Hi All,

I have been gradually modifying my 9-3 engine to get it into a state where it is ready to be transplainted into my kit car.
Mods include: 630cc injectors, 3 Bar MAP, Fuel Pump, Valve Springs (to be completed), Holset HE341 Turbo, 240mm paddle clutch + flywheel(will happen with the transplant, unless I fry the clutch before), when transplanted the engine will also be dry sumped.

Anyway here is my work fitting the turbo over a few days last week.

The new turbo its a little erm... BIG


Wideband


The turbo swap commenced, first I drained the oil and coolant system, removed numerous bits which were in the way including: the air box, the rad fan, the fan belt, the power steering pump, the aircon pump, the old manifold & turbo, the rad & induction hoses.

As my T3 9000 manifold has not yet arrived I tried bolting the turbo up to a late 9000 manifold via a T3 - T25 adapter, unfortunatly this made the oil drain too low for my liking and more importantly meant my exhaust would faul the water pump.


So I decided I would butcher the T3-T25 adapter and steal the T3 flange off it and weld this into the cast manifold, this worked supprisingly well, and the weld looks ok, though im sure I will find out once it gets hot exhaust gasses flowing through it, not that it really matters this is a temporary sollution till the propper manifold arrives.


The housing clears the block nicely with room to spare, it just has to be mounted round the oposite way, also had to 'clock' the turbo so a bracket had to be made up to move the actuator (this is only rough a propper one will be made at a later date)


A BIG thanks to adam for his help with the welding and the quick tutorial, and using up a couple of his holiday days from his day job!


My new 3" down pipe


Fitted the manifold properly with gasket etc, then cleaned up my actuator bracket so i didn't injour myself.


Placed a Saab 9000 radiator fan we had laying around in the unit up against the radiator as the original 9-3 fan was too deep at 6"! (thanks again Adam) and bolted the turbo in place


Some might call it a snug fit... may end up getting changed but will do for testing purposes.


Downpipe on with wideband scrfewed in place, note braided oil feed fitted, also oil drain in place at a angle i am now happy with, again this will be further improved when the new manifold arrives.


Final picture of manifold, mounted turbo, Braided Oil feed & narrow band showing clearances.


Also re-mounted the power steering pump, fitted Wideband and callibrated, shortened Fanbelt fitted as AC removed, filled Vital fluids.

Had it started and there is a bit of blowing round the v-band clamp which should be sorted when the correct size clamp arrives and is fitted at the weekend. On the up side there are no oil leeks and the turbo appears to be ok but wont know till I have the hoses and can actually run some boost this has been delayed as my 'Mr Silicone' order has only just arrived today, was supposed to be posted next day delivery last tuesday, turns out it was posted friday afternoon.... in the mean time I had had to book a hire car to get to work this week so not best amused, hoping all the correct bits are there, wont find out till I get home friday fingers crossed the beast will be running saturday!

I would like to extend my thanks to adam who has helped me for the last few days during his leave from work, I found out today yesterday was his birthday! there is dedication, thanks mate!!! Now feeling very guilty and will be taking you out to get very drunk.


[Edited on 17/10/11 by Dan.]

that thing will be totally mental in a kit. mine with the t25 is nuts, i thought about going up to a t28 but i like the fact that i have boost at 2300rpm.

I realise its totally over the top, build more as a project, the turbo may well be downgraded when it goes into the indy but will of cause try it first, my indy was never meant to be a serious car just a silly toy so it may stay yet if it is remotly drivable lol, my guestimation is power should be in the realms of 450bhp

Lotsa parts. Neatly welded up too.
WHAT? are you doing to do about a trans box though?.. Fragile is a charitable descriptor of the Saab box..my friend.
PS: I've blown up 3... so far. I've been saabing for 25+ years :-)
Power?? I'm guessing about 325 /330 IF you get it well setup.
Ooooh.. IMO lighter or ali flywheel is money better spent on Beer .
Why is it that everybody who dicks with their pore old Saab invariably comes up with silly HP numbers expectations?
IF it were that easy. We would all be driving 1000hp cars.. to go shopping :-).
Regardless, it will be interesting to see it , once all together though.

[Edited on 18/10/11 by Bare]

That is a huge turbo.

There's no space down tje front end to add more rad clearance, I know tje holset is a popular swap, have others had any burning issues with the lack of room for them?


I've just sold my Saab tuning kit, canusb, bdm, harness



Power - try 450bhp ! And that's without trying. I ran mine just short if 300 on a good day. And was very very rapid, but a handful.

Don't know if I would like 450 bhp and a turbo in a seven , it's too - predictably unpredictable.


Great fun however, but once that boost comes up and the NM builds, you will get nowt done for spinning wheels. Mine would spin up on a damp road in third.


Go for it....



Quirky and fast.

[Edited on 18/10/11 by T66]

Looks like you've had some fun putting that all together!

Congratulations is for the excellent photographically-illustrated post - nicely descriptive (although I don't understand .a lot of the technical turbo-related jargon).

