Saab 9-5 Aero - Hybrid Turbo and 9000 Bottom End - 350 bhp
Discussion
Project is finally complete; we have now activated Defcon, I mean Stage, 5.
It has been mapped for 540NM, and anywhere between 340 and 350 bhp (estimates, rolling road soon).
The power curve feels very AMG-esque, hitting peak torque of 398 lb ft (estimated) from low down and punching hard all the way to 6200 rpm with growing ferocity. It could produce more torque, according to Noobtune, but to give the gearbox and FWD a chance, that should be plenty.
Rolling road session is definitely on the cards. Does PistonHeads have any rolling road events coming up?
2nd gear is now useless in all but perfect conditions, but in 3rd gear it really takes you by surprise; properly savage, compared to what I'm used to, at least.
Picked up the car from mechanics on Saturday, and first impressions are that the Bilstein B12s and new suspension top mounts have completely transformed the handling. Where it was a wallowy boat before, it now handles very much like my dad's old mk 5 golf GTI, a proper B road weapon.
Anyone looking for some hardcore work on their Saab such as engine rebuilds, turbo installation, look no further than Tony Wallis, ex (Aussie) Saab mechanic based in Doncaster - http://www.saabrepairsdoncaster.co.uk
The stance has been improved immeasurably. I also had the wheel alignment done.
New suspension top mounts:
19t-7cm turbo and Kinugawa actuator installed:
New all-alloy race radiator sits nicely with the do88 intercooler:
Green Giant 465 cc/min injector installation and mapping carried out by the legendary Karl of Noobtune fame (strongly recommended - http://noobtune.co.uk/ ).
Since mapping has been carried out, fuel economy has actually improved! With the odd full throttle in 3rd/4th, and a 130 mile cruise down south via the M1, I averaged 35 mpg. Not a bad combination of power and economy for a 14 year old car!
It has been mapped for 540NM, and anywhere between 340 and 350 bhp (estimates, rolling road soon).
The power curve feels very AMG-esque, hitting peak torque of 398 lb ft (estimated) from low down and punching hard all the way to 6200 rpm with growing ferocity. It could produce more torque, according to Noobtune, but to give the gearbox and FWD a chance, that should be plenty.
Rolling road session is definitely on the cards. Does PistonHeads have any rolling road events coming up?
2nd gear is now useless in all but perfect conditions, but in 3rd gear it really takes you by surprise; properly savage, compared to what I'm used to, at least.
Picked up the car from mechanics on Saturday, and first impressions are that the Bilstein B12s and new suspension top mounts have completely transformed the handling. Where it was a wallowy boat before, it now handles very much like my dad's old mk 5 golf GTI, a proper B road weapon.
Anyone looking for some hardcore work on their Saab such as engine rebuilds, turbo installation, look no further than Tony Wallis, ex (Aussie) Saab mechanic based in Doncaster - http://www.saabrepairsdoncaster.co.uk
The stance has been improved immeasurably. I also had the wheel alignment done.
New suspension top mounts:
19t-7cm turbo and Kinugawa actuator installed:
New all-alloy race radiator sits nicely with the do88 intercooler:
Green Giant 465 cc/min injector installation and mapping carried out by the legendary Karl of Noobtune fame (strongly recommended - http://noobtune.co.uk/ ).
Since mapping has been carried out, fuel economy has actually improved! With the odd full throttle in 3rd/4th, and a 130 mile cruise down south via the M1, I averaged 35 mpg. Not a bad combination of power and economy for a 14 year old car!
Edited by HybridAero on Saturday 18th February 12:37
Not sure how I missed this thread! Top work!
With the 19T turbo, did you buy a complete turbo or did you upgrade your existing one? I'm contemplating fitting a 19T of some sort to my 9-3 (will be sticking to 300bhp though as it's cost enough without breaking open an engine to make it stronger!) but I'm not sure which road to go, ie Kinugawa or fit the bigger compressor.
With the 19T turbo, did you buy a complete turbo or did you upgrade your existing one? I'm contemplating fitting a 19T of some sort to my 9-3 (will be sticking to 300bhp though as it's cost enough without breaking open an engine to make it stronger!) but I'm not sure which road to go, ie Kinugawa or fit the bigger compressor.
