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 1973 96v4 with a modern twist

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T O P I C    R E V I E W
AnttiKPosted - 30 Nov 2020 : 18:17:22
This car was bought by my dad when it was new. It was daily driven until 2002 it was stored to a barn for 5 years. In 2007 it was taken in to use as a wedding car in my wedding. In 2010 I decided to install EFI to it and had to make full restoration to it.

The was quite a lot of work to do, but I managed to build up the car one metal piece at the time.

Starting point in 2011:


In 2014:








In the beginning of summer 2019 I was finally able to drive the car with Megasquirt 1 installed with following features:
-Peugeot 206 1.4 engine throttle body with ~39mm diameter installed to 1 barrel intake manifold
-Peugeot 306 1.6 fuel injectors 156cc
-Volvo740/Saab900 fuel filter
-Ford EDIS4 controller and edis coil pack
-QSP fuel pump in tank with 3/8" feed and return lines
-36-1 trigger wheel installed to balance axle pulley
-Volvo740 2 wire bosch idle pwm valve (same as in Saab9000?)

Here is a picture of the throttle body and fuel rails:


And engine bay:


It was fun to drive the car last summer. Better throttle response, better startup, less fuel consumption, milder exhaust fumes and so on..

In the end of last year I decided to fit 7.2 cam, sport exhaust from swedish saabclub modified with larger mufflers and Megasquirt 2 for more precise engine control and sequential injection. And the car works even better than last summer. Exhaust produces less noise inside the car, more power and less fuel consumption.



Continues..



15   L A T E S T    R E P L I E S    (Newest First)
DirtbikerPosted - 13 Sep 2023 : 21:32:54
garethdthomas500 at gmail dot com

Thanks!
AnttiKPosted - 12 Sep 2023 : 20:26:55
Hi Gareth,
Of course Just give me your email address and I will send the CAD file to you.

I installed the Saab NG9-3 Monroe gas rear shocks to 96. Those were little bit longer than the original 96 V4 rear shocks, but those fit very well to 96 by enlarging the lower bush hole to 16mm and narrowing it. I drove with those about a couple of months this summer and thought rear suspension was too hard for my purposes even though I liked the improved handling on corners and motorway speeds. Then I decided to buy adjustable AVO rear shocks and now the car suspension feels even better
DirtbikerPosted - 12 Sep 2023 : 07:20:29
Hi Antiik,
Project is looking great!
Would you be happy to share the CAD file for your flywheel?
Thanks
Gareth
DerekPosted - 01 May 2023 : 16:54:45
Duh! I was forgetting it's F.I.
AnttiKPosted - 01 May 2023 : 15:58:41
Fuel injectors are located in lower part of the manifold so there should be no fuel in the plenum, but probably there will be some fuel fumes in plenum anyway.
DerekPosted - 01 May 2023 : 12:18:36
Good work. I suspect that modern fuel will remove the paint inside the box but it will be gradual and the engine will digest it over time.
AnttiKPosted - 01 May 2023 : 08:06:05
Thanks, I also think that now the total setup is better in every way than the previous version of upper manifold. Next step for the engine will be the cylinder heads with dual exhaust ports, but first I am going to repair at least the driver side door and the probably the passenger side. Already made one repair piece for door yesterday.



The intake runners are rounded inside the plenum. I fabricated the runners first and in that way was able to smoothen the inside of the runners properly. After that the runners were welded to plenum.
VedrivePosted - 30 Apr 2023 : 17:19:46
Really like the total set up and looks AnttiK, compliments.
//Bonne
mellePosted - 30 Apr 2023 : 16:48:56
That looks even more awesome than last time. The grey paint on the plenum that matches the heater unit visually ties it all together, very nice work.

www.saabv4.com
DerekPosted - 30 Apr 2023 : 13:18:49
Is there anything in the way of baffling inside the box or do the pipes just fit flush with the sides? With carbs you might consider rounded flanges to help with gas flow.
It all looks very smart.
AnttiKPosted - 30 Apr 2023 : 09:06:37
quote:
Originally posted by Zagato
Incredible work you have done here... very well done.



Thanks!

Now the intake manifold is ready for summer. Did some testing with 3rd gear and it looks like small improvement in acceleration between 3000-5000RPM and acceleration between 5000-6000RPM is little bit slower. Also it feels like 4th gear has more torque when accelerating from 90km/h.

Another noticeable effect is that in 105km/h speed engine intake manifold has about 10% more vacuum than before. So there is possibility for lower fuel consumption

I changed the throttle body to new MG Rover 52mm Dellorto. Now the throttle returns to exactly the same position when releasing throttle.



mellePosted - 23 Feb 2023 : 20:15:29
Bloody hell Chris, where have you been hiding? Good to see you back!

www.saabv4.com
ZagatoPosted - 23 Feb 2023 : 15:36:17
Incredible work you have done here... very well done.


AnttiKPosted - 21 Feb 2023 : 10:08:01
I think the location of the upper manifold is now better than in previous version. Now the plenum is located closer to the cabin and there is more distance to the bonnet, therefore I was able to install the plenum in higher level. So the accessibility to different components below the plenum is now improved.

I have had problems with oscillating idle and tried many times to make it stable. Looks like new manifold did not correct it, but then I changed idle tuning so that idle air valve has constant value at idle and idle RPM tuning is made by changing ignition timing. According to the first tests idle is now very stable and the response time to RPM when changing the ignition timing is far quicker than changing air flow.
AnttiKPosted - 19 Feb 2023 : 19:58:22
Thanks guys! After watching youtube videos with dyno tests with different length runners in same engine and reading the theory I was certain that I will at least test longer runners.

For example the Holley sky-ram, where the idea to make one came from april fools joke. Ridiculously long runners, but massive improvement in low revs. So I thought I am going to make something between those runner lengths in the video and I need only get bit over 6000 revs in my engine.
https://www.youtube.com/watch?v=y9IERetMoL4&t=241s

Also the SF-750 flow bench manual has good theory and equations based on experience. Page 77
https://superflow.com/wp-content/themes/SuperFlow2020/downloads/SF-750_Manual.pdf

Mainly I have running the engine at idle and little between 2000-3000. First impression was that engine seems to be running with less noise and vibrations from engine, so the engine seems to be running even happier/smoother than before, but lets see on the road in april what is the reality. I am going to do some acceleration tests with 3rd gear from 1500 to 6000 RPM and megasquirt logs show the elapsed time.

Material cost for this manifold modification was about 50€. And few hours of welding and grinding. Also I noticed that 1. and 4. cylinders have about 1cm longer runners inside the cylinder head and I compensated the length in higher part of the manifold.

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