set aside the rear portion of the unit. I'm pointing to a plastic gear that is in the chain of gears that drives the odometer [and the trip meter as well]. Unfortunately, this easy-to-get-to plastic gear is NOT the one that gives up the ship in these speedometers. ARRRGGGHHH!

See that little brass gear? That little sucker isn't the one that goes tango uniform, either. But it has to be pulled to get to the bad one. The bad one is the GREY pot metal gear just to the right of the numbers register that is on the bottom in this photo, between the last register and the speedo frame. I built the little puller I'm holding. That little sucker pulls that wee brass gear quite nicely. THEN...I can take the numbers drums out, get the bad Grey gear [called an "advancer"], replace it and chuck it all back together. Fun times!

I hate to re-create wheels. So I spent time drawing [in rather a lot of detail] exploded views of all the gubbins in these speedometers. Makes the process of disassembly, cleaning, repair, oiling and reassembly a whole lot easier. So if your odometer refuses to odo, I can make it all better once again, because, see...I speak speedometer...HA!
I've been repairing these VDO speedos for some years now. I don't see them as some sort of mysterious device that can only be repaired after a lot of money has changed hands. Give me a shout--let's talk about what it takes to fix the VDO speedo in your wee Saab.

GIVE ME A BRAKE

I regularly have a need to bend pieces of sheet steel or aluminum, or strap of either persuasion. A small brake was in order, so....I built one. The component parts are shown here.


There are three pieces of 1.75" x 1.75" x 0.200" steel angle, some 0.200" thick pieces of plate [at the ends of two of the angles], a couple of 0.50" diameter "J" bolts, a 6.0" piece of 0.75" O.D. pipe, and two 7/16" bolts with nylock nuts.

Here it is, assembled, with a piece of 18 gauge sheet steel set in place, ready to be bent. [The light colored piece in the middle of the brake is the steel to be bent]. The aft, LOWER angle is mounted in my bench vise. The aft UPPER angle holds the piece to be bent into place by tightening the nuts on the welded-in-place bolts on either end. So now it is just a matter....

...of lifting the handle to bend the piece of steel sheet. The brake will accept metal up to 12.5" wide,
and will easily bend aluminum sheet up to 0.125" thick and steel sheet up to 16 gauge. It will also bend steel strap up to 0.125" thick and 2.0" wide.

The angle of the photo isn't great, but it does show the piece of 18 gauge bent to about 45 degrees. At this point, I simply loosen the two nuts on the aft TOP angle and slide the bent piece forward, out of the brake. As they say in the translated instructions, "Welding, some drilling and cut is to be required." Followed by three equally well translated paragraphs on how not to kill yourself with your welder, your drill press or your hack saw.
At any rate, this is an easy to build, and very useful little tool that takes up very little storage space for the 98% of the time you won't need it. And it works like a champ for that 2% of the time when you DO need it.

FREEWHEEL FOIBLE FIXED

You are looking at the front of another customer's Saab V4 transmission, mounted in my factory transmission press. The gear with the large teeth is the pinion gear. Above and to the left of that gear is a screwed-up input shaft hub. Inside that hub is the freewheel unit. The pulley-looking thing sticking out of the hub is whats called a "dog clutch" gear. Someone with probably good intentions had welded on half washers to hold the dog clutch engaged, rendering the freewheel inoperative, or as we call it,"neutered".

The problem with this neutering method is that it throws the main shaft out of balance, and makes it impossible to ever revert to freewheeling again. This is really not a good way to neuter the freewheel.

Here is the main shaft after I removed it from the transmission. You can clearly see the dog clutch piece dangling from the freewheel hub of the main shaft. Hmmmm.....what to do to save the expensive main shaft and dog clutch....hmmmm....

I put the sucker in my lathe and began to cut off the half washers, by cutting through the welds. This is the cutter set-up on the carriage fixture on my lathe. I have made the first cut in this picture.

