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Performance Modifications for the 9-5 This forum contains PERFORMANCE related Q&A's for the 9-5. This may also include suspension.

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Old 03-08-2014, 01:48 PM   #1
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project 2.sl0w

my 2001 saab 9-5 aero it has about 230,000 km on it, the turbo is leaking oil and the engine has lots of blow by. Recently i have bought 1999 saab 9-5 ( already parted out ) with a 1995 B204L bottom end mounted to a 1999 rebuilt t7 head and a 2001 9-5 Aero, model FM 55 B05 gear box with a Quaife helical limited slip differential already installed. The engine had 150k-km before the rebuild and 60k-km after the gear box has had 100k-km on it before the rebuild and 90k-km after. I will be using the shell to mock up a manifold and down pipe to fit a Holset hy35 9cm^2 from a 2002 dodge 1500 cummins turbo diesel into the shell in next few weeks and i will post pics and am welcome to suggestions people have. Im all about the budget.

Plan of action

1- mock up the manifold, down pipe, oil lines, air intake side, while the engine is still in the car.
2- take out the engine remove valve cover and oil pan to inspect and or clean the engine a little.
3- prep my 2001 to receive the new engine, fmic, delete ac.
4 - swap the engine and have a mild 350 whp tune





I will add pics of this i have or bought for this project it will take a few months for everything to be ready to install but i hope to have it in by the end of summer



Here are some pics of the donor hybrid engine it was rebuilt in 2011.

















** first few images are from DIP ( Dmitry P) **

Last edited by Saab95Aero; 03-11-2014 at 07:46 PM.
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Old 03-08-2014, 01:48 PM   #2
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1.0" tube ---------------------------
1.5" tube ---------------------------
3.0" tube ---------------------------
intake plumbing ---------------------
couplers ( 4-3 )(3-2.5)(2.5-???) ----
intercooler -------------------------
Blow off 1" rubber pipe -------------
Holset hy35 -------------------------
exhaust wrap ------------------------
turbo jacket ------------------------
Tial 38mm vband EWG / screamer pipe -
9000 manifold ----------------------
2x 3.0" 90 degree bends -------------
oil lines ---------------------------
loop coolant lines ------------------
v bands -----------------------------
holset back plate -------------------
injectors / spacers -----------------
wideband ----------------------------
machine fly wheel -------------------
clutch / presure plate --------------
slave cylinder ----------------------
Tune --------------------------------
short belt / AC delete --------------

Eeuro order
Axle Nut
Differential Oil Seal (5spd)
Engine Coolant Temperature Sensor
Engine Mount - Rear
Engine Water Pump Gasket
Engine Water Pump O-Ring
Exhaust Manifold Gasket
Heater core delete Hose
Intake Manifold Gasket
Intermediate Shaft Seal
Middle Intake Manifold Gasket
O-Ring (Oil Cooler)
Oil Dipstick Tube O-Ring (lower)
Oil Pick-Up Tube O-Ring
Thermostat Kit (89 Degree)
Throttle Body O-Ring


Updated parts list so far



beside a 1988 saab 9000 t3 manifold


3'' vband down pipe coming soon


big dreams
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Old 03-09-2014, 06:34 PM   #3
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Awaiting more updates!
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Old 03-09-2014, 07:23 PM   #4
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come see it in person you are local to me from what i remember ahaha
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Old 03-09-2014, 07:53 PM   #5
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Im in ottawa
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Old 03-09-2014, 08:06 PM   #6
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Im in ottawa
ohhh nvm i wanted to buy some parts off one at one point i swear ahaha il be posting updates as they come hope to have it running by june - july
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Old 03-09-2014, 08:24 PM   #7
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I have the same time line as you. We'll meet for sure as I have to go through tdot to get to Cambridge
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Old 03-09-2014, 09:16 PM   #8
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I have the same time line as you. We'll meet for sure as I have to go through tdot to get to Cambridge
okay will do buddy good luck pm me some info on your build!
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Old 03-11-2014, 10:11 AM   #9
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More stuff came in, 3'' vbands and flanges where about 60 bucks on the bay, the pipe i bought one extra came out to 35 dollars.







Im going to have to change the angle of one of the 90 degree pipes so the turbo can sit perfectly in the bay i still have to test fit it in my parts car.

Last edited by Saab95Aero; 03-11-2014 at 10:15 AM.
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Old 03-11-2014, 04:31 PM   #10
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There is way less room then in the 9-3 but with the correct angle everything should fit!




Fitment is not bad for just duct taped together, its really close to the rad small fans might be needed for this unless i try to move the rad up a little bit. I also will need to offset the pipes so they lean towards the right side a little about an inch. next step will be to tack up the pipes and test again.
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Old 03-12-2014, 05:33 AM   #11
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Gonna be a beast!
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Quote:
The only reason it took all day to install was because we couldn't keep our dicks out of each others mouths.
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Old 03-12-2014, 10:03 AM   #12
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thanks waiting on more stuff to come in and cant wait to get it tacked up
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Old 03-13-2014, 08:44 PM   #13
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Some easy work today I wired up my ECU to PC connection today also had an extra ACC unit soon i ripped the acc bus out and wired can lo and can hi so i can have a live data feed nice and neat! just need to order a canusb now.



Also picked up all the parts to make my " cobra " pipe off the turbo with the BPV recirc, pcv and evap connections

Last edited by Saab95Aero; 03-13-2014 at 08:57 PM.
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Old 03-18-2014, 04:24 PM   #14
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Wont clear the hood yet needs to be cut and tacked agian, need about an inch lower and half inch towards the valve cover

Last edited by Saab95Aero; 03-18-2014 at 04:43 PM.
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Old 03-18-2014, 04:48 PM   #15
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Some peoples just turn the manifold upside down and use 1-2 flanges from GS to space it out to get the turbo up there. Its a little cleaner maybe?
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Old 03-18-2014, 05:01 PM   #16
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Quote:
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Some peoples just turn the manifold upside down and use 1-2 flanges from GS to space it out to get the turbo up there. Its a little cleaner maybe?
Sorry I'm not sure what you mean? If i tried to use the gs spacer i would have real radiator mounting clearance issues it just barley clears as it is now i have to angel it more towards in engine... its trial and error. the 9-5 bay is way smaller then the 9-3 plus we have that stupid ass engine mount yoke that makes it even harder to fit.


I might have to aim the top t3 flange towards the front left of the car so it turbo sits a little offset not by much it just has to clear the yoke by a few mm i have a 4'' to 3'' coupler that will be there...





this is my idea for test two cut this out and re test the fitment



















edit--------- I have decided to swap the engine and gear box first then make a tubular manifold instead of my up pipe for a few reasons so not many big updates coming up for a little

Last edited by Saab95Aero; 03-31-2014 at 09:14 PM.
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Old 02-08-2015, 06:25 PM   #17
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project is finished and running pics coming soon.
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Old 02-09-2015, 04:57 AM   #18
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That escalated quickly, no updates then FINISHED!
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Quote:
The only reason it took all day to install was because we couldn't keep our dicks out of each others mouths.
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Old 02-09-2015, 07:41 AM   #19
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Yeah this forum slowed down a little and i kinda forgot about it but here she is.



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Old 02-10-2015, 06:23 AM   #20
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Yeah this forum slowed down a little and i kinda forgot about it but here she is.
Too busy on the Facebooks.
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