JZW Stage 5 Saab 9-3 v6 Aero

[griffin dai]

First bath of the year that snow foam stuff is nuts!!!



Ten quid well spent, nice clean bum



Cars booked in for an oil change and new coils/plugs next week, gone for Shell Helix this time, front coils are still the old 104's so new 112's going in and some fresh LFR7AiX plugs (not touching the rear bank! Looks a right faff!!)

Need to have a think about the fuel pump now, tempted to go for the AEM 50-1000 here instead of another standard pump. Then load the full stage 5 map back on plus 3bar map sensor. Hopefully fresh plugs/coils/pump will sort the throttle cut issues. Missing the oomph of the proper map

[griffin dai]

Thanks mate, bodyworks a bit tatty now though, needs a respray!

I've lost all my stage 1 clips but here's the stage 5 tune

https://youtu.be/5K_XumdrkYQ

[griffin dai]

Car's booked back in for the coils/plugs/oil change next week. New baby's put everything on hold a couple months but needs sorting now. Under pressure to sell up aswel from the missis and get something slower/practical!! No happening!

Then log some more runs and see if it's any better. Coils are a weak spot on these, some have success with the cheaper ones off eBay but I'm fitting genuine Bosch 112's all round. Plugs are coming up to 6k so best to change then all over. Hoping fresh plugs/coils will sort the throttle cut issues. Still there and it's defo new fuel pump time! Good chance it's a weak fuel pump though....

Having a bit of a mare with the the upgrade fuel pump, apparently the US v6 pump uses a different basket to the UK cars, still trying to get a solid answer on a yes/no if it'll fit, I think the US Aero shares the same basket as the TurboX so not sure if the AEM 50-1000 will even fit. Might have to go for another standard pump £££ and sensor but they're no longer available from SAAB so it'll have to be a refurbished one I've been told the stock pump is rated to 500bhp though so plenty of head room here with this turbo!

Few other bits to get done this year, do88 now sell an uprated alloy water radiator for a good price, fair by cheaper than the Courtney Sport version and it's had some decent feedback, will have to ditch this evo style Intercooler though as its 90mm thick and go for a thinner one from do88 (it's thinner but more surface area, I think it's 50mm) The VXR boys swear by the upgraded rads and it brings the coolant temp down a fair bit. I'll see how the cash flow is over summer!

One thing I'm 50/50 on is going up a couple turbo sizes, noticed the other month there's a bolt on TD04-20T with Garrett GTX style Billet wheel available now. No idea how well this performs but should spool up quicker and give more top end grunt so win win



Has anybody used KRS Turbo's before? I don't know anyone who's fitted this to their 9-3 yet so tempted to go for it, but it's a ball ache getting it mapped. Back & forward emailing logs then getting the map tweaked and could end up in the same boat as it's still not 100%

And really need to finish this audio side off!!! Should have got stuck in before the baby came!

[griffin dai]

HybridAero said:

Just seen that, that is just ludicrous! Would piss all over mine, it's quicker even that this! https://www.youtube.com/watch?v=4lFwNRl4mno

Goes alright with this 18t Not running that map at the moment though so it's not as manic but a tad quicker lower down, I'll load it back on with the 3 bar map sensor next week after the plugs & coils are changed.

Need to have a good think about that 20T upgrade above. I'm sure JZW's 20T car gets 60-90 in 3 secs dead but I think he's got tubular headers on his plus the mappings bound to be perfect! Not really sure if it's worth it here but would be nice to have a little extra oomph higher up, definitely want to concentrate on the cooling side though. Couple things I could do there like go for the external oil cooler plus do88 rad & IC then a turbo blanket. Battery's in the worst possible position too with the turbo sat right next to it! Some have moved this to the boot.....missis will have my balls though if it damaged her new shiny pram!

[griffin dai]

HybridAero said:

If you get chance, and a big enough private road, see what your time is 100-200 km/h - Mine does 11 sec I reckon you'll be well under 10 at that rate: https://www.youtube.com/watch?v=XKBcEpyvmPA - Is a 20T a direct swap for the 18T or is custom downpipe etc needed?

I think it's around 10 secs but need to time it again, only really timed/logged the 60-90's so JZW could do his thing

Yeah bolt on swap, they just rebuild the standard 15t from the Aero or Vectra VXR (same turbo) most have gone for the 19t but the 20T's meant to flow around 10% more than this. This 18t is standard fit on the Insignia VXR and I think the last 9-5 2.8 Aero. Should really have gone for the 20T but had this 18t for a cracking price and I'm pretty happy with it, it won't make the numbers the 19/20 gets though. Bit more sparkle up top would be nice but it's quick enough now under 80/90

[griffin dai]

TheAngryDog said:

is there anything bigger than the 20T? Or would it cause other issues?

A few have fitted gt30's & Holsets but afaik 20T is the biggest anyones gone with the td04?

https://sites.google.com/site/cbmotorworks/shop-an...

[griffin dai]

TheAngryDog said:

That's a fair old chunk of power. Looks like not being able to punch it below 3700 revs though?

Yours goes well from 50, just when you need it.

Yeah he's banged it into me not to go WOT under 3k as its too much stress on the rods and better to feed the power in gently then nail it after 3k. Had this issue from day one where it's hitting throttle cut and dumping some boost unles I backed off a tad then floored it again.

