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

[HybridAero]

The Spruce goose said:

What was it rated for?

550 NM, was dyno'd at 521 NM.

[HybridAero]

Stu08 said:

Great build - I'm on my journey with a standard 9-5 aero to stage 3. I have the downpipe and am thinking about replacing the injectors with green giants rather than a FPR as they're on 170,000 miles.

I can imagine it's a laugh to drive with the setup you've got.

I have a question regarding the fiberglass boot lid. Mine has the dreaded boot lid rust along the seam at the base. Apparently it's a design floor so not sure if I want to replace with another for it to do it again.

Is the fiberglass lid a one off? Will it fit, and be both functional and cosmetically identical to the metal lid?

Thanks for any information.

Thanks m8, make sure you align the injectors properly. If you don't know then ask Karl at Noobtune for his advice, don't want any underbonnet fires!

It's a laugh but desperately needs an LSD.

The fibreglass bonnet and boot are being made by a friend. What year is your 9-5? Let's see some pics!

PM me your email address and I'll get in touch as soon as the fibreglass panels are in production.

[HybridAero]

Master Bean said:

Sort your bicycle hoods out!

Will do, will look at some SPDs as well, problem is finding shoes to go with them that's where it gets expensive.

[HybridAero]

The Spruce goose said:

have you looked at the brake fluid is it cloudy, contaminated, that would be the slave failing, the rubbers going. it is only a rod pushed by the hydraulic force, shouldn't really impact engine revs. Sticky gear changes would be a symptom.

Yes fluid had ran out and slave was shot, just need the car to perform daily duties for now so hoping it drives better now.

[HybridAero]

Stu08 said:

Which LSD are you thinking of fitting? I'm sure I've seen it mentioned in the thread but can't find it now.

I've sent you an email - that'd be great to know about production replacement panels. Definitely interested in the boot lid to solve the rust issue!

I'm looking to fit a cone filter to mine (purely as I like the sound of a turbo). Do you know the dimensions of the cone you fitted? I'm looking at AEM dryflow cones as I'm not keen on oiled filters - although I'm not sure which size to fit.

Hi m8, thanks got your email, will let you know as soon as first batch have been made.

The plan is to get the big turbo in first, see how this low mileage gearbox copes then maybe next summer take it to Abbott Racing for a full rebuild including lightened flywheel, uprated internals and a Quaife LSD.

What you need is a Jetex 80mm cone filter sat inside a modified airbox. You'll need an aluminium pipe to extend the filter a little which Jetex can supply. Got any pics of yours?

[HybridAero]

Back on the road, drives like a dream with the resurfaced flywheel, new brake pads/fluid and new slave cylinder. Clutch seems pretty strong touch wood. Just want to nurse it around for a few months now until I have the money to swap for the bigger turbo.

[HybridAero]

RumbleOfThunder said:

Nice. Are you still running standard discs and calipers? I'd be thinking about beefing them up when the big turbo goes in.

Thanks. Funds permitting I'd like an AP Racing setup, but that's over £2k. A good compromise would be Ferodo DS2500 pads, Motul RBF600 brake fluid and braided lines, which I will most likely fit alongside the big turbo setup.

[HybridAero]

Don't know what's changed but it's absolutely going like the clappers since its recent service. Last night I hit 1814 mAir which equates to 430 lb ft!

[HybridAero]

Well the project has finally come to a close.

I had plans to take it to 500 bhp, but a friend off UKSaabs was selling his 480 bhp 9000.

Bit of cash his way and we had a deal!

Here she is - the drive home it was absolutely savage.

Going from a 19t to a GT3071 is quite a leap, much less responsive but when it kicks in boy do you need to be awake!



Bye bye 9-5!

Edited by HybridAero on Saturday 30th September 15:42

[HybridAero]

Spec list is as follows:

Engine rebored to just under 2.4L (Sutton Rebore)
3000mile old rebuild - all new timing, oil pump, seals, shells, bearings
etc.
Wossner pistons
Balanced B234 rods
Balanced crank/flywheel
ARP Studs
Maptun 268 Cams
Baffled deep sump
Custom large plenum intake Mani
Tubular Manifold
Garrett GT3071R turbo with braied lines
Tial 38mm External wastegate
Walbro 255 pump
Forge dump valve
Oversize ITG filter
Uprated alloy radiator (40% thicker)
60mm Allard intercooler
630cc siemens injectors
3 bar map sensor
Running approx. 444hp and 420ftlbs at the hubs (480 at the fly) at 1.6bar but will happily push over 500 if boost and ignition is pushed.
Poly bushed
3" V-banded downpipe and JT exhaust

Gearbox and transmission
Rebuilt box with shot peened and cryogenic treated 4.45 gearset and longer 9-5 5th.
Quaife LSD
Circlip and dowel strengthening mod
2004 crush sleeve
All new bearings
Millers CFS LS 75-140 NT oil

New driveshaft tripods
New SKF CV joints
New intermediate bearing
Lightweight flywheel 5.5kg
Poly bushed
Auber Temperature sensor / gauge
Sachs uprated clutch cover, Cg motorsport solid paddle friction plate, braided hose, uprated modified clutch master cylinder (ensures cleaner disengagement)

Suspension
2k mile Bilstein B6/8
SAS anti roll bars front rear
350lb front coilover conversions ( adjustable height)
600lb rear coilover (adjustable height)
New SKF wheel bearing
Poly bushed

