9-5 #MaintenanceMadness

Preparing for a little journey to Nordics I thought that some preventative maintenance was a smart thing to do. As the 9-5 was running very hot during normal “flat land” driving conditions i was a little reluctant to drive up in the mountains.

At least the OpenSID lets me read the real values of the engine coolant, shown as “Teng”. The indicator on the dials value 85-115 degrees Celsius as normal. So exactly in the middle of the gauge thus not precise enough.


This was already bugging me for a while so I decided to het this sorted. I also noticed that a newer style radiator was fitted, by the pre-previous owner. As this isn’t according the the specs I reverted to the default Nissens 68000A type radiator. Also I took care of the other maintenance items too. So I replaced the following;

Radiator (Nissens 68000a)
Thermostat (89 degrees Celsius)
Spark plugs (SAAB branded NGK BCPR7ES-11)
Fuel filter
Oil filter
Air intake filter
Interior filter (original SAAB part 12758726, as aftermarket didn’t fit properly)
Engine coolant
Engine oil 5W30 (Original SAAB part 93165211)


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T7suite in car cabling

After exchanging the T7 ECU for a couple of times, as i was experimenting with the T7Suite for diagnostics and tuning, i decided to pull the cable into the passengers aera to have an easy access to the P-bus. Also this enables to monitor and modify the ECU parametering more closely.

Now i can flash inside the car. After the flashing is successful just take out fuse 17 for a second and put it back in again. Now the new firmware of the ECU is activated.

Luckily we still have the snappies:

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New Sachs clutch for the 96 v4

After a engine overhaul we decided to put the old clutch back in again. Ouch, that was a big mistake! The car is still slipping on the clutch when the engine warms up.

So we have to cut the knot and install a new Sachs clutch kit. So i ordered one:

Clutch plate: Sachs 1878001537

Clutch pressure plate: Sachs 1882251101

So we removed the engine from the 96 V4 again.So i purchased the standard Sachs clutch from an internet based reseller. Quickly i learned that the friction plate has been assembled on the “wrong” side of the clutch center plate. So on the left the old “4 spring” plate and on the right the new “6 spring” plate. Here you can see that the friction-plate is mounted on the other side of the “6-plate” inner plate, making the rivets stick out more.

This is a default manufacturers production process now, so there are a few options:

– Milling 2 mm of the fly wheel. (Taking care of the problem once and for all).
– Grind the rivets of the clutch plate. (Doesn’t make the rivets stronger and needs to be done for every plate)
– Ignore the problem and wear out the clutch again in a few years. (Beunhaas solution)

I opted for the first; milling the fly wheel. Please note that the inner part is milled out for a 1.5-2 mm only that should be enough. Still the friction area still looks like a worn down mirror, is that a good thing? Don’t think so…


So i decided to also mill out the friction part of the flywheel. Only 0.1 mm has been taken off and smoothened with 0.01 mm offset to make the surface just a little less rough compared to the “anti-rivit” milling. Just take a close look and you will notice the subtle difference.


Having this problem out of the way we can hoist the engine back into it’s bay! Please note that we use a special tool to center the clutch before mouting the pressure group to the fly-wheel. Using this tool allows us to easily line up the parts for installing. Don’t forget to take the tool out again.

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96 V4… Aftermath

Yesterday we started and drove the V4 after a complete engine overhaul. The project started only 2 years ago…


And it was a great success! No leakage from the oil or coolant. Now we need to fine tune the engine. 🙂

PS. Never mind the mess…


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T7suite cabling












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