Saab 9-3 Aero

Heres mine

It's a 55 plate Saab 9-3 v6 Aero, ive had it just under 2 years now, haven't really touched it in the last 12 months but plan to get back at it this year (ive been a bit lazy compared to my old cars!)

Here it was the day I collected it, completely standard.

I dropped it off with the Saab garage same day for an oil change and fresh plugs ready for the remap booked for a couple days later

Interior is pretty nice with grey leather & light grey leather inserts, dash is bit plasticky tbh but still a nice place to sit.

Leagues ahead of my other Saabs for comfort & refinement.....but that Audio....terrible!! I've been in a few new shape 9-3's and all have sounded pretty bad. This has the full 13 speaker system and its still awful!

So the first job was an oil & filter change, fuel filter change and fit new plugs. I went for these NGK IridiumIX plugs as theyre recommended for the new map by JZW as standard plugs can throw a wobbly.

Also bought a BSR Optiflow intake kit which sounds like there's a DV fitted! Not to everyones tastes but really brings the v6 growl to life especially on start up. I like it anyway

A few days later I had it remapped, it's a JZW stage 1 'aggressive' map. You get 3 to upload via the obd2 port & laptop: 'Regular' 'aggressive' and 'revised' Should see 320bhp & 409ft/lbs 409 with the aggressive map and slightly more with the revised map but it's also a fair bit smoother and I prefer the slam you into the seat feeling. Power comes in nice and early and the extra torque over standard is pretty insane! Giggling like a school girl first time I floored it....and then the clutch slipped! More on that later

 

[griffindai]

Quite often the official main dealer is best place to get parts. I used to get all sorts of bits for my Skyline from main dealer up the road even though it wasn't a UK car and 20 years old and a lot cheaper then some 'specialist' places.

Yeah I think your right mate, I'll pop to the local VX garage next week and see what's available. I think the insignia's oil rerun gasket is bigger than mine so not sure if I need the vectra one here instead?

Fingers crossed my mapper in the states can sort a stage 1 tune for the 18t next week, I know he's got a stage 5 map for it but that's with the DP, IC & 550's installed so hopefully he can make a stage 1 tune for it, he usually sends 3 different maps to load (regular/aggressive/revised) so I'll try the regular and pray the clutch holds the extra torque! I doubt I'll see much more bhp as this tunes close to the standard injectors max duty cycle, but going off the vxr 18t maps they get a load more torque in the mid range (bags more!) but that's the Courtney map so god knows how much extra john will squeeze out of it....he's not shy either

Could be a nice cheap upgrade here for the Saab V6 boys, especially the Auto guys....no £2k to shell out on an upgrade clutch!

 

[griffindai]

Tweeter pods fit 100%

The wires run straight through the bottom so look pretty easy to fit up

Insides have been machined to fit the s25t tweeters perfectly

They fit but do need securing somehow as they're not a press fit into the housing, what's the best way to secure these? Would a few drops of superglue on the back be ok or is there a better method?

Really impressed though! These will look great fitted! I'll have to get the other style mounts for the mids though as they're a funny shape so no good for dome pods like these. I'll get these in a couple months when I've got the spare cash.....go faster bits need sorting first especially the clutch. Can't see it lasting very long one the 18t's fitted

 

[griffindai]

Pretty much set for JZW Stage 5 now

This is a 3" Downpipe for the Vectra VXR. One of the guys on UkSaabs kindly sorted me out with this over the weekend

Needs a tiny bit of fettling to fit, so the 3 bolt flange holes need making slightly bigger, my heat shield needs trimming as these usually foul here with the lambda sensor, lambda spacer also required or itll throw a CEL (or just ask to get it mapped out)

I'll also be reusing my old Magnaflow Racecat from the 9000 and have a 3" mid pipe made up with the race cat welded in. This mid pipe replaces the standard one with secondary cat and the DownPipe replaces the standard DP with primary cat....some just gut the primary cat instead of going for a full 3" set up but you have to keep the secondary cat fitted or for a race/sports cat for the MOT. The standard DP's pretty wide anyway.