Brakes
AP Racing 330mm calipers
Reyland front discs
Abbot racing rear discs
DS3000 pads all round
Braided lines all round
Abs removed

Wheels
Superleggera 17X7.5J.
2 sets:
Road tyres - Nankang NS2R
Track tyres - Michelin slicks

Interior
Corbeau Kevlar pro series bucket seats
3 inch Luke 4 point harness
Stock seat belts
Full aero interior (front seat tucked away safe and sound)
Alpine ezi-dab with amp, gain controller and front speakers only
330mm flocked nardi steering wheel with driftworks snap off boss

Gauges
Auber digital / programmable: Oil pressure, Water Temp, Gearbox Temp.
Afr gauge
Knock led
All in custom made carbon panels

Other
Rear Abbot trianguled/bolted rear strut brace
Maptun lightweight alloy front strut brace

Car lightened throughout - Weight approx 1300kg

[HybridAero]

RumbleOfThunder said:

Wow I didn't see that coming! Think I prefer the 9-5 on balance but that's a cracking 9000 with a small fortune spent on it. Any immediate plans or are you happy with the spec for now?

The 9-5 was more fun at sane speeds but this 9000 is a supercar! With 480 bhp and only weighing 1360 kg it's absolutely savage once the turbo wakes up. Sounds incredible also. No immediate plans at all, nice to have something that's sorted!

Edited by HybridAero on Sunday 1st October 01:32

[HybridAero]

Tipped the scales at 1360 kg.

With 480 bhp that gives it a power to weight ratio of 353 bhp per tonne.

To put that in perspective here's some cars with similar figures; funnily enough no front wheel drives there



Utter madness innit

[Nutty9000]

The 9-5 is now for sale as its new owner has had a great deal on a Supra. PM me for details - Thanks

[Nutty9000]

43655 said:

Hi, bit later to the party but any chance of more info/photos of that intake manifold?
I'd been musing about the feasibility of doing one like that, as the stock IM (on a B235) doesn't look particular evenly flowing, and moving the throttle to the side gives better flow of the intake pipework too. Win win!

Excellent build, may have been somewhat responsible for me now having an LSD and soon also Wossners and a td05 to go in my 9-5!

Thanks pal, got any pics of your 9-5? Would love to see another 9-5 tuning thread on here! The custom inlet is on my 9000 Aero which has replaced the 9-5 - See pics here: https://www.pistonheads.com/gassing/topic.asp?h=0&... and hear the induction roar here: https://www.youtube.com/watch?v=Lc_CvBCLCfc

Have you spoken to Karl@Noobtune re mapping? He's brilliant, a real wizard.

[Nutty9000]

egor110 said:

That is what i love with these saabs , that for a fraction of the cost you've got something pushing out the numbers of something far more expensive.

Imagine the phase 1 but lighter i think the cups something like 1020 kg , renault stated the 0-60 was 6.5 but supposedly autocar manged to do it in 6.2! , i know 0-60 isn't the be all and end all but for a b road weapon it's what i look at as it's not going to be doing over 60 much of the time.

Can't wait to see what you do next to your saab .

Funny reading this now as I'm now running a Ph1 172 and couldn't agree more, it's epic on b roads, deeply, deeply impressive.

And can vouch for the 6ish second 0-60! https://www.youtube.com/watch?v=sNUlfEdwU0c

[HybridAero]

So that's it, I decided I'd had enough of the 9k! With the clutch going the other day, further welding work needed, and a relentless thirst for oil, I decided enough was enough. A quick chinwag with the previous owner and we decided to do a straight swap.



In exchange for my old 9-5!


The 9-5's only done 1200 miles in the previous owner's hands, as the Taiwanese eBay turbo blew earlier this year, and he replaced with an AET 19t turbo (at the princely sum of £760), which is already smoking for some reason. Previous owner says it started smoking after only a couple of miles!

I spoke to Lee at AET and he sounds a good bloke and was more than willing to help, so the plan is to get this AET turbo off next month, send it across to Wakefield and get them to inspect it.

Strange considering I got nearly 20k miles out of the eBay cheapo turbo!

Once that's done I plan to just run the thing.

Need to get the (Phase 1 172) Clio sold also as I've decided it's just not practical enough and this 9-5 makes for a great all rounder.

[HybridAero]

BiTurbo228 said:

Very interesting indeed I'm sure I'll be mining this thread for information on how to affordably tune a Saab B-Series (one of the future plans for my Spitfire when I get tired of my mate's turbo 5 outdragging it is to try and mate a Saab B204 to an LT77 and stick that in there...).

Awesome, should be quite efficient in such a light body!

Not to be a bad influence but a b204 on stock internals made 666 bhp

http://www.serioussaab.co.uk/articles_pages/B2x4tr...

[HybridAero]

wormus said:

You sure it’s the turbo burning oil?

Hi m8, presumably it is because it only does it after full boost?

[HybridAero]

wormus said:

Ah, sounds like it. Let’s hope so.

Must admit, I’ve always preferred your 9-5. Glad you got it back.

It's a much better daily driver, especially given it has SOME sound deadening. 9k needed constant attention. Would like to try a big turbo one day on this 9-5 but for now the 19t is fantastic.

[HybridAero]

As I don't want to compromise on interior comfort, day-to-day usability and practicality, a clever way of saving weight I feel would be fibreglass bonnet and boot. Not sure how much it would compromise on safety though but here's roughly how it'd look (would be flush with no badges front or rear). In theory it should save around 50 kg.

Edited by HybridAero on Wednesday 15th August 23:44