JZW Stage 5 Saab 9-3 v6 Aero

[griffin dai]

I've been holding off adding the current car here but it's almost finished, so here goes!

Following on from this thread:
http://www.pistonheads.com/gassing/topic.asp?h=0&a...

I sold that 9-3 back in 2013 and bough this 9-3 Aero, so have had it just over 2 years now. Bought completely standard:



Didn't stay standard for long though! First mod was a JZW stage 1 remap taking it from 250bhp & 250ft/lbs to around 300bhp & 400ft/lbs depending what maps loaded. Some have seen 320ish & 430ish but haven't dynod mine so can't confirm.



Basically you get 3 stage 1 maps here to load, regular, agressive and revised. Just stuck with the aggressive map for the 2 years! Clutch slipped straight ways here and it's been slipping ever since! (New one coming in a week or so)

Then cooked the brakes the next day playing with a E46 M3!!! So had a mild upgrade to Mtec discs, yellow stuff pads, HEL lines & RBF600 fluid (massive difference in breaking and didn't break the bank either) kept these fitted for 2 years but swapped the rears for blue stuff NDX pads and have just upgraded the fronts again to vectra vxr 345's with DS2500 pads (really good!!)

A few weeks after getting the car I snagged some used Bilsten B8's, Eibach springs and a Maptun Strut brace from a forum member. Made a nice improvement over standard plus my front spring snapped on the way to the MOT station (couldn't make it up!!!!!) luckily these were hidden in the boot from the missis so did the full suspension swap before the mot!

The cars been basically left the same for 2 years bar tearing the interior out and deadening everywhere for the audio upgrade (these need it....it's crap)

The pan here was to build a little torque monster with either a TD04 upgrade to billet 19t or 20T (just larger compressor wheel over the 15t) but costs were mounting plus finding a clutch to hold the torque (around 530ft/lbs on the 19t....20T flows around 10% more) so decided to go for a 18t instead from the Insignia VXR (straight swap)



Bigger injectors needed here really as the standard ones are at max duty cycle around 350-360 bhp (JZW stage 3+ tune) and got really lucky, found a set of new 550's for sale around half price so snapped these up sharpish!



Then needed a bigger Intercooler so went for a Chinese EBay Evo IC, 90mm core



Fitted here but will probably have it moved to the front of the AC for better cooling



Then got lucky again and had a 3" Doiwnpipe off another forum member, virtually a straight fit as its off a Vectra VXR (same engine/box/clutch) but couldn't get it to seal properly as it fouled the block.




So now everything was ready to fit for a stage 5 tune.

Also had it fully pollybushed with Black power flex bushes bar the yellow engine mounts, 3 point subprime brace and a freshen up with new suspension parts and thick RnD drop links.

The car was with the garage for around a fortnight getting everything fitted, then dropped to Prospeed for a new exhaust. That vxr down pipe came in handy, it wouldn't seal at the turbo flange but got cut and welded to a new 3" DP. So now has a 3" turbo back system, sports cat (coming off for a 3" decaf next week) 3" resonator and rear muffler delete, so there's no back boxes just straight pipes out the back with quad tail pipes





Quick vid of the exhaust, hunting at idles normal here as its had the stage 5 re-flash and the ECU takes around 100 miles to fully adapt. Can't rev it here as it'll piss the neighbours off again Drones a bit at 2k but males a lovely noise when the v6 is on song. Pops & bangs like crazy on the overrun love it!!

http://youtu.be/gSqpr_sjtQ4

That's about as far as I've gone here. Next jobs a wheel alignment later this week, then it's off back in for the clutch upgrade. CG Motorsprt are making a limited run of their 666 & 777 kits for these, I'm going for the 777 kit which is a single mass flywheel conversion with 6 puck paddle clutch (needs to hold around 500ft/lbs here and maybe more if I do upgrade turbos again next year to the 20T or maybe a td04/GT30 hybrid)

Also have a Quaife ATB LSD here to fit (it needs it!!!)



And a Short Shifter ready to fit from BPS, fitting sometime next week

[LordGrover]

Kinell.

Sounds epic - you're a braver man than me.

[griffin dai]

Forgot to add (bloody iPad!!!)

BSR Optiflow kit fitted a few days after I bought it, zero increase in oomph but gives big smiles!



Vid with it fitted but standard exhaust

http://youtu.be/UQl2N1hhUyk

Also fitted some nicer mesh grills



345's fitted (cars filthy at the moment with all the work bee done to it...needs a good bath!)



Another exhaust clip with the first map, Rev 3 map currently loaded, bit easier on the clutch! Rev 2's going on next month when the clutch/diff are fitted (bonkers map that one!!!)

http://youtu.be/hEE017N02Js

Probably more I've missed out on here but will add later

[griffin dai]

LordGrover said:

Kinell.

Sounds epic - you're a braver man than me.

It's a bit of a handful now! Dying to see how it goes when the clutch's done, can't really get my foot down with it slipping & really needs that diff on there at stage 5.

[ALBA MELV]

Jesus!

Bet that surprises a few.

[griffin dai]

ALBA MELV said:

Jesus!

Bet that surprises a few.

Haven't tried yet mate, can't really with the clutch clinging on to life and my wheel alignments all over the place after all the suspension work last week. Should go well with the diff fitted though.

Tbf JZW Stage 1 is quick enough on these, you get a massive chunk of extra torque on his maps over standard, completely transforms the car (they're a bit tame standard and really need a remap to get them going)

The plan was to go straight for the billet 20T on a spare td04 but costs were mounting, and it's been a mare finding a clutch that'll hold the 20T's torque.

