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 Post subject: B204 - E85 500HP mods
PostPosted: Mon Apr 15, 2019 9:47 pm 

Joined: Mon Apr 15, 2019 9:37 pm
Posts: 1
Car Model: Non-Saab :D
Hi folks,
Planning to buy an Astra G Cab with a B204 engine, I've wanted that engine for quite a while now, as it is known as being bulletproof, and wanted a good sleeper!

Car has current engine mods and is doing 280hp:

B204 saab turbo and ECU
F18 box
Saab viggen clutch and upgraded flywheel
2.5 inch straight through exhaust
Induction kit
Front mount intercooler
Boost gauge
Stage 3 map
VXR inj

Besides a new fuel pump, bigger turbo, and a new tune, what parts would I need to make around 500hp running E85 (I'm in France and E85 is widely available here)

PostPosted: Tue Apr 16, 2019 5:39 am 
UKS Addict
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Joined: Mon Feb 19, 2007 4:12 pm
Posts: 8535
Location: Portsmouth
Car Model: 96 V4 & 9-3 Turbo-X
F28 gearbox
Spare F28 gearbox every 6 months (at that power the gearbox will be a service item!)
3in downpipe with sports cat
3 bar map sensor
630cc or better injectors (i dont know that the vrx injectors flow at)
Garrett GT30 turbo (or flow/boost equivalent)
Equal length exhaust manifold
Walboro 255 fuel pump
Forged rods and pistons (an overbore to 2.1l wouldn't hurt as you'll be struggling to get the 2.0 up to 500bhp)
Large-bore induction pipework from intercooler to throttlebody

And a suitable remap to make use of all this hardware.

Pretty sure I've remembered the shopping list, but someone else will correct me if I'm wrong. The bit im not sure on is the turbo needed to get a 2.0 up to 500bhp. Could end up needing a GT35, and possibly 850cc injectors.

EDIT: You'll also need a Limited Slip Diff at that power. No ifs, no buts. And probably traction control too or the car will be uncontrollable when the turbo spools up.

'75 96 V4 Anniversary Restoration Project
'09 9-3 Turbo-X Wagon No. 38
B204 Haynes Roadster Project

PostPosted: Tue Apr 16, 2019 11:51 am 
Barrelling Along
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Joined: Fri Nov 23, 2007 6:13 pm
Posts: 20101
Location: Maidstone
Car Model: 9-5 Aero
Have a Google for vigge - he had a 650-odd bhp 9-3.
His setup would be something to aim for. E85 will let you run more ignition timing and boost, but needs lots more volume of fuel to make it. Approx 35 to 40% thus fuel pump and injectors will need to be much bigger than achieving this power on petrol.

Don't forget handling and brakes and tyres....... as a convertible its not going to be great in the bends but it will need some serious mods to safely cope with 500bhp!
Perhaps get the car and enjoy it for what it is without sinking something in the region of 5-10,000 into it.
You could even buy some sort of V8 merc convertible with similar performance for less!

Power is nothing without control

PostPosted: Tue Apr 16, 2019 8:12 pm 
UKS Addict

Joined: Fri Apr 24, 2009 5:33 pm
Posts: 8443
Location: Derbyshire
Car Model: og93 RWD trackcar
Fuel pump & injectors as above.

GT3071 Turbo or larger with 3" downpipe.

Stock rods & pistons will cope with it.

Big intercooler.

Ideally longer duration cams & the volvo valve springs to suit a higher rev limit.

Your current will last about 5 mins on that kinda power..........

Project 9-3GT 484Bhp & 483lb ft / 654Nm

Mini cooper S 240Bhp

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