This is the second and final lathe set-up. The cut has gone through the welds and is into the half washers. My hope--at this point--was that the welding had not screwed up the freewheel hub. If it had, the mainshaft was junk.

VOILA! The cut is completed. The owner got lucky. The main shaft, the dog clutch and even the freewheel parts inside the hub were all still good. All I had to do from this point was to use the lathe cutter to clean up the end of the freewheel hub.
The point of this? There is a right way and many wrong ways to do something. This was one of the wrong ways that I managed to correct. I WILL neuter the freewheel, but do it the right way, so nothing is out of balance, and should the owner [or subsequent owner] ever get soft in the head and want to make the freewheel function again, he [or they] can do so.

BUSHED, BABY!

Bosch distributors, as used in Saabs with V4 engines, get old, tired and sloppy. [I've known some mechanics like that, too...]. Bosch didn't bother to put bushings at the BOTTOM of the distributor body, so over time and a lot of miles, the aluminum distributor body gets "hogged out". When that happens, the ignition point gap varies as the engine runs, the dwell changes, and the basic engine timing changes. And the engine runs like crap.

Here is my setup in that pretty blue lathe again, to machine out the bottom of the distributor body so I can install a bushing. I built a precision tool [mounted in the lathe chuck in this photo] to hold the distributor body on its exact center line. The precision lathe bit [shown in the steady chuck at the bottom of the photo] does not move. The chuck in the lathe rotates the distributor body as the steady chuck advances the bit through the body, machining the correct diameter hole as it goes.

Here I am using a larger bit in my big, commercial drill press to do a light chamfer in the freshly machined hole. This will allow the bushing to start into the distributor body easier.

I use a bolt that is machined to JUST slightly smaller than the diameter of the new bushing to guide the bushing into the distributor body. The bolt is long enough to fit through the bushing on the TOP end of the distributor body, so the bolt forms a perfect guide as I press the bushing into place. The bushing is an interference [plus] fit into the distributor body.

I use an adjustable reamer to open up the bushing to an inside diameter equal to the diameter of the distributor lower shaft, plus 0.003". I always HAND ream, and never attempt to speed up the reaming process as some might by putting the reamer in a hand drill. I ream a little, then test fit the shaft, and repeat the process until it is just right. When I'm finished with one of these Bosch distributors, it doesn't know it isn't young, vibrant and ready to go for thousands of miles once again.

EXHAUST & DONUTS

You are looking at the CHUCK end of my lathe. The piece in the lathe is the stator from a customer's alternator. The brass colored thingies are called "slip rings". The brushes in the alternator rub continuously against these slip rings and after about a jillion miles, wear grooves in the slip rings. Using this lathe set-up, I carefully cut the slip rings to a smooth surface without the grooves.
This doesn't have a darn thing to do with exhaust systems or donuts, but the lathe is a pretty color, yes? Well....

The deal with a lathe is to make a number of VERY light cuts. Getting heavy handed here can gouge [and ruin] the slip ring. That makes junk out of the whole alternator stator. Not good. A lathe is a great tool, when you know how to use it correctly.

NOW we can talk about exhaust systems and "donuts". On a Saab/Ford V4 engine, the donut fits against the exhaust manifold gasket. I open up the exhaust PORTS to gasket size, so the donut has to be opened up to an inside diameter just a wee bit larger than the gasket. This is the lathe set-up, showing the donut mounted in a special holding tool that I built.

Once again, I make a number of light cuts until I get the inside diameter that I want. You can see a previously cut donut laying on the lathe platform [yellow painted area], right behind the lathe carriage.

You are looking at the RIGHT side of a freshly rebuilt, high performance Saab V4 engine. I'm holding the opened-up donut in my left hand, and the end of an exhaust header pipe and pipe securing flange in my right. You can see that the dount is actually larger--by quite a bit--than the header pipe. This engine will get larger diameter header pipes, part of a big bore high performance exhaust system.

KEEP YOUR COOL!

