It's been over a month since my last update; for the most part, I've just been driving the SAAB around town and to and from work. I've futzed a bit with a small crack in the engine coolant expansion tank rather than throw the spare tank in, mostly out of laziness, as it drips only a few drops of coolant a trip. The vehicle continues to not burn oil or coolant, and everything more or less works properly.
I have had a few setbacks; I accidentally shorted something I shouldn't have and blew a fuse to one of two independent circuits that power the SRS control module. If it sees one of its two power sources go low or dark while the car is running, it will post a code, which expresses itself as the central warning and a SRS light on the dash. Unfortunately for me, prior to the '99 SAAB 9-3, the SRS system will not automatically reset a SRS code, even in the absence of the symptoms that caused it. For that, you need a GM Tech2 with SAAB software, and this is hideously expensive to acquire, even today. Alternately, you can pay a dealer to reset the code, but screw that. The only other option is to replace the SRS control module. I'm just going to live with the warning light, at least until a better option comes up. Annoying.
While under boost of 12-15 PSI, the silicone hose running from the intake side of the throttle body has pushed itself off the MAP sensor, causing all sorts of ECU confusion, knock/fuel cut, and misfire codes. I've replaced the hose with another that fits more snugly, hasn't happened since.
After a few warm days, I got motivated to recharge the AC system with ~22oz of r134a, hoping it had simply run low due to age. The auto-climate-control worked brilliantly that afternoon. The next day, the AC didn't work at all, and I checked the pressure-- the refrigerant had all escaped! I bought some more, this time laced with a UV-activated dye.
By the following evening, it had again lost all pressure, but using a borrowed UV flashlight, I quickly located the leak in the compressor to condenser hose, where it transitioned from soft line to hard line. The UV dye glowed fluorescent yellow. $78 later, I had a new OE fit replacement hose. Installing it, I couldn't seem to make the system hold a vacuum, but, I tried tightening both ends' bolts. I sheared one, but have since replaced it, and (knock on wood) as of this evening it seems to be a sealed system once again. I'll check tomorrow, if it is still holding the -18" Hg vacuum I gave it today, I should be good to go. The final piece of the puzzle will be a new receiver-drier, which should arrive in the mail on Monday. Then, another $30 in R134a refrigerant and maybe some ester oil to replace that which presumably was lost to leakage.
Today, I was driving out (to get the replacement bolt I mentioned) when I realized I could not shift into 5th all of a sudden. It became quickly apparent that the R gear was also no longer hittable on the stick shift. Careful not to put the car in a situation where reverse was needed, I completed the errand and returned home using 1st-4th gears. Putting it up on ramps, I quickly discovered the likely cause for my shifting woes:
That's the transmission mount, on the left/driver side of the engine/transmission assembly. To get this photo, I put that corner up on a stand, and then using a floor jack, I raised the transmission itself. Whee, though at least I'm seeing replacements for only $50.
Finally, I've ordered some new tires to put on the SAAB. Discount Tires Direct's ebay store had a special promotion: free shipping and a $100 rebate on four tires. I ordered a set of four Hankook Ventus V4 205/50R16s, $377 shipped. Should be $277 after rebate.
Since it pretty much is looking like a re-thread or helicoil or something, my task going forward should be simplified. Maybe what I should have done from the get-go rather than trying to extract the stud remnants... 1/4 drill bit, straight down. Fortunately, these studs only screw in about 3/4-1" deep.
