Fuel Pump, More Brakes, Brake Lines, and Fun!!

So it's been a while since the last time I posted about my 9-5 Brake Swap. Since then I've done quite a few things...

• Fuel Pump - Jay Racing 340LPH (found here: http://www.jayracing.com/fuel-pumps-c-2_5/jay-racing-pro-series-342-fuel-pump-pt342-340-lph-high-pressure-p-2619.html)
• Fuel Filter
• Fuel Tank Straps (cause my other ones were a casualty of Wisconsin winters)
• Front Brakes (yeah, they were stock, but they're still on the list)
• Front passengers side brake hose (this one was fun!!)

Anyways, here's some pictures and a little bit talking through what all happened. 

#1 Fuel Pump

Yes, it was fun. I dropped the tank (which some people think is nuts), removed the old straps since I ordered new ones (thank you Wisconsin for destroying the nuts and making it impossible to remove these without a sawzall -- note don't use your cut off wheel, you may need a new car/garage/etc -- sparks + gas tank = bad)

Now after the tank is out, you remove the fuel pump (consult WIS if you really need to look into how to do this) I searched Saab Central on how to take the fuel pump apart, here are some pics of that. 

Here it is all taken apart. 

Ways to not get high on gas fumes -- yes that's a standard plastic bag. 

So this was the fun part. See the fingers inside the fuel pump holder/screen -- you need to trim those down CAREFULLY with a Dremel tool to make them fit. I had a Tool Shop "rotary tool" (aka piece of shit) that I was using originally. 

Yeah, I went out and got a real Dremel tool, it made my life easy! -- The quality was probably 500x better, even using the same accessories that I got with the tool shop rotary tool.

Here is a stock pump (left) next to the modified pump (right) only way you can really tell is from the fuel line. 

#1: Use Submersible Fuel Line --  I used: http://www.oreillyauto.com/site/c/detail/GAT0/27093.oap?pt=N0887&ppt=C0222 

#2: Use injection hose clamps. 

Here's the tank with the fuel pump reinstalled. I put the tank, straps, etc back in the car at this point and hooked everything up. -- My dog turbo (lower right hand corner) was trying to help, then said screw it. lol

Next on the agenda was my fuel filter, which was old, crusty and dented. I ended up having to drill out the screw that held this in and replaced it with something more meaty, with better turning power. 

With all these fuel system projects done (except my injectors, which I need to get another intake manifold for -- story in another blog lol) I went and did the front brakes. Drivers side was going well till I found the bolt below, which isn't a factory bolt. Seems that at some point someone either broke a bolt (which imo would be impressive) or cross threaded the hole (more likely) and then found a bolt in the shop that was similar in size, tapped for that and stuffed it in. Which leaves me with the bolt below, and me worrying about my upright in the future. I guess I'll have to put that on the list of things to watch out for. At least it work for the time being.

And the fun part of the whole job. I had to flare on a new fitting on the passengers side to fix it from my adventure when I broke (more like the wheel rubbed through because this guy didn't pay attention during reassembly since I was rushing) a brake hose last year. This involved cutting the line high enough that I could then flare in a fitting, put in a union, then flare a metric fitting on the end of the other one and connect the new hose. All in all it went good. And I can say this Genuine Saab (or Goodridge) updated their stainless brake hoses, they now have a nice plastic cover.  

Then after my lovely wife, Kristie, helped me bleed the brakes (I think I'm lucky) I was able to take the car for a drive. Sans the front bumper, which needs a little more repair. 

Over the next week I have the following projects: 

• Lower the 2010 9-3 Sport Sedan - Koni Shocks, Megan Racing Springs, new Strut Mounts and bearings, and new end links. 
• The '02 Viggen Convertible gets a new thermostat, temp sensor, O2 sensors, rear motor mount, and an oil change
• The '99 LB Viggen gets the front pumper put back on, a trans fluid change and an oil change. 

Other than that I shouldn't lose my mind too much... I'm sure I forgot something anyways. lol

OG 9-3 (Base, SE, Viggen) 9-5 Aero Rear Brake Upgrade.

This past weekend I upgraded the rear brakes on my LB Viggen to the (2002-2004 9-5 Aero 300mm Vented rear discs, caliper, etc). Comparing the hardware this is a HUGE upgrade. The discs are substantially larger (both diameter, and the fact that they're vented). The caliper is a single piston caliper, which may seem like a downgrade however the dual piston caliper that's on the OG 9-3 is solid mounted where these calipers are mounted on a bracket so they are able to slide. Last but not least the pad is larger. 

You may ask how badly I needed brakes... This should answer the question. This should also answer the question why you shouldn't buy Chinese eBay pads and rotor sets.  This pad/rotor set had somewhere around 15-20k miles on it (from my understanding), I've never seen a set of pads/rotors wear this quickly. Anyways /rant.

So here's the hardware I purchased for this upgrade, everything except the lines are a necessity (there are write-ups out there on how to upgrade the calipers using stock lines). When searching out vehicles I searched for parts for a 2003 Saab 9-5 Aero. 

1. 300mm Rear Rotors

2. Rear Pads for Said Vehicle

3. Calipers (I purchased them from O'Reilly's since they have a lifetime Warranty - PN: 19-2746, 19-2747 -- they were special order and took about 5 days to show up)

4. Caliper Brackets (I got these from a junk yard with core calipers for $20 -- this saved me $150ish in core charges)

5. Brake Lines (These came from Genuine Saab. Goodridge 40005 and Goodridge RR Lines - these really came in handy since my car was rusty and the stock lines were... well I think hard to remove would have been an understatement)

This is nearly a full bolt in modification, which is excellent. The only thing that I had to modify were the dust shields to clear the calipers. 

And here are some more pictures...

New vs Old Rotor

New vs Old Caliper (and Line)

The Finished Product.