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Perpetual Pain in the @ss (with delicious turbo flavor)

montecarloz31

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Returning to car mods, with a Saab

Might actually have something worth some mods for once! After the tragic death of my 200 I decided to go without a car payment and get something cheap and boosted.
Went kinda out of the box with a 2005 Saab 9-5 Arc. Ive always liked these oddballs, the Arc is a step below the aero, same drivetrain but detuned to 220HP from 250HP and a softer suspension. Equipped with a 2.3L 4 cylinder fitted with a Mitsubishi TD04 turbo charger it produces a respectable 258tq. I ended up with an automatic, it was hard to find a clean manual and its just easier logistically with the wife unable to drive one (the 5 speed auto in these is basically bullet proof though).

Its got its bumps and bruises, also some differed maintenance that I'm getting caught up with. But overall it runs and drive great! this is my first boosted vehicle so I'm enjoying the spool. Nicely equipped missing only the vented seats and harmon kardon stereo. Its MSRP was north of 40k new.

First minor mod was to pull the massive stock airbox out and replace it with a K&N cone, it's already in the fenderwell and the filter adds very little power but now the turbo and blow-off valve are actually audible, worth it lol.

Onto some pictures!


Death of the 200, guy braked hard in front of me and I swerved to avoid, went in the ditch and hit a culvert.








Massive stock airbox


I'm not sure where I'm going to go with this car, the HP increase to Aero levels is easy with either a tune or a PCM swap. They have some aftermarket and a large enthusiast base, the stuff is there is I decided to go there. For now its getting it caught up on small fixes.
 
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Euro

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Holy cow, glad you came out of that roll over ok! Nice replacement!
 

montecarloz31

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Not much interest is a rarer and now bankrupted car manufacturer? No big deal, I'll continue anyway haha.

As far as getting it caught up on maintenance items I've changed the trans fluid (long process, takes 12 quarts and 3 drains to get it done) and replaced the motor mounts. I fixed the data port (the hot wire had gotten pushed back) and scanned it's engine light finally, ended up being the boost bypass valve not working properly, the vacuum lines to it were brittle and broke off. New vacuum lines and it boosts much smoother now. Mounts were completely done, it no longer has a vibration when at stop signs. New valve cover gaskets and plugs went in along with a respray of the valve cover and upper engine mount horseshoe.



Last annoying thing to deal with is the clunk up front over bumps, it's either the control arm bushings or the strut mount, I'm just gong to pick up a front kit with the arms, ball joints, tie-rod ends, and sway bar endlinks along with a set of front struts/springs and do it all. I'd like to put on the blisten set up at all 4 corners but the kit is $1200 so that probably won't be approved lol. Plan to pick up a stage 2 PCM for it, already has the intake upgrade needed, it will boost it to 260hp and 300tq. On to some pics!

Headlights in the process of being cleared up



Clean for now, still needs a good wax



Much better without the yellowed headlights







The very Saab ignition key location and the only cup holder in the front of this car, and anything bigger than that can likes to fall over in it, my one major complaint



Comfortable seats, all power and heated



Cleaned up the engine bay a bit, much better looking with the fresh paint as well





New vac line on the boost bypass



New upper engine mount, the other 2 replaced aren't visible, the trans mount is under the main fuse block and the torque arm is in the front on the bottom.



Bad picture of the one spot of rust in this thing, common area on the 9-5

 

Dasfinc

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Is it just me, or does the car have a bit of a Rake to it?

I'd be willing to bet your front suspension clunk is related.
 

montecarloz31

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Its were it is parked in my yard, the rear wheels are on the sidewalk and the front are on a slope, pretty even on flat ground but I have no doubt at 140k it needs struts. Oh and come to find out this does have the Harmon Kardon sound system, I was messing around in the trunk looking for a rattle and spotted the HK branded subs on the edges of the rear deck behind cover panels, I was looking more toward the middle when I did my inspection.

Can a mod change the title to this thread to something less stupid haha, more like returning to car mods
 

boostedguy05

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[MENTION=5]Mook[/MENTION]

please see above request.


Congrats on the new to you car.

i hate the ignition location on these cars.
 

montecarloz31

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[MENTION=5]Mook[/MENTION]

please see above request.


Congrats on the new to you car.

i hate the ignition location on these cars.

It takes some getting used to hah. It was fun when the guy who put the new tires on couldn't figure out how to start it. It supposedly makes it much harder to steal/hotwire, :dunno:
 

ldyzluvdis06

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my dads new VW passat also has a dumb ass start location button, located down on the center console! i think that key location on your car is even worse. lol
 

willsmysticcobra

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I have an 05 9-3 Aero and I still enjoy driving it. Simple bolt on mods and stage 3 Brew City Boost stage 3 tune 285 hp/300tq. It scrapes going into my garage and also needs a new strut mount I believe but all in all its a good car.

 

montecarloz31

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I have an 05 9-3 Aero and I still enjoy driving it. Simple bolt on mods and stage 3 Brew City Boost stage 3 tune 285 hp/300tq. It scrapes going into my garage and also needs a new strut mount I believe but all in all its a good car.


Been looking at the Brew City stage 2, Not sure when I'll get the bolt ons put in to support the stage 3. Yeah this thing scrapes everywhere, it came with a small tear in the front lip, trying not make it worse. Does the strut mount make a rattle/clunk over bumps?
 

willsmysticcobra

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That might be the sway bar end link. The strut mount/ bearings make a weird coil winding sound. Once you take the wheel off and really inspect, i'm sure the issue will stand out to you.
 

montecarloz31

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I think its the control arm bushings, they seem to have allot of play in them, the sway bar links looked good
 

montecarloz31

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That might be the sway bar end link. The strut mount/ bearings make a weird coil winding sound. Once you take the wheel off and really inspect, i'm sure the issue will stand out to you.

Are you running an aftermarket exhaust on yours? I guess I had a weak spot where the pipe feeds into the huge resonator in the middle of the car, hit a bump yesterday and it broke right off (funny this car is extremely clean underneath). It broke flush with the resonator body so no real way to fix. Gonna run it to my exhaust guy on Tuesday and see about just removing that and the factory muffler and run 1 muffler in the middle to *maybe* dual pipes in the back. Just want it to sound good.

Anyone else have any suggestions either?
 

willsmysticcobra

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I have switched up the exhaust a few times now. I went from wild to mild, and am running a 3in down pipe though stock exhaust piping exiting out of a generic , yet tastefully looking and sounding magnaflow dual 3in tipped muffler. I'll try and get a video for sound, but the idea you listed will sound nice.

 

montecarloz31

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So small update. The car did end up with a single 2.5" exhaust with a magnaflow muffler, sounds so much better now! No drone, not ricey for a 4 banger, just a little deep growl. Also got a detail done for the season, probably had not seen wax for 10 years haha. 3 step wax (rubbing compound, polish, wax), cleaned and treated the leather, cleaned and treated glass.

Lined up with the other toys on the farm


All Clean!


I'll have to upload more pics from my phone.
 

montecarloz31

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I have switched up the exhaust a few times now. I went from wild to mild, and am running a 3in down pipe though stock exhaust piping exiting out of a generic , yet tastefully looking and sounding magnaflow dual 3in tipped muffler. I'll try and get a video for sound, but the idea you listed will sound nice.


Its funny its the same color too haha. I really like those wheels too, my snow set are 9-3 wheels but not those. Really wish they made a lip spoiler like that for the 9-5
 

Euro

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That is an annoying AF location for the ignition key. How many times have you whacked it with your arm?
 

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