Lugy said:
Not sure how I missed this thread! Top work!
With the 19T turbo, did you buy a complete turbo or did you upgrade your existing one? I'm contemplating fitting a 19T of some sort to my 9-3 (will be sticking to 300bhp though as it's cost enough without breaking open an engine to make it stronger!) but I'm not sure which road to go, ie Kinugawa or fit the bigger compressor.
I bought the 19t in parts off eBay, such as the 7cm exhaust housing. CHRA blade was balanced by Tony my mechanic, so the 19t is a bit of a Frankenstein. You will need the bigger compressor wheel AND the Kinugawa, but you should confirm with Noobtune which actuator spring you need. I used a 0.8 spring, which refers to base boost. The Kinugawa helps control the 19t.With the 19T turbo, did you buy a complete turbo or did you upgrade your existing one? I'm contemplating fitting a 19T of some sort to my 9-3 (will be sticking to 300bhp though as it's cost enough without breaking open an engine to make it stronger!) but I'm not sure which road to go, ie Kinugawa or fit the bigger compressor.
Edited by HybridAero on Saturday 12th March 00:06
griffin dai said:
Nice 
Quaife next then
Where did you get the rad from? That's the next big purchase for mine
Hi mate the rad was off eBay from a guy in Leicester:Quaife next then
Where did you get the rad from? That's the next big purchase for mine
http://www.ebay.co.uk/itm/SAAB-9-5-2-0L-2-3L-B205-...
Wouldn't mind a straight cut gearbox but ran out of funds! LSD would be very handy. Need to check your thread when I get 5 minutes!
Bigphatcgar said:
Looking good , have you seen the custom Albert made exhaust manifolds
Get out their destroying bmw egos.......
Yeh the Albert downpipes look fantastic, but I went for a full 3" Abbott Racing system. It's pretty noisy!Get out their destroying bmw egos.......
Have surprised a few 3.0 diesel Audis and BMWs, they are not amused!
markirl said:
How have you found the ride quality since changing to the B12s?
Absolutely phenomenal. The old suspension was knackered and it honestly makes the car feel brand new. Worth replacing the top mounts and bearings whilst you're at it. It is a little stiffer but it's completely different. It's weird, it rides how I'd imagine an AMG would ride, definitely worth the investment. Order from Germany though and save yourself over 100 quid.What car did you have previously? I've just posted a "what car" thread on the main forum but the thing that has always stopped me from buying a 9-5 was the handling and I thought if you fixed the handling you destroyed the ride! Interesting to hear the B12 rides well, I imagine it's pretty firm though? Our area is riddled with bad potholes 
markirl said:
What car did you have previously? I've just posted a "what car" thread on the main forum but the thing that has always stopped me from buying a 9-5 was the handling and I thought if you fixed the handling you destroyed the ride! Interesting to hear the B12 rides well, I imagine it's pretty firm though? Our area is riddled with bad potholes
Had an LS400, 2 Focuses, Saxo VTS, Ford Econovan and Mitsubishi Magna amongst a few other sheds, I'd say it's just as good over potholes, and only sits about 10 mm lower. All can say is you'll be mightily impressed with the ride quality of the B12s, it rides like a (sporty) luxury car.https://youtu.be/1i2SwE9m-R4
Edited by HybridAero on Thursday 10th March 20:40
Lugy said:
Not sure how I missed this thread! Top work!
With the 19T turbo, did you buy a complete turbo or did you upgrade your existing one? I'm contemplating fitting a 19T of some sort to my 9-3 (will be sticking to 300bhp though as it's cost enough without breaking open an engine to make it stronger!) but I'm not sure which road to go, ie Kinugawa or fit the bigger compressor.
Hi mate, just found the listings on eBay, for your perusal:With the 19T turbo, did you buy a complete turbo or did you upgrade your existing one? I'm contemplating fitting a 19T of some sort to my 9-3 (will be sticking to 300bhp though as it's cost enough without breaking open an engine to make it stronger!) but I'm not sure which road to go, ie Kinugawa or fit the bigger compressor.