Engines with a lot more than stock horsepower [or an air conditioner, or both] need a lot more than stock COOLING! This is how I do it when my customer is serious about protecting his [expensive] high performance V4 Saab engine. This is a "take no prisoners" radiator and fan set-up. I have built a large number of systems just like this one and they really work!

The dual Flex-A-Lite 850 cfm 10" fans are shown above the modified Sonett III radiator. This set up is going into a Saab 95 wagon with a 115 bhp V4 engine, and will ultimately also have an air conditioner unit installed. Note the mount straps [at ends and center] with quarter inch mount bolts welded in place. Flex-A-Lite wants you to mount the fans to the radiator CORE, which is a very bad idea. The strap mount system I use prevents damage to the radiator core, from the weight and constant vibration of the fans.

Here the fans are set in place to check the fit on the rebuilt, re-cored radiator. I snug the fans up as close to the radiator core as I can, though nothing actually quite touches the core.

The assembled unit, ready for installation. The relays and the adjustable thermal switch will be mounted forward on the left inner fender well of the Saab 95. All the wires are shielded and clamped into place. I don't believe in doing a half-assed job on any work I do, and this is a good example.

This is the wiring layout for the dual fan set up. The thermostatic switch will turn on the primary [left] fan at the preset coolant temperature. When the air conditioner compressor turns ON, the secondary [right] fan will come on. The driver can flip a toggle switch to turn on either [or both] fans. Whenever either fan comes on, for whatever reason, the monitor light next to the override switch for that fan will light up. Your V4 engine would LOVE to have a killer cooling system like this in front of it!

YA! NOW VE GO FAST!

Well, this engine is done and ready to drop into the customer's car. It is an over-bored 1700cc Saab V4 that will produce around 115 horsepower. With the proper COOLING SYSTEM this engine will run at 6000 rpm for as long as the owner has the road and the courage to drive it that way.

This little screamer has a big 2 bbl Weber carb, a high torque cam, big valves, big ports, a light flywheel, and is fully balanced to race engine spec's. Saab-o-files will note the lack of a fan pulley on the front cover. Horsepower, guys, equals HEAT, and this sucker will have a BIG radiator with two electric fans.

From the back, you can see the light flywheel, the rebuilt, recalibrated, recurved distributor, and get a peek at the back side of the Weber carburetor. I spend a lot of time modiflying, measuring, fitting all the engine parts and carefully tightening every bolt and nut to the correct torque spec's on my engines. I build every engine as if I intended to use it in one of my own cars. And...YA SURE! I LIKE TO GO FAST!

PISTONEERING, PART 2

Here I'm putting on a connecting rod cap...AND doing it so the numbers on cap and rod are on the same side--a VERY good idea.

I have already checked each of the rod bearings for the correct clearance. Time to "button 'er up."

Being a belt and suspenders sort of guy, I add LOKTITE to the con rod nuts. Cheap insurance, see...

I'm using a recently calibrated precision "clicker" torque wrench to tighten the rod bolts to exactly the correct torque. And yup, I DO check them all twice. Note the new [orange] rear crankshaft seal. You can also just see two of the five new [brass color] water jacket expansion plugs in the block. All the reciprocating parts of this engine have been precision balanced by a local shop that has built over 5000 V8 racing engines. He thinks its FUN to do a little Ford V4!
Engines that we build in this horsepower range idle smoothly, are completely reliable and have amazing performance.

PISTONEERING, PART 1

Here is a nice set of new oversize pistons on rebuilt connecting rods. The four are balanced to 1/10 of a gram--NICE when you expect the engine to "live" at elevated RPM!

Note the new connecting rod bearings and a set of V8 rod bolts and nuts. V8??? Yeah...I get serious when I build a hot V4 engine! This one will produce about 110 horsepower for our customer. He wants to go fast! How about you?

I'm holding the number 3 piston assembly, with the piston ring compressor tool compressing the rings. Note the orange sleeves on the connecting rod bolts.These keep the bolts from damaging the crankshaft journal when the piston is tapped into place.