Three further comments
- one - I think you are finding space a bit of a problem in the tin-top engine bay, - you are going to seriously struggle with that in the MK, aren't you? - Are you fitting an intercooler?
- two - You say Adam gave up some leave to help - it is very satisfying using your learnt skills to create something like that - he wouldn't have done it if he wasn't enjoying himself?
- three - whether it has 300 or 450 bhp will be pretty academic - I can spin my rear wheels on a dry road without any problem with a 'mere' 150 bhp - you will have a job controlling yours - it will take some practice, and it will still eat tyres!


Good luck with the fitment into the Kit!

[Edited on 18/10/11 by stevegough]

Thanks for the comments guys, power wise these are not dreamed up numbers just numbers in the range of other people using simIlar setups.
The saab gearbox is a weak point, however the boost will be programmed to come in gradually and be limited in 1st and 2nd gears this should increase the longevity of the box, not really a major concern as the Saab will be getting broken for parts around Christmas when the engine comes out.
Space wise there is more room in the Saab I was just trying to avoid moving the rad etc, I know it will fit in the Indy having seen adam fit his in the much smaller tiger though a custom manifold may be required.
The flywheel will not be a lightened one just a 240mm one to replace the 228 mm one that is currently in there as it will fail to hold the power, when it goes in the kit it will be mated to a T5 box and paddle clutch.
Will post an update at the weekend when it's all up and running, will also be re-mapping my friends 9-3 for around 260hp from 154hp on completely standard parts, I know this will work nicely as its what I did with mine prior to this project.

Little update as promissed all be it a little late, well the turbo has been fitted for aprox 8K miles now, huge intercooler also fitted which is doing its job nicely keeping intake temps down with no noticable increase in lag...all is well.
The car was ment to be broken by now but its been too much fun so im keeping it on the road till the MOT runs out, so i have 2 more months of fun...
Anyway, I would guestimate it is currently running at 400BHP or there abouts, its an absolute animal when the boost comes in, i.e it will spin the wheels in excess of the national speed limit on wet roads (on a private road of cause...). On dry roads it will spin in first, 2nd but I have programmed the boost limit in these gears so it doesnt spin up. In 3rd and up the clutch is not liking it much and is slipping, still not bad considering its the standard 228mm item
Will be taking it to a rolling road day in the not too distant future so should have some accurate numbers then, may need to limit the boost a little for the clutch though. Spool is pretty late 1Bar at 4K rpm 1.8 bar at 4.5K, below 4K it is prettly lifeless in comparisan.

When the transplant occours I will be fitting a tubular manifold this should bring spool down by ~300RPM and fitting different cams, again this should bring spool down by a further ~300RPM. Giving me a much more acceptable power band from 3.5K RPM to 7.5K RPM. This will allow me to map the boost curve more gently and still get the gains of the big turbo.
If however low end performance is still lacking, I am considering sequential turbo chagring; using the standard T25 for the low down boost (2K-4K) and the Holset to pull the rest of the way to the readline. Ideally I will avoid having to do this as I like to keep things simple, but it is an option if necessary, space permitting.

[Edited on 1/4/12 by Dan.]

quote:

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Originally posted by Dan.
Little update as promissed all be it a little late, well the turbo has been fitted for aprox 8K miles now, huge intercooler also fitted which is doing its job nicely keeping intake temps down with no noticable increase in lag...all is well.
The car was ment to be broken by now but its been too much fun so im keeping it on the road till the MOT runs out, so i have 2 more months of fun...
Anyway, I would guestimate it is currently running at 400BHP or there abouts, its an absolute animal when the boost comes in, i.e it will spin the wheels in excess of the national speed limit on wet roads (on a private road of cause...). On dry roads it will spin in first, 2nd but I have programmed the boost limit in these gears so it doesnt spin up. In 3rd and up the clutch is not liking it much and is slipping, still not bad considering its the standard 228mm item
Will be taking it to a rolling road day in the not too distant future so should have some accurate numbers then, may need to limit the boost a little for the clutch though. Spool is pretty late 1Bar at 4K rpm 1.8 bar at 4.5K, below 4K it is prettly lifeless in comparisan.

When the transplant occours I will be fitting a tubular manifold this should bring spool down by ~300RPM and fitting different cams, again this should bring spool down by a further ~300RPM. Giving me a much more acceptable power band from 3.5K RPM to 7.5K RPM. This will allow me to map the boost curve more gently and still get the gains of the big turbo.
If however low end performance is still lacking, I am considering sequential turbo chagring; using the standard T25 for the low down boost (2K-4K) and the Holset to pull the rest of the way to the readline. Ideally I will avoid having to do this as I like to keep things simple, but it is an option if necessary, space permitting.

[Edited on 1/4/12 by Dan.]

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There is little movement in the engine... tbh I was half expecting to crack the weld on the manifold but it has been fine, that said under accelleration the engine would move away from the rad rather than towards so I guess thats why i have got away with it thus far...

Which engine are you using? The T5 or T7 ?

I'm guessing you know the T7 pistons were lightened and don't do well with much more than 300bhp.


Or have you swapped them ?

T5 engine, no internal mods what so ever.

bet its mental lol looks very good fun keep up the good work pal