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

[HybridAero]

Thanks all, yeh will have to check out the Vmax section of this forum, would love to race an E39 M5 once everything is fitted and mapped. Definitely need an LSD at some point, but think the first major mod after the engine work is a set of Bilstein B12s, unless anyone can recommend a better suspension set-up? Not looking to make it a full-on track weapon because it isn't exactly a good base car, but on standard springs and dampers it's a wallowy old hector.

Currently waiting for Maptun / Neo Bros to have a black recirculating dump valve in stock, and also apparently I need some fuel rail washers for installation of the green giant injectors, but can't work out where to source them.

Turbo and everything else being fitted around 23rd Jan, and almost at 1000 miles so will start revving past 4000 rpm occasionally.

[HybridAero]

Shotdog said:

Love these old saabs absolute sleepers! My dad had a 900 turbo that was chipped when I was growing up it was a right weapon! I too am interested in a VmAx type event! Drag racing from a standstill is alright but I struggle for traction I prefer rolling starts and embarrassing the big boys!

Yeh they're cool ain't they, especially the older 900s and 9000s. Seen your 135i, what a monster! Funnily enough I went out in my boss's stock 135i the other day and was amazed how it pulls so strong from low down, and then pulls even harder from 4000 rpm onwards, proper weapons, can't imagine what yours must be like with 500 bhp!

[HybridAero]

Turns out Maptun had some fuel rail washers and recirculating dump / diverter valve in stock, so ordered them.

Also ordered some 'high performance' spark plugs from Maptun, which 'run at a cooler temperature giving better results for highly tuned 9-5s'.

https://www.maptunparts.com/service-items/spark-pl...

Just got to wait for 19t turbo bits to arrive, then will begin installation.

[HybridAero]

19t turbo blade is held up in customs, so my engine tuner Tony has had to put off the final build for a few weeks, which is frustrating.

On the bright side, have received the following items.

Maptun recirculating dump valve, in black to keep the black theme going:







NGK BCR8ES spark plugs, recommended for higher performance B235R / B234 powered Saabs:



..and a set of fuel rail washers, all ordered direct from Maptun in Sweden:



Car has now surpassed 1000 miles since rebuild so gave it some welly up to 5k revs and it feels very smooth, can't imagine what it will be like with the 19t and king cobra installed and mapped, along with all the other parts.

I'm considering a suspension upgrade for this. Can anyone recommend whether Bilstein B12s are worth a look? I have no current plans for any track days but there is so much room for improvement with the current setup.

Edited by HybridAero on Saturday 18th February 12:33

[HybridAero]

griffin dai said:

Have you upgraded the fuel pump & map sensor? I had to on the 9000 when going above stage 3 to stage 4 with the bigger IC & GG's (roughly 310/315bhp....standard td04 was maxed out there though)

There's was some info on a cheap(ish) LSD on UKS but I can't find the thread.

Found out I don't need an uprated map sensor as that only applies to t5 engine management, whereas mine is running t7.

[HybridAero]

griffin dai said:

Try eBay for the plugs next time now you know the p/n. I think I used to pay around 2 quid a plug back then.

I've got the Eibachs & b8's on my 9-3, so same as the b12 kit. No complaints here but the 9-3's not that bad handling standard, these just lowered it an extra 20mm and helped with cornering on long sweeping bends. Nice/popular combo on mine but not sure how they'll be on the 9-5 (usually can't go wrong with Eibach & Billies though)

Yeh I paid over the odds for the spark plugs but wanted to get everything in one order ready for today, but turns out there wasn't any need to rush. Are the Bilsteins / Eibachs adjustable? I only want a 10mm drop as worried about the downpipe hitting anything.

[HybridAero]

Bri957 said:

http://www.ebay.co.uk/ulk/itm/361374148078

There are other sellers around the same price range.

Thanks, that's over 100 quid cheaper than off UK eBay inc postage!