King cobra-ready compressor housing wheel:
http://www.ebay.co.uk/itm/SAAB-9-3-9-5-AERO-TD04-1...
7cm Exhaust Housing:
http://www.ebay.com/itm/Mitsubishi-TD04HL-7cm-Turb...
Edited by HybridAero on Saturday 18th February 12:37
Just received this 'air request' graph off Karl at Noobtune, which refers AFAIK the amount of torque and (as a result bhp) being requested with the t7 mapping (t7suite); as you can see it's pretty linear:
Pearl of wisdom from Noobtune:
The torque in the midrange should be accurate from request to road, it's only the horsepower that will be inaccurate simply because it's a calculation and will (in reality) depend on flow, housing, actuator strength, exhaust, intake restriction etc etc.
Pearl of wisdom from Noobtune:
The torque in the midrange should be accurate from request to road, it's only the horsepower that will be inaccurate simply because it's a calculation and will (in reality) depend on flow, housing, actuator strength, exhaust, intake restriction etc etc.
Edited by HybridAero on Saturday 18th February 12:38
After a quick scrub yesterday (while the weather was nice), realised it could do with some work on the front and rear bumpers, new sharkfin antenna on the roof, and a wheel refurb. Not sure whether to go for silver wheel refurb and new centre caps, or gunmetal and black centre caps.
Interior is very smart for the age and wants for nothing; the leather seems to be incredibly hard-wearing. Needs a new head unit though, thinking of an Alpine. Can anyone recommend a decent single or double-DIN head unit, with Bluetooth?
Interior is very smart for the age and wants for nothing; the leather seems to be incredibly hard-wearing. Needs a new head unit though, thinking of an Alpine. Can anyone recommend a decent single or double-DIN head unit, with Bluetooth?
Edited by HybridAero on Monday 14th March 13:48
great work love it, I am a 9-5 aero owner with a remap and some hirsch bits, I really want a aero auto wagon with Lpg, currently on the lookout.
Have you seen these guys? https://www.facebook.com/shellfant best aftermarket dash idea I have seen for the Saab.
I am looking at the android headunits from these guys, http://www.eonon.co.uk/ seem to get good reviews and don't look too chinese/ebay style!
Good to hear about Tony Wallis spoke to him a couple of times and he would be who I would use for any engine rebuild work.
Have you seen these guys? https://www.facebook.com/shellfant best aftermarket dash idea I have seen for the Saab.
I am looking at the android headunits from these guys, http://www.eonon.co.uk/ seem to get good reviews and don't look too chinese/ebay style!
Good to hear about Tony Wallis spoke to him a couple of times and he would be who I would use for any engine rebuild work.
HybridAero said:
Just received this 'air request' graph off Karl at Noobtune, which refers AFAIK the amount of torque and (as a result bhp) being requested with the t7 mapping (t7suite). So I was wrong about hitting peak torque at 1600 rpm, but as you can see it's pretty linear:
Pearl of wisdom from Noobtune:
The torque in the midrange should be accurate from request to road, it's only the horsepower that will be inaccurate simply because it's a calculation and will (in reality) depend on flow, housing, actuator strength, exhaust, intake restriction etc etc.
I find that fascinating, I love these cars and what you've done to yours. This is a proper sleeper! Pearl of wisdom from Noobtune:
The torque in the midrange should be accurate from request to road, it's only the horsepower that will be inaccurate simply because it's a calculation and will (in reality) depend on flow, housing, actuator strength, exhaust, intake restriction etc etc.
Edited by HybridAero on Saturday 12th March 19:09
Your torque curve is superb although how usable is it? In lower gears presumably you are managing grip levels which in itself I also love as it really then becomes a car you have to drive well to get the best from.
My RB5 makes 343bhp on its standard map (I have 6 switchable maps) and looks completely different to this. On the normal map my car makes around 340lb/ft or around 470nm (I can't remember the exact number) but in an entirely different way and grip isn't a problem even in the wet. Below is my dyno output in its standard map (it has a more aggressive map with anti-lag/launch control etc).
Any ideas what time this would post on a quarter mile run?
Anyway top work and I'd love to see it at a track day!
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