So next purchase is the unprated clutch which I'm 99% certain will be the SPEC mini twin disc kit as it's only slightly more expensive than a spec 3+ with spec billet flywheel (twin kits basically 2x stage 3 disks plus a flywheel) also has more clamping force and rated to 650ft/lbs so a good 100-150ft/lbs safety net there vs the 3+ which although rated for around 550 has slipped on a few 19t stage 5 cars with 530ish ft/lbs. Definitely slips with their E85 19t tunes anyway!!

Then the Quaife ATB LSD from Abbott Racing (its gonna need it!!) and get the lot fitted. Shouldn't cost much more to fit the diff as they're there anyway when they fit the clutch flywheel so makes sense to fit it here.

Still not sure on how much power/torque I'll get with the 18t but I recon 380/390hp & 500ft/lbs is do-able 19t guys are seeing 415hp & 532ft/lbs so will be interesting to see how this does

 

[griffindai]

Cars now serviced,

New Yellowstuff R pads fitted up front and fresh rbf600 fluid with a new front HEL line fitted (last one HEL sent was the wrong size) So now stops a lot better!! The fluid should have been changed last year really.

Fresh redline gearbox oil, still a little difficult to get 1st but nowhere near as notchy. Next job is the gearbox turret repair.

Couple bits need attention

Rear n/s brake caliper has siezed, so it's got to go back for a new one plus fit these Bluestuff NDX pads.

Suspension needs a bit of an overhaul!

Needs...
Both front steering & rear suspension arms (excessive play in both)
Both front tyres low (4x new Rainsport 3's ordered....should be here tomorrow) these RS3's have done less than 5k!! I think I killed them last week on the daily 80 mile commute to work! They looked a bit flat even after pumping up, so I've gone for 97xl this time maybe better than 94 load?

Rear trailing arm & rear bottom axle bushes need replacing (powerflex to the rescue!!)

List goes on

Exhaust badly corroded (ive noticed it's slightly blowing but nothing major) stainless system on the cards after the clutch upgrade just hope it holds off until after the mot!
Drop link gaitor starting to crack
Rear brake pipes corroded (seems a common fault on these, so much so the garage make their own to fit)

So a few things to sort here! This stage 5 tune will have to wait a bit longer! No mega rush anyway as there's a problem with the new custom SPEC twin disc kit, SPEC are having a mare with this getting it to work so have shelved it until after racing season then getting back at it. Seems there's a load of v6 guys after a decent clutch! The other option is get or custom made.

Anyone tried CG Clutches before lads?

 

[griffindai]

Rainsport 3's now fitted all round. Jeez wet grip on these are incredible!!! 62 quid a corner! Billy bargain!!

Also nipped to the postie to collect a 2nd hand mesh grill (these hardly ever pop up used!)

Looks like the bumper has to come off to remove the old one and fit this so I'll add to the list next month. They'll have to take the bumper off to fit the intercooler anyway.

Just trying to figure out what to pollybush now then it's going back in next payday and getting a few jobs done

 

[griffindai]

Paydays around the corner.....Pollybush time!

Got a lot to replace & upgrade next month, basically having a suspension refresh.

First job is replace the seized rear caliper for new and fit the bluestuff NDX pads!

Its getting fully polybushed now so all Black Powerflex bar the engine mounts (both yellow) plus purple front ARB and Front Wishbone Front Bush its getting the following changed/replaced (may as well spend the extra while its all in bits and just get it all done!)

Front wishbone rear bushes
http://www.neobrothers.co.uk/front-....html?osCsid=c31bcb18ac97ae7ebcef65cf87b0a2ae

Rear engine mount (yellow)
http://www.neobrothers.co.uk/rear-e....html?osCsid=c31bcb18ac97ae7ebcef65cf87b0a2ae

So that's the front end fully pollybushed, now the rears will be all black bushes...purples listed below but they're going in the same place!