This is a three handed job. One to tap the piston into the bore, one to guide the rod into place on the crankshaft journal. The third to keep the ring compressor tight. Oh yeah--and the arrow on the piston crown has to face FORWARD as the piston is tapped into place with a wooden hammer handle. Piece 'a cake, mate!

Here I've rotated the engine upside down. I've just pulled one of the protective sleeves off a con rod bolt. Nice to use the right tools for the job, eh? I have 'em all! I've been rebuilding these engines for 42 years and counting. I've probably done about 300 stock, race & rally engines in that time....

OPERATING IN A VACUUM

I've never been much for "...oh, I think that's OK..." when it comes to rebuilding distributors. The engines that get my rebuilt distributors don't think much of guesswork, either. This picture shows a special tool that I built, a MightyVac and the data sheet that records exactly what was done to a typical distributor and the results of the rebuild work.

I plot out the curves--shown on the data sheet--for mechanical advance [top] and vacuum advance [bottom]. The mechanical advance curve is checked on the SUN distributor machine. I correct that curve by taking the distributor apart and changing advance springs. Testing it again on the SUN machine tells me if I managed to get the correct springs or not. This can go on....and on....I call it the perverse nature of inanimate objects....

This is the tool I built to test the advance curve of any Bosch vacuum advance unit [the silver "pot" mounted on the tool at the bottom of the photo]. I attach a MightyVac to the vacuum advance unit and start applying vacuum to the advance unit. I read the vacuum applied [on the MightyVac dial] for each degree of advance [shown on the scale at the end of the red tool. I record that on the graph on the data sheet.

Another view of the tool. The scale at the end is calibrated in degrees, taken off a precision protractor. It's a lot of screwing around to make an old, nasty, dirty, tired, worn-out distributor like new again! But the engines my distributors go into think my time was well worth it. A guy told me once he thought I operated in a vacuum. I told him I probably did but it was a precision one.

TRANSMISSION TOOL TIME

A customer brought me a Saab V4 transmission that had been "completely overhauled" by his mechanic. The "completely overhauled" trans made it 964 miles before it blew. The sucker blew on the freeway. In rush hour traffic. My very unhappy customer said his "wrench" told him that he just used "simple tools" to overhaul transmissions, and "none of that fancy stuff...."

The description of the wrench's "simple tools" sounded like the ones shown here.

This is my Saab factory transmission press. Without it, you can do more damage to a V4 transmission than you fix!

I used EVERY TOOL shown here, along with the factory press to do the overhaul, so the trans will stay together and give great service for thousands and thousands of miles.

When I overhaul a Saab V4 transmission, I do it right the first time, using precision tools and the Saab factory service manual. If your transmission needs an overhaul, make sure your mechanic has the factory press and special tools. If he doesn't, then find a mechanic who does. Don't believe a mechanic who says, "Oh, I don't need a special transmission press or any fancy tools."
Have it done right the first time, or you'll get to pay twice for a rebuild.

SAAB WIPER MOTOR: OF COURSE IT NEEDS REBUILDING!

This is a dead Lucas wiper motor, as used in 1970 and later Saab 95 and 96 cars. It ran very slowly on one speed only, and refused to self park. After close to 40 years of work, it needed some attention.

This motor was actually less grubby than most of the motors I get to rehabilitate.

Now the ancient motor is CLEAN [!] and has a new brush and spring plate installed, and the self-park mechanism has been repaired. Speaking of ancient parts, I built that Heathkit multimeter in 1956. It still works like new!

Here are all the "guts" of the Lucas motor, just before reassembly. The self-park switch is out of sight, mounted on the main motor body.

The moment of truth. The motor is mounted on the test board. Yup, it works on both speeds [at the correct rpm for each speed] and it self parks. Voila!

Looking better than new, Lord Lucas' wiper motor is ready for another 40 years of work...
When you send us your wiper motor, you can expect a quick turnaround time and reliable wipers for years of rainy days to come.