I was able to spend some time on the Saab recently and have some updates.
Project #1 was to complete the fuel pump installation by securing the lock ring. This turned out to be a bigger PITA than expected. I could not get the ring to lock in using the hammer and chisel I used to get the old one off. I bought a specialty tool that promised to do the job, but it didn't even fit. I modified it by cutting some bits off, but it was a piece of crap. The metal was so weak that it bent, causing it to slip and snapped off one of the fuel lines. ARGH! After some time, I figured out ways to MacGyver the lines and get them reconnected, but still could not get the lock ring to seal. I was frustrated enough to walk away and sleep on it. I made the decision that trying to avoid dropping the tank was causing more effort than it was worth.
I decided to start over by ordering an OEM quality pump (the cheap one was pretty loud) and starting over again. I dropped the tank, pulled everything out, and dropped in the new tank with all lines plugged in properly instead of held together with band clamps and crossed fingers. This is fuel, it should be done right. And I used the original lock ring instead of the one that came with the pump, and it snapped right into place. I finished up by making a cover to replace the metal that was removed, it just seemed like a good idea.
Then I moved on to the brakes and shocks/struts, starting in the rear. The pads were shot, and the rotors were pretty rusted. Maybe they could have been turned, but I decided to just get an affordable set of rotors and pads and start with new stuff. They are drilled and slotted which was not necessary, but it looks cool so whatever. While back there, I swapped out the shocks with new Bilstein units. No idea how old the existing units were, but they were pretty crusty and not expensive, so why not.
Here again, I needed a female star socket in a size that I did not have, so off to Amazon to order a set. When it came time to compress the brake pistons, all of the tools that I had did not work. The Saab requires a twist and compress action, so off to Harbor Freight to buy the right tool for the job. Ugh. But at least it worked well and I had the rear end finished.
For the front, the struts didn't look bad, but I thought it best to upgrade the front with the rear, so in went matching Bilsteins. Of course, the nut on the top of the strut was not a size I had in my open-end Gear Wrench set. Argh! So I had to hold the shaft with an allen wrench and MacGyver a way to hold the nut in place. PITA, but I got it done.
Replacing the rotors was pretty straightforward, breaking some of the bolts was hard, but things were going along well. Until I got to the little set screw that holds the passenger-side rotor in place. It was frozen, and the allen key pretty quickly stripped out. Que the Dremel tool to cut a slot, then the impact driver to pop it loose. Happily, it came out and hopefully, I can find a replacement.
I do want to change the brake fluid, but I hate bleeding brakes and may leave that to a shop to deal with. They are working and after bedding the pads, I will see if I get inspired to do it.
After all that work, I moved to the engine. An oil change was pretty easy. Engine ail filter and cabin air filter were simple. Swapping the coolant was OK, but I thought the petcock was closed when I started refilling the coolant. It was not and I lost a 1/2 gal of Dexcool before I figured it out. Ugh. I also cleaned battery terminals and secured some hoses and such.
I think it is ready to go off for state inspection now, fingers crossed that it will pass. No clue about emissions, but I think it will be OK. Next up is teaching myself to buff the paint and make it shiny, that should be an experience.