I've been driving with the tamer map on here the last year, dying to see how it pulls with fresh coils, new map sensor and the full stage 5 map back on here

[griffin dai]

Jimmy Recard said:

I'm looking into getting one of these (probably an automatic though) and this thread is a pretty good reference of experiences. Very helpful for me

The autos are really nice on these. Nice & cheap to tune aswel with no upgrade clutch or diff to splash out on! Really needs the diff here though as its a bit of a handful! Only issue I've heard of is the valve body's going on the autos, around a grand to fix

[griffin dai]

TheAngryDog said:

That's a bit of a bummer, I like to use the gearbox but I also like being able to go WOT below 3k. Perhaps a less aggressive map?

Yeah can be a bit annoying, I'll see how it is Tuesday He's made the map a little richer lower down and its helped a lot with the throttle cut issue, little bit quicker between 40-60 but also lost a bit of sparkle up top. Can't have it all I guess!

[griffin dai]

Jimmy Recard said:

That's good news! I realised that I haven't heard of many problems with V6 turbo Vectras with that gearbox but I haven't looked into it yet.

I know this isn't technically a Saab, but it seems like a lot of car for the money:
http://www2.autotrader.co.uk/classified/advert/201...

Basically the same cars mate, I think the Vectra VXR is the best looking of the three though, pretty rare aswel. Just had a look and the Cadillac's interiors looks very similar to the 9-3!

If your after a v6 9-3 there might a couple still for sale on UKSaabs.

They do need a remap though to get them going, pretty slow standard. If it's an auto your set on I'd take a closer look at JZW, Vtuner or Brew City Boost. Manual I'd probably go for Maptun as its more clutch friendly than the US tuners and they've got an excellent rep but Auto I'd be sticking one of the others on there

[griffin dai]

Jimmy Recard said:

Thanks for that tip. I'll check them out - the only mapper I've looked at so far is Maptun

Can't really go wrong with Maptun but here's the others to take a look at:

http://www.jzwtuning.com/product-category/saab-v6-...

http://www.vermonttuning.com/product/saab-28t-stag...

https://www.brewcityboost.com/product/brew-city-bo...

[griffin dai]

Jimmy Recard said:

Amazingly not - registered on the 20th of March 2006 and the tax applied to cars registered from the 23rd of March. It's pretty much as late as it could be and still be on the lower rate

Are you planning on upgrading the audio at all? 2003-2006 cars are seriously crap here and it's a complicated fibre optic system, pretty difficult to upgrade bar changing the speakers and adding some sound deadening. 07 onwards are miles easier to upgrade with a good double din HU and a tidy amp

I think I'd stump up the extra tax and go for a facelift car If starting again to save the hassle of what I went through, lots of swearing & bleeding knuckles!!!

[griffin dai]

Cars in the garage now getting worked on Also found some rbf600 hiding upstairs so the brake fluids getting changed same time

[griffin dai]

All done, seems to be pulling smoother from 40/50 in 3rd, can't really feel the throttle cut here but I will see how it is with the full fat map tomorrow.

Couple issues were brought up though and need sorting (to do list just got a bit longer!)

Some noise around the aux belt, could be the water pump.
Inlet manifold to server vacum pipe is snapped, just been glued back together, I'll get another this week.

[griffin dai]

Jimmy Recard said:

I've looked at the one in the link I sent, and I'm pretty sure that has the facelift sound system. At least the head unit looks like it?

I'm in two minds....I've been driving an Astra for the last 14 months as I try to save up, but I really do fancy one of these.

Looks like, I'm not clued up on the Cadillac though? Is it that or the 9-3 your after?

[griffin dai]

Full fat stage 5 map & 3 bar sensor back on. I forgot how bonkers this thing was Quaife had a good work out earlier Still has a touch of throttle cut but not as bad, new coils have made a nice difference. Pulls really hard now. Nice to have the extra oomph back higher up.

I think I'll still go for the fuel pump though so I know it's done & running right.

[griffin dai]

Could be the end of this one



Gutted ain't the word

[griffin dai]

Was hoping (praying as I've got a spare upstairs!) it was just the turbo grenading itself out the exhaust, but the amount of oil it's lost I think it's thrown a rod. Must have ran lean, few quick misfires & detonated

Felt like rocks were getting thrown through the exhaust.

I'll have a better idea tomorrow but it's not looking good

[griffin dai]

HybridAero said:

Sorry to hear Dai, is it worth/possible upgrading the rods and pistons next time if it is the rod?

Yeah feeling pretty depressed here!

Nah I won't bother mate, it needed a few quid spent on it before this happened like a new fuel pump - £500 dash gauge cluster & reprogram £250-350 and a respray £2k+ easily a few thousand but the plan was to keep it a long time so didn't mind doing these jobs over time. fking gutted!!!

I'll get an endoscope and take a look when the plugs are out and a better look around the engine as it's so tight there to see anything.
99% sure it's thrown a rod though. I'll send the pics to the garage then so they'll have a better idea and see if it's worth getting it transported to them. If it's fubard I'll strip as much as I can over the next couple months and get it to them over summer to get the box & clutch off (Quaife!)

I've been fancying a nice Vectra VXR for ages anyway! Most of the upgrade bits will fit, either that or go for a 08/09 v6 aero wagon next year and swap everything over.

It's got around 700 quids worth in bushes on there alone so I've got to try & get these off

[griffin dai]

Mikeeb said:

Why not just pick up another engine for it?

It's an option, the Vectra vxr shares the same engine, seen a few used ones from £500ish but I've done this before with a previous car and the 2nd engine was also shagged and we didn't know until it was all in and fired up. Not sure how much labours involved with fitting a new motor in these though?

A new Saab b284 is around £4.5k so that's out!