Rear arb
http://www.neobrothers.co.uk/rear-a....html?osCsid=c31bcb18ac97ae7ebcef65cf87b0a2ae

Rear lower arm inner bush
http://www.neobrothers.co.uk/rear-l....html?osCsid=c31bcb18ac97ae7ebcef65cf87b0a2ae

Rear lower arm outer bush
http://www.neobrothers.co.uk/rear-l....html?osCsid=c31bcb18ac97ae7ebcef65cf87b0a2ae

Rear trailing front bush
http://www.neobrothers.co.uk/rear-t....html?osCsid=c31bcb18ac97ae7ebcef65cf87b0a2ae

Rear upper inner bush
http://www.neobrothers.co.uk/rear-u....html?osCsid=c31bcb18ac97ae7ebcef65cf87b0a2ae

Rear upper outer rose bush
http://www.neobrothers.co.uk/rear-u....html?osCsid=c31bcb18ac97ae7ebcef65cf87b0a2ae

Also replacimg the following for new:

Rear Track Rod Arm/Toe In Cross Stay
http://www.neobrothers.co.uk/rear-track-armtoe-cross-stay-alternative-saab-sport-p-3578.html?

Lower Control Arm & Ball Joints
http://www.neobrothers.co.uk/lower-control-ball-joint-alternative-saab-0312-p-4372.html?

Strut top mounts & bearings
http://www.neobrothers.co.uk/advanced_search_result.php?keywords=top+mount+9-3+sport

Just waiting for these too come back in stock, seem to be a popular upgrade with the VX guys.
http://rndmotorsport.co.uk/epages/950003929.sf/en_GB/?ObjectPath=/Shops/950003929/Products/0121

Then get the lot properly aligned! Not sure where to take it yet though?

 

[griffindai]

Also have a short shifter coming from the states.

Ive gone for the Billet Pro Shop kit over TWM, came in a bit cheaper as its on sale plus has free shipping!
http://www.billetproshop.com/product/saab-9-3-5-speed-short-shifter-2003-2006/

Also went for the clamp kit
http://www.billetproshop.com/product/2003-2006-saab-9-3-cable-clamp/

And a differmt weighted gearknob
http://www.billetproshop.com/product/100-series/

I'll be keeping the GS shifter mount kit, this lot along with the turret repair kit should make a nice difference to the poor gearchange!

 

[T9 man]

Very nice Dai

 

[griffindai]

Can't wait mate!

I'm giving Demos a call next week then he can order all the bits in, they don't usually stock the Black series but should have then in pretty soon then send a nice big box off!! (he's been excellent help again)

Once this lots fitted.....stage 5 time! Finally!!

 

[griffindai]

My short shifters arrived from the states, looks/feels excellent quality but spot the mistake

They're sending the correct 6 speed engraved knob out tomorrow!

Also ordered a few powerflex black series bushes and new suspension bits & bobs to replace the old worn parts. Can't go for the full polly kit just yet, this clutch is getting critical so needs upgrading asap and have to keep some cash back for this.

I don't think the mini twin kits going to be available anytime soon so it looks like I'll get the SPEC 3+ and SPEC flywheel. I can get a standard friction disc updated for cheap but just can't get a definite answer on how much torque it'll hold

 

[griffindai]

Few things ordered now ready to fit next week

345mm brake upgrade from the Vectra VXR, comes with the carriers and calipers, discs & pads. Hard to find a set (been looking for ages!!) so figured I'd go for them! Not really 100% if they fit under my alloys, gonna be a very very close fit!!

