Saab 9-5 Aero - Hybrid Turbo and 9000 Bottom End - 350 bhp

Saab 9-5 Aero - Hybrid Turbo and 9000 Bottom End - 350 bhp

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HybridAero

Original Poster:

1,340 posts

99 months

Wednesday 30th December 2015
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Picked up this 2002 9-5 Aero manual a couple of months back for £650 with 163k miles, with a view to turning it from a shed into something a bit more purposeful.




After a tidy up, involving a proper clean inside and out, along with a wheel refurb in gunmetal/anthracite, she was looking pretty tidy and stealthy:






Following a stage 1 remap in September (takes them from 250 bhp/258 lb ft to 275 bhp/309 lb ft), there was a bottom end failure, which is a known issue on the b235r engine (the pistons in these were built to a cost, whereas on the previous 9000 they were more robust Mahle pistons). The bottom end itself on a 9000 is much stronger, and following recommendations from forum members at UKSaabs, my engine tuner Tony, and remap specialist Noobtune, I decided to rebuild with a 'hybrid' b234 bottom end.

With the following modifications, the 2.3 turbo 16 valve lump is capable of 350 bhp and 540 NM / 398 lb ft. When you take into consideration that an e39 M5 weighs 200 kg more (1520 vs 1720 kg), and has 369 lb ft (and has to rev higher to deliver that much torque), it doesn't take a genius to realise this will be a fairly swift motor once complete. Throw in the fact that front wheel drive configuration results in less power loss between crank and wheel, on the road performance will be surprisingly brutal.

I am currently in the process of running the engine in, and will be conducting first oil change at 400 miles. For the first 1000 miles I will not be revving the car above 4000 rpm, then she will be mapped.

Current build spec is as follows:

b234/b235r hybrid engine - installed and begun running-in period
td04 19t turbo with 7cm exhaust housing - Not yet installed
Less restrictive, freer flowing king cobra intake from the 2006 onwards 9-5 Aero - Not yet installed
Kinugawa turbo actuator - Not yet installed
Maptun recirculating dump valve - Not yet installed
BOSCH Green Giant 465 cc injectors - Not yet installed
Abbott Racing 3" exhaust system including downpipe - Installed and much louder, but only when you want it to be
JR air filter - Installed at the same time as the downpipe and intercooler so can't attribute any difference to this in isolation
do88 intercooler and pipework - Installed, car seems to pick up much better now at low revs
550NM Maptun clutch - Installed (bit grabby in 1st but has a purposeful feel to it)
Polybushed all round
Uprated pads (Ferodo)
Vredestein Ultrac Sessanta tyres at the front, Uniroyal Rainsport at the back
Enlarged air intake snorkel from 3.0 v6 diesel 9-5
Considering Bilstein B12 suspension (which includes revalved Bilstein B12 shocks/dampers and Eibach springs)

All-in, the project has set me back around £4k, which includes £650 for the car (which was in a state when I bought it).

Here are pics of her at present:







Edited by HybridAero on Saturday 18th February 12:27

TotalControl

8,016 posts

197 months

Wednesday 30th December 2015
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That's pretty decent. And here I am still considering a Noobtune remap on my auto 9-3 vector. I'll need to call Carl soon.

Not that fuel efficiency is at the top of your list with mods like that, but what kind of mpg can you expect after this has been done?

HybridAero

Original Poster:

1,340 posts

99 months

Wednesday 30th December 2015
quotequote all
TotalControl said:
That's pretty decent. And here I am still considering a Noobtune remap on my auto 9-3 vector. I'll need to call Carl soon.

Not that fuel efficiency is at the top of your list with mods like that, but what kind of mpg can you expect after this has been done?
Can strongly recommend Noobtune, he's a real wizard at tuning these things, mine is currently a stage 1 but after running and mapping it will be considered a stage 5.

Fuel economy is unaffected from stage 0 to stage 1, might even have improved.

