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1994-2002 [Subscribe to Daily Digest] |
Yes, this is very achievable.
With turbo charged engines, there are two routes to more power. One is to increase the boost. The other is to increase the air charge density.
The air charge density can be increased independant of the boost pressure by lowering the air charge temperature. The focus is on eliminating or antenuating things that increase the temperature.
Pressure drops in the intake system increase temperature. On your vehicle, there should be a turbo discharge silencer which can be removed with hand tools. A K&N 33-2663 drop in air filter will help as well. There are a couple of ways to modify your air box, to remove the 15" snorkle tube, and extend, possibly enlarging, the openning. Remember the goal is avoiding heat, so the intake should not get any hot air from under the hood.
The throttle body intake transition casting is held on with two 10mm hex bolts and a couple of hose clamps. It has to be removed, and ground and smoothed. It has some normal minor casting flaws, and a major design error for years 1994 through 1999. As the small end there is a 3/16" step in the flow, which creates a 3/8" sharp edged step reduction in the diameter. You need to grind this out to blend from a 1.5mm wall to match the tubing. Grind as far up as you can. Also, smooth out the big end, and reduce the exit wall thickess to 2mm. This will then create a flow match to the step in the throttle body. If you make it thinner, you will create a problem. Clean the throttle body while you are there, some solvent on a cloth is all that you need. Clean the o-ring and dress with some silicone grease when refitting. This will produce more power, but it will feel strange, as the engine will also run smoother. The turbulance that is created by this design errot causes uneven fueling.
Use a 1" drum sander. Perhaps you can use 1 1.5" sander in later stages, but there is a danger of severe oscilations which could cause injury or dammage. A flex shaft and a 1" medium grit sanding drum seems ideal. A course drum might work well for the intial stages where massive amounts of melal removal are needed. Others have been satisfied usind a Dremel tool. Wash the casting with detergent and water before fitting to the vehicle. See photos posted under 'throttle body transistionn casting rework' from September. Can't remember the exact title.
You also need a Saab sports exhaust if you are going to be increasing the boost. This will be your major expen$e. You could go dealer installed, or purchase it over the web. Exhaust systems are a pain as a DIY.
Boost can come later. My suggestions on this do stir up some debate. All of the other items are not subject to any controversy.
For the summer months, you can insulate parts of your intake system, this will allow you to have respectable power as the temperatures get into the 100's. This is also inexpensive. You do not need to get the high tech, high expense exotic materials for most of the job.
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