Basically this kit below from Courts but has DS2500 pads Never tried these pads before so keen to see how they compare to yellow stuff.

http://www.courtenaysport.co.uk/buy...grade-kit-front-vectra-c/signum/prod_485.html

Currently has the 314mm Aero brakes with Mtec discs, yellow stuff pads, HEL lines & RBF600 fluid. Pretty good upgrade over standard brakes and would be probably be fine on a standard car or stage 1 with less torque! But really struggling to stop me here with the JZW tune!! Just feels like it needs that extra foot to come to a halt and they've only been on there a couple months! They'd be cooked at stage 5 so best to upgrade sooner than later! Should be a nice brake upgrade.....if they fit!

Plus some new bushes & suspension bits from Neo Brothers who've been excellent again!!

And some Heko wind deflectors to fit
Cars going in for a full Valet Monday so I'll fit these once it's nice & shiny

Having no joy getting a reply from RnD with these droplinks, and no phone number so might have to stump for the HD ones instead

 

[griffindai]

Brakes are here

Discs weigh a ton!! I'm booked in for Friday morning.....hope they fit!! Keen to see how much better 345's with ds2500 are vs 314's with yellowstuff

Car had a mini valet yesterday, did a good job (hate car cleaning!!!! Prefer driving it!!)

Nice to have it clean!!

The bushes, suspension bits & IC swap will have to wait until August now. Garage is fully booked all week and I'm away again working.

Still no joy with the clutch (needs to be sorted ASAP) slipping like a good 'un now

 

[T9 man]

 

[griffindai]

Getting there Os!!

This clutch though....nightmare!!! I think Autos are the way forward with the v6 if you want any decent power out of it!

How's the beast going

 

[T9 man]

The old boy is doing ok thanks Dai, it still see's it as a challenge to try and empty dads wallet at every opportunity but what can you do?

 

[griffindai]

Well the v6 wheels clear the VXR calipers (just about!!!)

Just swapped the calipers to test fit them until I'm home next then the 345's are going on, the balance weight just clears it. I'll see about getting these moved slightly just in case!

Standard:

Booked in for the 30th to fit the pollybushes, suspension bits, fit the 345's and the Evo IC. Around 12 hours labour all in!! Looks like these bushes are a right mate to fit!

 

[griffindai]

Finally!!!!!!!!

The Rose joined droplinks I've been waiting on for 2 months are back in stock and arrived yesterday

According the VXR lot these sharpen things up nicely, should feel like a different car with the front fully pollybushed & these

Replacement rear brake caliper also coming as mines seized and needs changing ASAP! Then the bluestuff NDX pads can go on and bar a couple rear bushes that's the handling & brakes sorted (Quaife LSD will be fitted same time as the clutch)

 

[griffindai]

Heko wind deflectors fitted

Fair bit more wind noise when driving above 60 but have been great for driving around town with the windows just cracked open slightly. Front went on prefect but the rears need a bit of adjusting at the top.

 

[griffindai]

Back to the drawing board with this clutch upgrade. The mini twin disc kit looks dead in the water (feel sorry for the guys who were in the group buy) and just been chatting to a few others with the SPEC 3+ and they're having issues at stage 5. Sounds like the SPEC kit is a shimmed standard pressure plate and their own disc options.... then painted blue! Always thought they had a fancy uprated pp but doesn't seem the case. It's a lot of outlay to shell out and have it slip after a couple thousand miles

Tempted to just get the Sachs clutch for £350 and ask to have the torque toned down a tad to 450-460ft/lbs. Or a standard LUK clutch from eBay for £80 and have the friction disc relined for £50....and hope for the best! Gutted! Really wanted a little monster here but it's not going to happen!! These engines can produce a shed load of torque (on the right tune) but hardly any clutch options available to hold it bar a clutchmasters FX850 (big bucks!!!)

Should still be plenty quick enough with the 18t though as it's got a much wider spread of torque vs the diesel like delivery in getting now so makes more power across the rev range. Aiming to get everything done in August, brakes/suspension getting done Friday.

