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9Kwrecker 12-30-2015 07:16 AM

Project Road Trip
Traveled 1000+ miles in 36 hours over Monday and Tuesday to get this and drive it back to Ohio:

The important part:

5MT, 206K, I'm the 3rd owner.

Has a GS short shifter, GS intake, and Forge diverter valve. Not tuned (yet). Also a new clutch, slave, TOB. Wheels in the pics have new Michelin snows, and it came with the stock Aero's with (IIRC) good Hankooks.

Has a few needs. I don't think it's boosting right as it feels slower than my dad's '00 Aero. Need new headlight bulbs, the pair it has are dim as desk lamps. That said, it ran great all the way from Long Island to Cleveland, returned about 27 MPG at ~75-80 MPH.

srp 12-30-2015 07:48 AM

Nice score. Looks pretty clean for 200K+ miles.

9Kwrecker 12-30-2015 08:09 AM

It is really clean, here's some pics I asked for from the PO before I made the drive:

It was a CT car until it moved to Long Island a year ago. Did I miss a memo and CT cars don't get crusty?

Cark 12-31-2015 03:32 AM

CT doesn't see nearly as much snow/salt as northern New England, that's for sure!

Car looks very nice, a lot like my 02 linear gone Aero. You'll enjoy it very much.

Daven 01-01-2016 11:30 AM


This one checks all the boxes. Nice snag! If the dog legs are that clean the rest of the car is probably just as well cared for.

9Kwrecker 01-02-2016 07:35 PM

I fixed the boosting problem by swapping on the BPC from my red wagon.
While I was in there I found that the top hose was disconnected and plugged with a bolt. Anybody ever see or do that before?

Tboy 01-03-2016 11:44 AM

Where in Ohio are you?

Had they done this?:
T7 Turbo Bypass Valve Mods – TrollTuner

9Kwrecker 01-03-2016 12:49 PM

I'm near Cleveland.

I don't think that's been done, quick look under the hood the hoses look like stock setup.
It was a hose on the bpc that was plugged, that looks like they're messing with the diverter.

9Kwrecker 01-10-2016 07:06 PM

I found a lot of vac lines yesterday that were rotten. I replaced all those and now the car pulls much better, however, I'm still getting P0101. I think next I'll inspect the air filter and MAF.

Since this is a picture thread, Saturday was 55* and decent here, so the car got a thorough hand wash and a long cruise:

Then today there was this situation:

Also got the headlight bulbs replaced, incredible difference.

9Kwrecker 01-12-2016 06:11 AM

Was discussing this in Saabeh's wagon thread, but I ordered this sub from:

At first I was a little bummed that they don't offer Prime shipping (still free), but I ordered it on a Thursday and it was here the following Monday. Looks like a quality piece. As soon as it's above freezing here, hopefully this weekend, I'll be putting it in.

Saabeh 01-12-2016 07:23 AM

Where do you want me to move this?

9Kwrecker 01-12-2016 08:13 AM

Duh, I guess I should have mentioned that part.
General 9-5 Posts/Information should work.

9Kwrecker 01-12-2016 03:29 PM

Saabeh, thanks for moving this thread!

Still chasing down a boost problem, throwing code P1110. I just took out the forge DV and inspected it, put a clean piece of line on it, and I can't force air through it in either direction.
While it was off, just for giggles, I did the same thing on the long vac line going from the DV to the "Vacuum Valve" (thing on the firewall with 3 vac lines and a plug). Seen here:
Genuine SAAB Vacuum Valve 55562854 - Free Shipping

I was able to force air in either direction through that valve using the line to the DV. Should I be able to do that?

9Kwrecker 01-12-2016 04:02 PM

After little more research I found a WIS screenshot on SC with info about that valve. It looks like if that valve fails to open when the throttle is closed, P1110 is generated.

Tboy 01-13-2016 05:23 PM

Glad you found it.

Let us know how that sub works out. I always have a soft spot for little subs. I don't know what it is, they are just cool. I think it is the magnet to come ratio!

Saabeh 01-14-2016 07:19 AM

What are those little plugs on the inside of the doglegs?

mike d 01-14-2016 08:31 AM

cool car, I had to travel to get my 02 aero wagon with a 5spd, it was a 600ish mile drive home.

the 5spd aero wagons are worth traveling for, there are so few of them, they are truly one of the saabs that is worth more than the blue book

9Kwrecker 01-14-2016 11:22 AM


What are those little plugs on the inside of the doglegs?
No idea, I actually didn't really notice them, but I'll look. Maybe sunroof drains?


cool car, I had to travel to get my 02 aero wagon with a 5spd, it was a 600ish mile drive home.

the 5spd aero wagons are worth traveling for, there are so few of them, they are truly one of the saabs that is worth more than the blue book
I completely agree, I was *this* close to buying the $9K Cosmic Blue wagon that Garry Small still has for sale when I found this one. I still had to travel a long way for it, but 1/3 the price worked out much better for me even if this one has a few niggling problems.

Side note miked, the PO of my car told me he had talked to you about tuning this car before he decided to sell it. Expect to hear from me in the spring when this thing is at full stage 0 with all the kinks worked out.

9Kwrecker 01-16-2016 06:28 PM

Status update after spending 8 hours at the shop today:

I found that the K&N filter that the PO had held on with zip ties and a piece of exhaust pipe(!) was filthy. I took that off and put the stock air box and filter back.
I also found that the MAF was filthy, not surprising looking at the filter. Took that apart and cleaned it well with MAF cleaner.
Replaced the spark plugs, looking at them made us think the car was running lean for some time.
Finally, after checking every vacuum valve and line in the system and deciding that they were fine, we checked the wastegate. That was really far out of adjustment, we shortened it about 7 turns to get it in line.

End result: I think I'm finally getting full power out of the Aero. It really moves now. Good spool up and no more symptoms that feel like fuel starvation. Holds boost till I start to run out of revs.

Oh, and I also installed the subwoofer. That little guy sure sounds better than the stock unit that had no cone left.

I should be a fuel filter away from ready to tune at this point.

Tboy 01-16-2016 07:06 PM

Awesome! What are your tunning plans?

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