Saab B204e to Calibra SE5 - & So It Begins.....!

[Chavtastic]

Thanks for that, good info. I'll be doing the same in ditching the aircon.

Good luck

[Rangie1]

This should make somebody struggle out of his sickbed for the weekend!

Bit more body bashing and plastic removal (from the sides of the saab radiator) resulted in all 3 items fitting as pictured and with no need to move the rad from the original calibra mounting points just need to make up a couple of small brackets to locate things in place and get James to slap a coat of black paint on the bent metal and the jobs "a goodun"

Andy

[DanSE4]

Hmmmmmmm,

Can't quite tell as that's a s**t pic Andy but looks like you have the intercooler quite proud of that front impact beam (where we had it initially it was nicely below it).

Don't count your chickens until that's been held in place with cable ties & you try getting the bumper over it (as much as the bumper will need a little chopping to accommodate the intercooler, you may be pushing your luck there)!

[Rangie1]

The bumper beam isn't on there mate!!

[DanSE4]

I'd be getting those front brakes uprated sooner rather than later then!

[Miscbrah]

Well that's some super work right there! Honestly you get more done when I'm not there 'helping'!

(This is actually true. )

I'm sorry I'll have to be ditching the operation for this weekend as I've been running some crazy fever and cough/sneezing/sick/other accessories. Managed two half days at work this week, but all I'm good for is sitting here and sweating for now.

While I remember, there's another part of the loom I need to run by yourself Dan. I'll post myself a memo. The B204E low pressure turbo has no boost controller, but can become the 180-odd bhp B204L with the addition of one (and perhaps a remap though Nige is sure many come with necessary software anyway.) I've located the plug for this but it's on the loom still in the car. If necessary it runs from pins 2 and 26 on the ecu so I guess we can wire in after the fact if need be also.

Thanks again guys for all your help and all the hard work.

[Rangie1]

The bumper beam isn't on there mate!!

Which doesn't mean that I'm not planning to refit it !!
It was removed to make hitting the panel behind it easier!! that's the one you can see with the holes in it - rest assured the intercooler is in exactly the same place as it was!! (with the exception of now being the right way round )

I'd be getting those front brakes uprated sooner rather than later then!

Umm !! me too !! but that's a conversation we've already had!!

[Rangie1]

Stripped and half the bearings done!!

Hopefully the rest tomorrow

Then I just have to get it back together!!

[Miscbrah]

Stripped and half the bearings done!!

Hopefully the rest tomorrow

Then I just have to get it back together!!

Ho lee fuq. That is quite a sight! Andy I swear you're one productive guy when I'm not there! You trying to tell me something??

I was NOT expecting to see that this evening! I will shower you with fags and chicken burgers come Sunday!

Well, yeah. Erring on the side of caution a bit. Bought it from a gentleman called Vauxmaster on MIG. He recalled a vague mileage of 60-70k iirc? Wasn't certain on mileage (and not sure I remember right even) but it came from an Astra GTE along with the engine, which he'd stripped and noted as having been in incredible condition internally and externally. He'd mentioned if it were him that he'd change the main bearings and give it a little tlc. Offered his own guy to do the work if I couldn't get it done but his guy wasn't available. Got that F20 and another one in unknown condition for £50 I think it was.

Andy you f*ing leg end.

[DanSE4]

So, we may have an engine & gearbox to go in at the weekend then?

[Miscbrah]

So, we may have an engine & gearbox to go in at the weekend then?

*moist*

[DanSE4]

*moist*

Just remain at *slightly damp* for now, I've still got to sort the wiring once it's in!

[Miscbrah]

*clammy*

Yeah on that subject I have that plug thing to show you. It's not necessary to get us working though.

Not mission critical.

Please don't hit me.

EDIT - is it worth mentioning I was so excited I had a dream about gearboxes last night?

[DanSE4]

Bit more done today although a breakage during the F20 stripdown (nothing to do with me!!) means the F18 is going in for now, what James does about that in the future is up to him.

I'm not entirely happy with the clutch arrangement but again, if it gets James by for now then it'll do.

The F18 had a pot flywheel but that wont fit on the b204 as the centre hole is larger then the flange on the crankshaft end so have to use the SAAB flat flywheel which means also having to use the SAAB pressure plate. Have to use the friction plate from the F18 as the input shaft is thinner so the SAAB friction plate is no good.

The friction plate is notably smaller than the pressure plate now.



It's got to the point of use what we have to make this thing at least drive otherwise James's shopping list will be going through the roof & it'll just carry on taking longer & longer.

Clutch & gearbox all assembled now & attached to engine.



So, engine in tomorrow & then I'll leave James & Andy with the plumping while I don the soldering iron & get this loom sorted out. I chopped the 3 small connectors with plenty of wire on each from the old NE loom so got to get my head around that lot!

[Miscbrah]

Safely moist now! Lovely lovely work Dan and Andy, cheers again guys for yet again giving me your weekends!!

*cough* 'tis an F18 though.

Yeah, best of what we had to hand and still within torque specs for the B204E. HOPEFULLY it won't slip with the parts of my stage 1 clutch, but then again I'll be driving it like it's a milk float anyway. Will get an F20 in there soonest, but can handle that down south and away from people trying to have Saab swap-free Christmases!

Will be up there tomorrow with my white DI cassette!