Exhaust wise I'm just fiting the 3" DP, 3" race cat in the mid pipe, middle resonator replaced with a magnaflow one and rear muffler delete. So 'should' sound like this if I get it right!

 

[rdp50734]

Shame about the clutch issues but still it will be superb once its all done!

I like the sound of the newer exhaust, and the car looks great!

 

[griffindai]

Shame about the clutch issues but still it will be superb once its all done!

I like the sound of the newer exhaust, and the car looks great!

Thanks mate. May be onto a solution for the clutch with a UK custom clutch firm. The can supply an off the shelf Vectra VXR unit to hold 40% over standard so 360ft/lbs (no good!!) but after a few emails back & forward they're interested in making a custom clutch plus smf. Ones good for 80% increase (450ft/lbs) and the others a paddle clutch which will hold 150% more! 625ft/lbs. so tempted to go for this, I know the paddle clutches get mixed reviews as its on/off but with the low mileage I do these days and no more work commute I'm not bothered as long as it holds the torque. Bonus here is next year I could then upgrade the standard 15t TD04 turbo again to the 20T billet wheel which is around 10% more oomph than the super 19t gets, so may be around 580ft/lbs. That's a good 100 more than I'm expecting on the 18t

LSD's getting orderd next week, definitely have to get this!! Planning to get the transmission side up & running in August then finally get it on the dyno and see where it's at. Then go straight to stage 5 end of the month

Cars getting collected later, some bad news though! The intercooler can't be fitted, I know it physically fits as its been done before but the pipes I got told to get are all wrong. I'll see what they say later. There's a custom place local to me who specialize in Golfs & Audis, seen a few with massive FMIC's fitted so will take it there and see if they can sort something.

 

[griffindai]

Right quick change of plan with the car while its in bits at the garage.

The downpipe & exhaust is off as they've had to strip bits & pieces to fit the various bushes (massive job!!!!) they've been non stop and working hard on it.

So as they've got easy access to the turbo we decided it makes sense to fit the 18t now instead of coming back next month and stripping the lot down again. Same with the DP, that standard ones in a state and the bolts have snapped so will need to be driled and sorted out, so the TX auto 3" DP from the VXR is going on now (instead of next month as planned) It's maybe 2-3 inches shorter than the standard pipe when they're side by side so won't fit onto the standard system, but not a problem now as I'm getting a new system built anyway in the next week or so. Just means I can't bring it back home as it'll only have a 3"DP fitted and nothing else!

So the exhaust plan is to have the TX 3" DP from the turbo connected to a 3" decatted mid pipe (but also have the old cat welded onto another mid pipe to swap over for the mot) Then whole new 3" cat back, resonator swapped for a magnaflow one and both back boxes ditched for straight pipes. Gonna be very loud.....but in a nice asbo way

Intercooler also having issues fitting as the pipes I supplied were wrong. I thought they were 2.5" > 2.25" on the v6 but it's 2.5" so need to get a couple 2.5" 45 degree pipes & 2.5" joiners to the garage asap to get the IC fitted.

Just PM'd JZW for a suitable stage 3+ 18t map so fingers crossed he can sort that sometime next week either that or fit the 550's now and go straight to stage 5

 

[griffindai]

Stage 5 map ordered

Cars booked in for the 17th for the full 3" turbo back system, mot due next weekend so the exhausts staying standard until then. Turbo & injectors going on Monday, IC Monday then il pop down to load the map off my laptop.

Clutch, flywheel & diff getting ordered mid next week so it should be all done towards the end of August

 

[griffindai]

Quaife LSD's here from Abbott Racing

I've sent a spare clutch & DMF to CG Motorsport so they can check against what they have and see what they can offer as an upgrade.

18t's fitted, 3"DP, IC & 550's should be fitted today then the bushes & brakes changed this week. Stage 5 maps here ready to load then it's getting recovered to Prospeed for a full 3" system and booked in for the mot next day.