In its current state (without mapping), it gets 32 mpg combined, that includes the odd blast and a mixture of A, B and M roads, running on Shell V-Power. I'm more than happy with that, considering the performance. They're also incredibly comfy. 38-40 mpg is doable on a cruise.

Edited by HybridAero on Saturday 23 January 00:09

HybridAero

Original Poster:

1,340 posts

99 months

Wednesday 30th December 2015
quotequote all
And a few more pics:

do88 intake:



Standard 15t turbo blade vs 19t:



(This is just an example - the above 19t blade is clipped, which mine won't be - Clipped is better for low down grunt but I (and my gearbox would) prefer a vicious top end and cruisy, gentler power delivery at low revs).

Few more pics of recent machine polish:






Edited by HybridAero on Saturday 18th February 12:24

poing

8,743 posts

199 months

Wednesday 30th December 2015
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That's going to surprise a few people!

Someone at work has a 93 2.8t and he says the overtaking power is just silly, it has less power than you are going to have so I can only imagine the fun. These old SAAB's, especially the fast ones, are developing a nice cult following. cool

qwertina

113 posts

197 months

Wednesday 30th December 2015
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That really floats my boat! Looks like an excellent build, bet you can't wait for the run in period to be over.

MrMoonyMan

2,582 posts

210 months

Wednesday 30th December 2015
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Coooool thumbup

Master Bean

3,517 posts

119 months

Wednesday 30th December 2015
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We'll have to race. And you need some bilstein b12 suspension gubbins.

Edited by Master Bean on Wednesday 30th December 22:27

HybridAero

Original Poster:

1,340 posts

99 months

Wednesday 30th December 2015
quotequote all
poing said:
That's going to surprise a few people!

Someone at work has a 93 2.8t and he says the overtaking power is just silly, it has less power than you are going to have so I can only imagine the fun. These old SAAB's, especially the fast ones, are developing a nice cult following. cool
Yeh the torque the 2.8 can produce even with a few light mods is unreal, 442 lb ft is achievable with just downpipe and better induction. Amazing how fast you can go not revving past 4k in these boosted Saabs.

Edited by HybridAero on Thursday 31st December 10:15

HybridAero

Original Poster:

1,340 posts

99 months

Wednesday 30th December 2015
quotequote all
qwertina said:
That really floats my boat! Looks like an excellent build, bet you can't wait for the run in period to be over.
Glad it isn't a peaky revvy car as I can't rev it! Plenty of rev variation though as I've heard that's necessary when running an engine in. I will increase max revs to 5k at 1000 miles then 6k at 1500 miles, but really on the road you never need more than 4k.

HybridAero

Original Poster:

1,340 posts

99 months

Wednesday 30th December 2015
quotequote all
Master Bean said:
We'll have to race. And you need some bilstein b12 suspension gubbins.

Edited by Master Bean on Wednesday 30th December 22:27
She is a bit floaty, much better than before with the polybushing, but plenty of room for improvement. Bilsteins definitely next on the list.

Edited by HybridAero on Wednesday 30th December 23:00

anonymous-user

53 months

Wednesday 30th December 2015
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There's another Aero on here that is around your figures.

AntiLagGC8

1,724 posts

111 months

Wednesday 30th December 2015
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I love it! This is what we would call a sleeper!

My Impreza is a modded 2.0t and makes 355bhp currently but only has 340lbft so quite a bit less than this monster! I find the parallels in the engine configuration interesting. I'm going for 450bhp this coming year which is easily achievable with a bigger turbo and remap. Still my build has cost more than double yours so far, so its great value!

I'm curious how traction will be with it being FWD and that much torque. Are you doing anything special in that area?

Also any plans for track days?

HybridAero

Original Poster:

1,340 posts

99 months

Thursday 31st December 2015
quotequote all
AntiLagGC8 said:
I love it! This is what we would call a sleeper!

My Impreza is a modded 2.0t and makes 355bhp currently but only has 340lbft so quite a bit less than this monster! I find the parallels in the engine configuration interesting. I'm going for 450bhp this coming year which is easily achievable with a bigger turbo and remap. Still my build has cost more than double yours so far, so its great value!

