16 Valve B202 engine rebuild 2011

[aero84]

Hi

Awesome job, looks great.

What kind of enginecontrol system are you using? Trionic 5 or an aftermarket EFI..

[squaab99t]

Dennis, how come you didn't use that awesome load leveler on the engine hoist we got a few weeks back?

I still had the climbing webbing still rigged up to the head. When I pulled the engine out it was balanced pretty well, so I reused it. Maybe next time. That webbing I got from Gregg is due for retirement. 10 years old with oil in places is not good gamble.

[squaab99t]

Hi

Awesome job, looks great.

What kind of enginecontrol system are you using? Trionic 5 or an aftermarket EFI..

Aftermarket; EMS 8860 out of Australia.


Link to my install album.
http://www.saabphotos.com/gallery/8860-ECU?page=1
It was about mid range on cost and capability at the time I bought it. 2002?
It was a great way to get started. The thing was its maps were blank. They had 4 cylinder base maps, but not Saab specific. Many many hours road and dyno tuning.

[squaab99t]

All done Final assembly of the I/C plumbing, body trim, and wheels last night. This evening my wife helped me slip on the hood.

Went to a drive to get fresh fuel and pick up dinner at a favorite Chinese hole in the wall restaurant. Drove fantastic, and no leaks or funny noises. The GT3071 felt like it spooled up fast and gave a lot of air even set at 7psi. Tried varying the RPM and engine load.

[turbo stephan]

Sweet... Take your time and break in the new rings. I can't wait to hear more about the new driving characteristics with the GT3071. It's on the list for the 99 EMS

Mhhhh.... good dumplings after the first drive. What a treat...

[squaab99t]

Sweet... Take your time and break in the new rings. I can't wait to hear more about the new driving characteristics with the GT3071. It's on the list for the 99 EMS

Mhhhh.... good dumplings after the first drive. What a treat...

GT3071R... skipping right to the good stuff. We will have to plan that out because of its size and plumbing requirements. Remember the 99 is much shorter, but the fan is in the front, but where is your intercooler? It will be a nice exercise in packaging.

I figured city driving and running for take out is a great way to test and break in the engine.

Yes, the Fu Man Dumpling house rocks. I have a garlic breath hangover this morning...

[KPAero]

Really nice work, everything looks so nice and clean. Can't wait to hear how she runs after engine break in is complete!

[turbo stephan]

GT3071R... skipping right to the good stuff. We will have to plan that out because of its size and plumbing requirements. Remember the 99 is much shorter, but the fan is in the front, but where is your intercooler? It will be a nice exercise in packaging.

I figured city driving and running for take out is a great way to test and break in the engine.

Yes, the Fu Man Dumpling house rocks. I have a garlic breath hangover this morning...

I think I have seen somebody using a GT3071R in a 99 with B202 turbo somewhere, but I can't exactly remember where. The intercooler is going to be tricky but instead of using a FMIC I was thinking of an intercooler that runs with water. I heard they are much more efficient than the FMICs and you don't have that much lag either. I'll do research on that though before we start.

I almost forgot about that good garlic bread... Time to come down soon...

[SwedeSport]

You could always do a top mount intercooler. It worked great on my buddies sub 10 second 2.2 Shelby Charger.

I inherited the scoop after he blew the motor to smithereens for the last time... those Diamond Star 4 bangers made some power, but the top ends couldnt take it.

[squaab99t]

Really nice work, everything looks so nice and clean. Can't wait to hear how she runs after engine break in is complete!

Thanks, luckily I have the time, personality, and resources to do it that way. It is also my hobby. This rebuild went really well. I'm reading a thread on SC were his rebuild not so well, engine vibration, lifters clicking, sticky trans bearings...
I still need to run it thru emissions testing and buy tabs. This is where it all started, when it did not pass emissions.

[99sven]

What are emission tests??

[squaab99t]

Wow Dennis, the motor is beautiful! For some reason the direct to plug coil packs (and sweet mounting bracket!) are the final bits that push it over the top and say "THIS THING MEANS BUSINESS!"

The coil on plug was a fun project. I really wanted to ditch the coil, wires, cap and rotor plus get a hotter spark. I originally wanted to try to drive the Saab DIC, but my ECU was only a trigger igniter so I switch to the LS2 coils. In the end I was really happy with the results and no Saab DIC baggage.
FYI link on SC to the project
http://www.saabcentral.com/forums/showt ... =coil+plug

Now that SC sold out, from now on I'll post all my good shit here...

[squaab99t]

What are emission tests??

Did some studying for the tests today. Tuned the ECU to run nice and lean where they do the testing, idle and cruise. Passed with flying colors. About a 1/3 of the limits on HC and almost non existent CO% . I'm sure it was pumping out the NOX running lean, but that is not measured. In certain areas of Washington state we have do emissions testing every 2 years until the car is 25 years old, so one more round for this car.

[squaab99t]

Wow Dennis, the motor is beautiful! For some reason the direct to plug coil packs (and sweet mounting bracket!) are the final bits that push it over the top and say "THIS THING MEANS BUSINESS!"

Update to the ignition. I was never very happy with the MSD LS2 truck coil aftermarket replacements. I had to close up the gap to .024 to prevent the spark from being blown out at 18 psi. A small gap creates hard starting and poor idle.
When we went to SEMA this year we talked to a standalone ECU manufacture and he suggested we use the LS9 smart coil found on the supercharged Corvettes. He called it the "flame thrower". With this info, off to the Chevy display to find the part number.
Long story short. Got some coils and did some testing to see if driveablity and start up improved. What a difference, smoother and more responsive.
After I did my mockup in aluminum, it was time to make a final part for perm install.

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I have some surplus titanium .090 sheet that I have been dying to use on a project.
Heavy card stock is great for laying out the features and it also reflects how whimpy or stiff the structure will be.

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End product in Ti. It was a bitch to get good argon coverage. Even with a jumbo gas lens I had to back plate it to keep the gas in the weld area. The purple or bluing means oxidation. Shiney silver or the straw color is what you want.

[squaab99t]

Final installation.

I used OEM Delphi HT leads. 7mm wire, silicone boots and wire. 8 pieces for $39. Got to love economics. Quite a few more LSx engines than Saabs with distributers.

I will see how the single attach point per coil works out. Coils seems stiff enough and the way the coils sits against the bracket it does not rotate about the fastener.
If it drys up tomorrow, I'll give it a high boost run and see if it jumps a .036" gap without blowing out the spark.