Clutch/diff will be done end of month then I think that's everything done!

 

[griffindai]

Clutch ordered

http://www.clutch-specialists.co.uk...ch-kit-with-solid-mass-flywheel_p31006055.htm

Single mass flywheel conversion with heavy duty cover and choice of either 666 or 777 friction disc.

It's also a paddle clutch and they come in either 8, 5 or 4 paddle. I'm guessing there's a few on here who've had a paddle clutch in the past! What would you recommend going for?

They also do a lightened flywheel option but have been advised against going too light (around 6-7kgs like I have in the past) as its a paddle clutch and to keep it the same weight as the standard DMF or just a couple kg's lighter.

Theyre making a small batch of 5 to start and should be built and here in 3 weeks

 

[griffindai]

Popped to the garage today to load the map, but if a panic as it kept saying error and wouldn't load but updated the software again and it's got the rev2 stage 5 map loaded now.

The VXR 3" DP did bolt up to the standard system but there's a leak somewhere, can't really see if it's the turbo>DP flange or DP > mid pipe but definitely not sealed and chucking the fumes out!! Fingers crossed it's the latter or I'll have to get a new 3"DP built for the new system Monday.

All bushes fitted, brakes on (look massive with these 17's!!)

Fair way to go but we're getting there

 

[griffindai]

Cars down with Prospeed now getting the ful exhaust upgraded.

The VXR DP just wouldn't seal with the turbo so he's had to cut the flange off this and bin it, then weld the flange onto a new 3" DP and build another (50/50 if it would seal properly anyway) Plans for the midpipe also changed! I wanted a 3" decat here and the old cat welded onto a changeable pipe to swap over come mot time but decided to sack this idea and just have a sports cat fitted permanently (it's HUGE this thing!!!) the center resonators getting ditched and he's building a nice long one, then straight pipes out the back but no quad tail pipes as planned, he'd have to cut the bumper to fit a pair of nice ones either side or fit small ones....so it's having oval pipes each side instead.

Booked in for the MOT Thursday now as it won't be ready in time.

Spoke to CG Motorsport and it's a 6 paddle clutch I'll be having so happy with that. Looking at mid sept until it's all up & running, get some logs off the the mapper to adjust the map to get it all running nice then it think!! That's the performance side done!

 

[griffindai]

Exhausts done

Had a lovely surprise when I walked in!!! He was busy fitting the quad pipes like I originally wanted!!

Straight pipes out the back, did a really nice job on this. Very loud though!!! I haven't had a loud exhaust since the old 9000 Aero!

Dropped it back off with the Saab garage, drive there was interesting!! Pulls a lot harder at stage 5!!!! Clutch slip is a lot worst here (expected) Tiny bit of extra turbo lag but nothing really, feels much nicer to drive with the new system, sounds great. Pops & bangs on the over run

Failed the MOT on emissions though, I've emailed the mapper so hopefully I'll have another one to load tomorrow for a retest.

 

[griffindai]

All MOT'd now. I'm ditching this sports cat though and just fully decatting it in a couple weeks then keeping the standard cat for mot day.

Couple vids. First ones the emissions map I had, no issues here:

2nd's the rev2 map, hunting a bit at idle here also on a 30 mile run earlier felt like its dumping the boost around 3k @ wot in 5th & 6th. Not sure if it's a coil about to go (expected!!) or maybe the map needs adjusting, bit of turbo flutter also. Vids sent to JZW but can't get any proper logs off to him yet until the clutches done, then the 500 mile break in period so looking at maybe October until we can really get cracking on this. I can't cane it anyway so just basically driving normal until it's sorted & running safe.

I'll try the other maps tomorrow from cold start and have a decent run with each (3 maps here to try)

It's getting booked in for a full wheel alignment Tuesday, all over the shop here!!

I'll get a few more vids up and a couple in the cabin at wot. V6 sounds lovely when you open it up!!

