It's one of those short first start videos here
Video

But this may help anyone suffering fueling issues:

During testing it was found that the first fuel pump fitted was just not up to the job. Sometimes it worked, sometimes it didn't. The first fault with the pump was that it could not get above 2 bar and this really upset the SAAB fuel management system. So the pump was dumped in favour of an 8 bar pump. This new pump sounds like a small jet aircraft instead of the softer prop powered model aircraft sound of the old pump. Lots of rubber mountings later and things are relatively sane again in the sound department.

The next problem was found to be the fuel tank outlet being small at 8mm in diameter. This would have been fine whilst the on tick over but starting and running up hill at high RMP or at full boost meant the pump could not deliver the correct fuel pressure at 3 bar @ 1.7 L/min at around 185BHP up to aprox 3.5 bar at 2.5 L/min at aprox 400BHP.

So the fuel pipes were increased to 10mm. The outlet to the fuel pump increased to 12mm. The heavy duty pump wiring ran from the front of the car to the pump along with better earth wiring. It seems the pump is a little sensitive to volts drop when on crank, the heavier wiring solved this issue.

But I am a very happy bunny coz it runs!!!!!

First drive this weekend with a little luck and some good weather

nice work

come on peter pull your socks up mine is back on the road now with saab power if your at stoneleigh come and find me and i will take you out for a run at the end of the day if i can get my car out of the hall


great to hear it running btw. have you tested the clutch yet?

[Edited on 6/4/2011 by ashg]

I think I may have driven past your house on sunday morning! as I caught a glimpse of your bonnet in the doorway and instantly though oooh wonder if that belongs to someone on here! if it was you then it looks might awsome! (even though I did only see the bonnet up!) and if it wasnt you then please ignore me! Either way does look mighty fun!

Sounds good Peter. Need to get mine started and sounds like I might need to upgrade the fuel pipe to the pump!!

Cheers all.

Ash the clutch seems to work fine. Not been anywhere to make it hot yet and not tried any fast get goes but tiz smooth and refined to the foot much like the 93 clutch. The 95 is better than the 93 coz it bites later and is more progressive. This one bites early, which makes for longer shifts. Not much you can do with the SAAB Aero hydro clutches, they can take a hell of a pounding and handle massive torque, but kind of a fixed response even with a big bore master cylinder which is odd.

Found a water leak that I have to deal with before any more testing. And oh what a suprise it's in a pig of a place to get at

Ho hum hate Mr. Sod..........

quote:

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Originally posted by PeterV


The next problem was found to be the fuel tank outlet being small at 8mm in diameter. This would have been fine whilst the on tick over but starting and running up hill at high RMP or at full boost meant the pump could not deliver the correct fuel pressure at 3 bar @ 1.7 L/min at around 185BHP up to aprox 3.5 bar at 2.5 L/min at aprox 400BHP.

So the fuel pipes were increased to 10mm. The outlet to the fuel pump increased to 12mm. The heavy duty pump wiring ran from the front of the car to the pump along with better earth wiring. It seems the pump is a little sensitive to volts drop when on crank, the heavier wiring solved this issue.

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quote:

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Originally posted by BigFaceDave
I think I may have driven past your house on sunday morning! as I caught a glimpse of your bonnet in the doorway and instantly though oooh wonder if that belongs to someone on here! if it was you then it looks might awsome! (even though I did only see the bonnet up!) and if it wasnt you then please ignore me! Either way does look mighty fun!

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quote:

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Originally posted by jimgiblett
Hi, what fuel filter are you using? I have been hunting around for something with 10-12mm in/outlets but the best I can find is 8mm.

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Does the Suzi Rhino filter have large inlet/outlet? I am using a 300ZX filter but it only has 8mm tails. With a Bosch 044 pump I want to avoid cavitation.

Jim

quote:

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Originally posted by PeterV

quote:

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Originally posted by jimgiblett
Hi, what fuel filter are you using? I have been hunting around for something with 10-12mm in/outlets but the best I can find is 8mm.

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I'm using an inline pre-filter from Car Builder Solutions (don't get the plastic pipe fit one coz it crushes real quick). The main fillter is from an old Suzi Rhino Jeep the unit is also inline. Tried to avoid the Banjo fitting ones coz I ended up a tad tight on space.

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Yep I have 10mm pipe going in and out from the SJ140 filter. Apart from the fact it's a sealed plastic throw away part it seems perfect. There could be a "Sleaze Bay" miss lead coz I got it from there, but it sure is a 10mm in/out pipe fit and has Suzuki mould mark. I hope not coz I figured the problem was solved

Didn't realise the old SJ410 was injection. Plastic filters are normally for the carb variant and IMHO will no take to kindlt to having 3-5bar pushed through them.

- Jim

Looking good!
What weights due to the Saab engine? I ask as having been a Saab owner/tweaker since '84, I had always assumed these to be seriously heavy lumps.
Is it time to rethink that view?
Are you using OEM fuel pump and filter? You should .. these are capable to close to 400hp /massive injectors.
Certainly My 234R setup at an optimistic :-) 300 hp is nowhere near the real world limits.

Jim - Yep the filter is plastic. Is all moulded so there is no weak spots for things to go wrong. If it were screw together of clipped then there would be a problem. Made sure of that coz the old glass filter with screw in plastic 8mm pipe fittings could not take 3 bar. Leaked horribly from the threads and the pipe unions

This one has taken the output of my FSE race pump at it's max output (quoted 8 Bar but not sure of exact pressure coz my pressure gauge only goes to 4.5) without issue. Cycled paraffin through @ 4 bar for over hour without any sign of problem before my makeshift valve cried enough causing my paraffin container to inflate like a party balloon and then rupture. Still winters over the wife don’t need to heat the green houses any more…… he said hopefully

With my water leak fixed I’m now monitoring the return line from the fuel rail, keen to make sure there is no pressure build up there. So far so good but I’m still trying to trick the fuelling system into giving me some max requirement for long enough to read the gauge.

Been of a week messing with this fuel system. May have taken longer coz I’m just real nervous of stuff that goes whoof phutt ouch, but it does seem a tricky little issue.

Bare - The B204 Engine weight is 110Kg dry. I think the 2.3 205BHP Duratec is 112Kg so it’s not so bad. Engine height is more of a problem than the weight. The GM R28 gearbox is 60Kg so is a tad heavy. Expect to tweaked 320BHP before further, expensive, upgrades to aprox 400BHP. Going to kick off with around 220-240BHP with a soft tune until I understand this car a little better.