[HybridAero]

Evoluzione said:

They're £20 - £30 delivered on Ebay too...

Yeh I noticed those cheaper ones but they're not recirculating. This Maptun one was 60 quid whereas the Abbott one is 130, so thought not too bad for a reputable brand.

[HybridAero]

carinaman said:

Recirculating ones don't make that attention grabbing blow off noise?

According to this guy http://www.saabcentral.com/forums/showthread.php?t... (and a couple of UKS members:

'you CANNOT run an atmospheric valve on a T7 car (your SAAB 9-5 for example). The computer senses the drop in pressure and thinks there is a vacuum leak, the car will not run correctly. Your only option is to get a BOV with a recirculating attachment, essentially turning it into a BPV, it will just be louder.'

Would be cool though to have that sound.

[HybridAero]

The revs seem to be slow to drop between gears - Is this likely to be an issue with the throttle body?

[HybridAero]

BricktopST205 said:

I think this is a Saab feature. Being the mile muncher executive saloon it was built for the transition between shifts always seems a little delayed to smooth out the gear changes. Unless mine is broken as well!

Have ordered a new Throttle Body O-ring (Bottom) as apparently this could be causing the revs to drop slowly.

Also the gearbox is a bit stiff, might get the oil changed.

[HybridAero]

In other news, I have ordered a set of Bilstein B12s, which are B8s that have been 'revalved' and have Eibach springs.



Cheapest I found in the UK were £608, and I managed to source some direct from Germany for £513 inc shipping:

http://www.mk-fahrwerkstechnik.de/BILSTEIN-B12-Pro...

Totally transforms the car apparently, and as the current suspension is corroded, it should be a vast improvement.

Also, the 19t has arrived, so all being well the car will have these installed, along with the uprated actuator, injectors and king cobra not this weekend but next.

Then mapping. Going from stage 1 to 5 in one leap should be interesting.

Edited by HybridAero on Saturday 25th March 14:12

[HybridAero]

Evoluzione said:

Yes they are.
They're probably all made in the same factory, it's just the vendors have had their name put on them.

I stand corrected, they don't look like they were bespoke made for my car though and no half measures with this project

[HybridAero]

Master Bean said:

Need some new pics.

More pics to follow, and some acceleration vids .

Final turbo part has arrived (king cobra was fouling the water pump so needed a king cobra ready TD04 19T compressor housing wheel).

Bilstein B12s have been installed but don't want to bother my mechanic for more pics as he's snowed under with work at the minute.

Edited by HybridAero on Saturday 18th February 12:35

[HybridAero]

19t hybrid turbo, king cobra, kinugawa actuator, ngk spark plugs and recirculating dump valve have been installed. Just received these pics from my mechanic:



As has the enlarged Isuzu air snorkel from the 3.0 V6 diesel 9-5 of the same era.



Pretty excited.

Edited by HybridAero on Saturday 18th February 12:35

[HybridAero]

Rear Bilstein B12s now fitted. Had a call from the mechanic earlier saying the radiator is leaking. So close yet so far lol

Edited by HybridAero on Saturday 18th February 12:36

[HybridAero]

Wheel alignment now complete, and has a pretty good stance now I must say:



Was going to replace leaking radiator with a good used one, but decided to get an all-alloy 'race spec' radiator:

Edited by HybridAero on Saturday 18th February 12:36

[HybridAero]

wormus said:

Nice base car somebody: http://www.ebay.co.uk/itm/Saab-9-5-69-000-miles-Fu...

How would an automatic Vector be a good base car for tuning? So many manual Aeros out there would be mad not to get one of them.

[HybridAero]

wormus said:

Fair point but most have done intergalactic mileages. Right engine though and let's face it, the Saab manual box is not the best. 300hp auto could work nicely

Edited by wormus on Monday 29th February 19:03

Yeh the manual gearbox is pretty awful, would love a quaife gearset

[HybridAero]

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!

Edited by HybridAero on Saturday 18th February 12:37