 

[T9 man]

Well that gets a big thumbs up from me Dave

 

[griffindai]

Thanks Os, getting there!

Just had a few more maps to try from John, he's said the hunting idle and throttle cut is normal on a new flash as the ECU has to learn all over again and can take around 100 miles to fully adapt to the map. (Phew!!!) thought I had a problem there! More used to the t5 set up! Just pull the battery for 15 mins, then cane it everywhere so it adapts

 

[griffindai]

Wheel alignment & sort the camber done today. MASSIVE difference!! Pretty surprised how much of a difference it's made!

He took me out in it quickly to see how better it is, took a sharp bend way faster than I ever have and it just stuck like glue! Had visions of it under steering across the road like it usually does!

60 quid well spent. It's going back for another when the clutch is swapped, they've got to drop the subframe to get the box out so it'll be off again. I'm getting some eibach camber bolts this time though so he can fine tune it a little more. Really happy with it though. Corners miles better

 

[griffindai]

Cars now fully decatted

Quick Exhaust clip

Standard cat welded onto an interchangeable for mot time

Having a issue with boost cut at the moment, I'll be getting the HP Tuners software JZW sells over the weekend then hopefully he can sort this after seeing a few logs. Fingers crossed it's just the map needs toning down, I think it's got the 19t map loaded? So 415bhp & 532ft/lbs and I'm a fair bit off here. Either this or maybe the fuel pumps on its way out, dodgy coil (expected) or the boost control solenoids going (but that's brand new so should be fine)

Will find out soon enough!

Going well though, sounds evil now with the straight through system!! Bonkers!

 

[T9 man]

 

[griffindai]

Right quick update on this....

I'm still getting boost cut which sounds more like its throttle cut. I was hoping Dash Command on iPad/iPhone could pick out the issue but it doesn't have the right parameters for my tuner to see, so I've had to go for a ecu tuning program called HP Tuners. I was looking at getting this anyway but not for another month until the clutch was on and settled in.

http://www.hptuners.com/index.php

So this should show any issues I'm having plus John (JZW) can fine tune the stage 5 map and get everything as perfect as he can, basically have to log any runs then email him the info, remap, re-log, email & remap until it's done. For this I need the vcm scanner:

http://www.hptuners.com/products/vcmscanner.php

So still getting this throttle cut and over boost issue and there's a strong fuel smell on start up & shut down, also the exhaust tips are pitch black so I think it's over fuelling here a bit! I've asked what 18t map is on here and he's mentioned it's pointless loading the 18t map and just go for 20T instead, so maybe that's what's causing the throttle cut here, pretty certain it's got the 20T map loaded and he's going to just tone this down a bit when he gets the HP Tuners logs

And that sort of ties in with the info I've had from Dash Command! When I tested the peak bhp & torque at stage 1 it was pretty accurate, just a few digits out from what it should be, tried it this week at stage 5 and got 420bhp with 540ft/lbs torque which is pretty much stage 5 20T territory and way (waaay!!!) above the vxr 18t guys usually get. Not sure how accurate DC is though, I mainly use it for fault codes.

So will be taking it easy now until I get HP Tuners on there!

Spoke to CG clutches earlier and it should be here by the weekend So it's booked in for next week to get this upgraded plus fit the Quaife. Needs that 500 mile break in they've advised, lots of logging done here just to make sure it's running safe then some proper logs done and he can fine tune the map.

 

[griffindai]

Finally.....car should be ready by the weekend! I'll update the thread later with all that's happened the last month...been a bit emotional trying to sort the new clutch & HP Tuners software out!

Can't wait to have it back, just have to take it easy to run the clutch in then crack on with the logging side to get it set up nice, had a couple map tweaks to sort the throttle cut issue. And needs another wheel alignment (subframes been off 3 times in 5 weeks so needs doing again)

 

[T9 man]

I am sure your efforts will be worth the wait Dave.