I'm curious how traction will be with it being FWD and that much torque. Are you doing anything special in that area?

Also any plans for track days?
That must absolutely fly! What model year is your Impreza? I went out in a friend's 3 door white Type-R import with 300 bhp and that was savage both in-gear and from a standing start.

Traction-wise I am planning on getting a Quaife LSD, but no traction issues so far; the torque is limited in 1st gear to protect the gearbox and 2nd gear is fine in the dry, which I guess is down to the tyres.

I'd love to give some trackdays a go, but would have to get a baffled sump first. Various UKSaabs members suffered engine failures due to oil surging to one side of the engine and starving the other, on long and fast sweeping bends.

Of more interest to me are VMAX type events, from a rolling start.

To give y'all some context:

Here's a 9-3 Aero with similar engine spec racing a Lamborghini Gallardo from a rolling start: https://www.youtube.com/watch?v=jzbdkP85uco

Also while I'm on YouTube, back to how I was talking about the strength of the b234 lump, here's one running a reputed 618.7 bhp: https://www.youtube.com/watch?v=GU6mKshHTpo

Edited by HybridAero on Friday 1st January 15:49

griffin dai

3,194 posts

148 months

Thursday 31st December 2015
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Nice mate beer The 19t's a great bolt on swap to get decent power out of the 2.3, nice & responsive too so should catch a few out here wink kinda wish I'd done this on my old 9000 instead of spending loads on the gt28rs & gt30 build.

Definitely look into the Quaife though. It's made a MASSIVE difference in my v6 aero.

HybridAero

Original Poster:

1,340 posts

99 months

Thursday 31st December 2015
quotequote all
griffin dai said:
Nice mate beer The 19t's a great bolt on swap to get decent power out of the 2.3, nice & responsive too so should catch a few out here wink kinda wish I'd done this on my old 9000 instead of spending loads on the gt28rs & gt30 build.

Definitely look into the Quaife though. It's made a MASSIVE difference in my v6 aero.
Thanks beer yeh the plan is to create something that is still driveable, with an OEM feel, sort of like an Aero R had Saab ever made one.

Will a Quaife diff put less stress on the gearbox? This is the weak point with these once heavily boosted.

Does the diff make any difference in day-to-day driving?

Edited by HybridAero on Thursday 31st December 10:37

griffin dai

3,194 posts

148 months

Thursday 31st December 2015
quotequote all
HybridAero said:
Thanks beer yeh the plan is to create something that is still driveable, with an OEM feel, sort of like an Aero R had Saab ever made one.

Will a Quaife diff put less stress on the gearbox? This is the weak point with these once heavily boosted.

Does the diff make any difference in day-to-day driving?

Edited by HybridAero on Thursday 31st December 10:37
Probably more strain, it really hooks up when you floor it, I kept the TCS on all month but had it switched off yesterday and you can really feel it now, just grips like crazy and pulls you around the corner where before you'd have to back right off or it'll under steer,, even driving normally you can feel it working, just tugs you that little bit tighter into the corner. TCS is staying off now smile

I've got a 6 puck paddle clutch fitted though so it does jolt/feel a little aggressive pulling off but more noticeable if the wheels aren't straight. Great mod though, expensive but worth it

HybridAero

Original Poster:

1,340 posts

99 months

Thursday 31st December 2015
quotequote all
The Spruce goose said:
There's another Aero on here that is around your figures.
Sounds good, have they done a thread on it?

wormus

14,509 posts

202 months

Thursday 31st December 2015
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Love this and I admire you spending a small fortune on a car that's worth nothing just to make it better. Should be fast and comfy for not very much outlay.

I'd be tempted to do similar to mine but it would almost certainly end in disaster. smile

outnumbered

4,067 posts

233 months

Thursday 31st December 2015
quotequote all
clap Sleeper Saabs are very cool smile



Edited by outnumbered on Friday 1st January 10:10