I'm still in the dark here really with what it'll be putting out, stage 4 is around 475ft/lbs and stage 5 (19t) is around 530 so it's somewhere in between, just hope the 777 clutch kit holds ok. It's rated at 150% over standard on their site so should hold around 620ft/lbs but I'm not anywhere near that. I think it'll be ok.....

Probably end up going for the 20T next year after I've got used to this one. I'll see how it goes

[-crookedtail-]

Love it griffin dai, actually you helped in my decision to get my albeit standard one. Had it 10 months and it hasn't missed a beat, I'm always tempted by a JZW map although maybe just the stage one will do for me!

[griffin dai]

-crookedtail- said:

Love it griffin dai, actually you helped in my decision to get my albeit standard one. Had it 10 months and it hasn't missed a beat, I'm always tempted by a JZW map although maybe just the stage one will do for me!

Cool!

Stage 1 is definitely plenty mate, just the clutch to think about depending on your mileage. That CG clutch run I've organised is pretty cheap though, works out £650 plus post for UKS members, their 666 kit will be fine for stage 1. Pretty cheap considering a standard DMF is close to 500 quid alone!

[griffin dai]

Forgot to add! Had the windows tinted



Then added some heko wind deflectors



And here's a better pic of the back with the new exhaust fitted....& my PH sticker

[Shadow R1]

I have been following this one over on the Saab forum.
Loads of work gone into it, usually to destroy that poor clutch even faster.

The audio stuff goes far beyond just the sound deadening, head unit, amps, speakers sets, done in a tasteful way.

[griffin dai]

Shadow R1 said:

I have been following this one over on the Saab forum.
Loads of work gone into it, usually to destroy that poor clutch even faster.

The audio stuff goes far beyond just the sound deadening, head unit, amps, speakers sets, done in a tasteful way.

Music side should be all done around Novemeber mate. Still can't believe I spent ages looking for decent speakers then bought ones that have no chance of fitting with out a ton of work

Doors should be easy to get done but the dash mids Looks like either the entire dash has to come out or windscreen!!

I might just keep these tucked away for another car and get some 3 way focals!

[Glassman]

griffin dai said:

Forgot to add! Had the windows tinted

Tug, surely.

[Chris x]

at the quad exhausts and tints.

Love the rest, bet it surprises a few people!

[griffin dai]

Glassman said:

Tug, surely.

I think I've been lucky so far mate, 2 years and not even a 2nd glance. I have been thinking of going a shade lighter up front though.

[griffin dai]

Chris x said:

at the quad exhausts and tints.

Love the rest, bet it surprises a few people!

Bit marmite these quads & tints

Almost had some 6x4 ovals as I didn't fancy having the bumper cut, so had a nice surprise when I saw these He did a good job of it. One pipe sticks it's slightly more than the other to follow the bumper line.

[Pebbles167]

Always liked these, engine sounds immense!

A guy i know has one and says his has 360bhp with nothing but a larger intercooler and a map. Possible?

[griffin dai]

Pebbles167 said:

Always liked these, engine sounds immense!

A guy i know has one and says his has 360bhp with nothing but a larger intercooler and a map. Possible?

He'll also need a 3" Downpipe mate (or just gut his pre cat out and save a few quid!) JZW stage 3+ gets around 360bhp & 450-460ft/lbs. (3"DP, bigger IC and stage 3+ map) Vtuner also gets a decent whack from their remaps, Euro tuners (Maptun/Hirsch) have similar power but tend to run less torque to keep the clutch happy.

Same engine & box as the Vectra VXR but I don't think many have gone the JZW route and stuck with the VX tuners.

360's right at the max you can safely run on standard injectors though.

[Heaveho]

Just a word based on experience, those ebay intercoolers are " usually " poor, in my experience. If it's made for an Evo, chances are it doesn't perform anything like as well as the Evo factory intercooler, which is known to be very good, and not worth changing below 450 brake. The temps on the ebay one I had were appalling, and I binned it and bought an ETS, not cheap, but keeps temps low. The HDI 2 ones are also very good. I measure temps, it's worth paying attention to.

Love the car, btw.

[griffin dai]

Heaveho said:

Just a word based on experience, those ebay intercoolers are " usually " poor, in my experience. If it's made for an Evo, chances are it doesn't perform anything like as well as the Evo factory intercooler, which is known to be very good, and not worth changing below 450 brake. The temps on the ebay one I had were appalling, and I binned it and bought an ETS, not cheap, but keeps temps low. The HDI 2 ones are also very good. I measure temps, it's worth paying attention to.

Love the car, btw.

Thanks mate. I'll suck it & see with this one, the last eBay IC was great though, miles better than the £650 one I took off, that was the 76x300x450 core on my old 9000.

http://www.pistonheads.com/gassing/topic.asp?h=...

Lots of the 9-3 guys have the Evo one fitted as its almost a drop in fit (not on mine though as its been placed behind the AC instead of in front) but most are around 300 - 350hp give or take.

[griffin dai]

Just had a wheel alignment done after all the suspension upgrades. Jesus!!!!! A hell of a difference!! Really surprised how much better it corners. Both front & rear were well out, he's also sorted the camber out and it's driving nice now.

I've never had a wheel alignment done before so didn't know what to expect, the cars never handled this well, was decent enough befor the bushes were fitted then came back all over the place so needed doing, loads more confidence in the corners now. Dying to see what the Quaife can do

It's got to go back in next month after the clutch upgrade, subframes got to come off again so I'll book it back in for the alignment plus adding the Eibach camber bolts so he can set it up a little better. £60 well spent!