 

[griffindai]

Thanks Os, finger crossed for the weekend!! Got a few bits & pieces to sort then it should be running nice next month.

With the stage 5 tune it really needs a custom map on there, JZW offers his own hand held scanner, so you can log & save the runs, then email them to him, he works his magic and you go again. Or there's the option to go for the HP Tuners scanner which is meant to be much better and let him see exactly what's going on especially with this throttle cut issue I'm having....

So the scanner arrived last month. But no activation key!! This was a right ball ache to sort out, took around a week of emails, joining their forum, registering the product and loads of messing until it was done. Bit stressful as I wanted this done before the clutch swap and after all the swearing & stress it was down to having the older software on the instal disc and just needed updating! That was a pain to sort out!!!!!

Here's the scanner & bits & bobs

HP Tuners software installed and up & running with the correct parameters John wanted.

^^^^ I tried logging a few run with Dash Command hoping he'd have the info on there, but it doesn't support a few of the parameters so couldn't do a lot with it. So basically if you want to go for the stage 5 tune.....you really need HP Tuners to get it set up right. So that's another £350 vanished!!

So that's one big headache out the way! The clutch should be sorted Friday.

 

[griffindai]

This clutch was another massive headache!

Had problems sourcing some new diff bearings as Saab doesn't seem to have these anywhere, so after after a week or so the garage sourced a set, also needed new seals.

The 777 kit got sent out 4 weeks ago, the garage got cracking on it the next day, Quaife was installed fine (meant to be dead easy on this F40 box) but this single mass flywheel was a few mm too big and wouldn't fit. So the job had to be put on hold for a week until a replacement flywheel was sent. That took 3 1/2 weeks to arrive!!! Feel bad for the garage here as he booked it back in a couple more times to be done and had to cancel other jobs or put them on hold to get mine finished, but the flywheel wasn't sent on time as promised (twice!!) so out a ramp out of action for a fortnight or so waiting for this flywheel to turn up.

Also needed new flywheel bolts as the standard ones are too long, and I think this was probably the hold up. So these 666 & 777 kits will now ship out with the correct bolts.

The new flywheel & bolts arrived last Thursday, cars now booked in this Friday and just hope this time the flywheel is correct, bolts fit and it 'works'.......

With the clutch they gave the option of sprung or unsprung so have gone with sprung. And confirmed again it's the 777 paddle clutch with 6 puck ceramic disc, I think the 666 organic disc will throw in the towel with this much torque, but should be fine for up to stage 3+ cars (roughly 460ft/lbs)

Some pics of the kit that's getting fitted:

Quaife ATB LSD

Slave Cylinder & release bearing

Redline 75W80 MTL

Aaaand!!! The clutch & single mass flywheel (heavy!!)

 

[griffindai]

So hopefully that's the transmission side done, just needs the 500 mile run in period then I can get it logged and mapped properly. For the tuning side John's been testing his stage 5 map with a 3 bar map sensor (which is standard fit on the 9-3 tid) and had excellent results with this.

He runs the stage 5 tunes up close to 20psi but boost levels get close to the standard map sensors limit at 22.5psi so added these map sensors to the stage 5 tunes and it sounds like it's made a nice difference. Some right on the edge (19t & 20T) would get the throttle cut or boost dump every now and then (what's happening to me with the 18t) but with the new tune and the 3 bar map sensor they're not having that problem anymore. So hopefully this'll cure it

This bit went over my head though but the ecu gurus here will understand better!

That is over 306 Grams per Second air flow through the motor or 41# per minute


The plan now is to collect the car on the weekend, swap map sensors over and re flash the map to see if it's cured the throttle cut. Another wheel alignment as it's probably all over the shop now (got some Eibach camber bolts this time!!)
Take it easy for 500 miles and then finally get him a log with HP Tuners (just needs a few hard pulls between 3-6k)
Probably a few more tweaks to the map and then I 'think'....were done!!