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 Post subject: 9-5 Aero HOT
PostPosted: Thu Dec 22, 2016 1:00 pm 
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Joined: Tue Aug 16, 2016 11:38 pm
Posts: 88
Location: Cheltenham
Car Models: saab 9-5 Aero HOT 2003
Hi, This is my project.

I bought my car in August off a dude up North. It's done a few miles but its in pretty good condition apart from very rusty underneath.
Edit: Ok it looks rusty but structurally sound. Sorry for not making that Clear to start with.
The last owner I think had a sump drop and I guess I'll do the PCV6 thing as well.
Also forgot to mention the last owner removed the Air-Con because there was a fault with it.

This thread will be a slow one as I am only 21 and an apprentice so Insurance is a bit pricey and I also spend my money on lots of other C*ap.

To Do list: Anything that is Blue is completed

New Rocker cover
Service; Air filter, Oil, oil filter, fuel filter
Torque Rod to engine poly bushed
Auxiliary put into the Headunit
De-scabbing of rust and undercoated
Complete Breather Hose Kit
All Bushes replaced with Powerflex
Blacking Out of Front grill
Sump Drop
Straight Through Stainless Pipe
Induction Kit

Replacement of Air-con
Lowered Springs
Up-rated Shocks
DO88 Inter-cooler
Removal of rust on rear arch
Tidy up of plastic trim.
Speaker Upgrade
Yellow Front Fogs



That's about all I can think of now that i want doing.

Removal and change of Rocker Cover
Image

Auxiliary Input on Headunit.
Image

New Discs.
Image
Image
That's all the photo's I have so far as its mucky so will take some next time it's cleaned



Cheers for looking.


Last edited by guffers158 on Wed May 27, 2020 12:57 pm, edited 35 times in total.

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 Post subject: Re: 9-5 Aero HOT
PostPosted: Thu Dec 22, 2016 1:26 pm 
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Joined: Sun Aug 15, 2004 9:39 am
Posts: 41731
Location: SW Herts
Car Models: 2007 9-5 Aero est. 300hp Hirsch. 9-3 2010 9-3 Carlsson
Looking good.

For springs and shocks, I'm pleased with the Bilstein B8 and Eibach kit. If you replace the top mounts USE GENUINE Saab/Boge ones. The free ones I got with the kit failed in 500 miles.

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 Post subject: Re: 9-5 Aero HOT
PostPosted: Thu Dec 22, 2016 5:43 pm 
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Joined: Fri Nov 23, 2007 6:13 pm
Posts: 20603
Location: Maidstone
Car Models: 9-5 Aero
Just a mo........................

guffers158 wrote:

I bought my car in August of a dude up North. It's done a few miles but its in pretty good condition
apart from very rusty underneath.



I'd suggest re-thinking your plans for the car (unless you are a welder by trade ;)). Without wanting to wee all over your chips, it would be silly to spend a lot of time, effort and money on upgrades to this car only for it to be declared a total wreck come MOT time due to lots of corrosion. You'd then need to find another car and enjoy the ball-ache of swapping everything from one to the other.

Why not enjoy the car for what it is, get to know the car and it's ideosyncracies and spend the time looking for a decent example that'll be worth tweaking.

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Prefers driving over polishing or reading.


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 Post subject: Re: 9-5 Aero HOT
PostPosted: Thu Dec 22, 2016 5:46 pm 
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Joined: Sun Jan 27, 2013 10:20 pm
Posts: 2128
Car Models: 2004, 9-5 Aero, Noob 3
Personally, if you intend to keep it, I'd sort the rust first before spending the cash on the mods.

Edit: Rich beat me too it :)


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 Post subject: Re: 9-5 Aero HOT
PostPosted: Thu Dec 22, 2016 6:07 pm 
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Joined: Wed Jul 27, 2016 10:16 pm
Posts: 114
Location: Hampshire
Car Models: 9-5 Aero HOT, M135i, X5 M50d
Where's the pics? Sounds like a lot of work - is the car tidy?

You don't say if the rust is structural or not...

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 Post subject: Re: 9-5 Aero HOT
PostPosted: Thu Dec 22, 2016 6:33 pm 
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Barrelling Along
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Joined: Fri Nov 23, 2007 6:13 pm
Posts: 20603
Location: Maidstone
Car Models: 9-5 Aero
also, the very first thing I'd have on your list is a sump drop and clean out, plus fitting the PCV 6 breather system (if it isn't already there..........)

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Prefers driving over polishing or reading.


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 Post subject: Re: 9-5 Aero HOT
PostPosted: Thu Dec 22, 2016 7:00 pm 
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Joined: Sun Oct 28, 2007 11:31 am
Posts: 2420
Location: Chatham, Kent.
Car Models: 9-5 Aero 2002
McVities wrote:
Just a mo........................

guffers158 wrote:

I bought my car in August of a dude up North. It's done a few miles but its in pretty good condition
apart from very rusty underneath.



I'd suggest re-thinking your plans for the car (unless you are a welder by trade ;)). Without wanting to wee all over your chips, it would be silly to spend a lot of time, effort and money on upgrades to this car only for it to be declared a total wreck come MOT time due to lots of corrosion. You'd then need to find another car and enjoy the ball-ache of swapping everything from one to the other.

Why not enjoy the car for what it is, get to know the car and it's ideosyncracies and spend the time looking for a decent example that'll be worth tweaking.


Rich, like you, I have looked at a lot of 9-5's and I've yet to see one with SERIOUS rust, surface rust yes, but not serious structural rust, maybe its just a case of getting the old wire brush out and giving it some elbow grease and rust prevention of some sort.

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2000 9-5 Aero Estate Auto. Maptun Stage I (Broken)


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 Post subject: Re: 9-5 Aero HOT
PostPosted: Tue Mar 21, 2017 9:39 am 
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Joined: Tue Aug 16, 2016 11:38 pm
Posts: 88
Location: Cheltenham
Car Models: saab 9-5 Aero HOT 2003
Had the car MOT'd last week. It passed. With advisories for a couple of bulbs and the Sub frame bushes which I have just bought. Also bought the Meyle HD drop links to replace. Also the headlamps need a clean.


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 Post subject: Re: 9-5 Aero HOT
PostPosted: Tue Mar 21, 2017 7:52 pm 
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Joined: Tue May 26, 2009 10:13 am
Posts: 13
Car Models: 9-5 Aero Estate
phil_saab wrote:
McVities wrote:
Just a mo........................

guffers158 wrote:

I bought my car in August of a dude up North. It's done a few miles but its in pretty good condition
apart from very rusty underneath.



I'd suggest re-thinking your plans for the car (unless you are a welder by trade ;)). Without wanting to wee all over your chips, it would be silly to spend a lot of time, effort and money on upgrades to this car only for it to be declared a total wreck come MOT time due to lots of corrosion. You'd then need to find another car and enjoy the ball-ache of swapping everything from one to the other.

Why not enjoy the car for what it is, get to know the car and it's ideosyncracies and spend the time looking for a decent example that'll be worth tweaking.


Rich, like you, I have looked at a lot of 9-5's and I've yet to see one with SERIOUS rust, surface rust yes, but not serious structural rust, maybe its just a case of getting the old wire brush out and giving it some elbow grease and rust prevention of some sort.


Sadly I have. My 2002 Aero needed £1000 worth of welding for it's last MOT and now there's a huge hole in the spare wheel well :/ The specialist that did the job said he'd never seen one that bad.

Test date 23 November 2016
Test Result Fail
Odometer reading
124,889 miles
Reason(s) for failure
Nearside Rear Suspension component mounting prescribed area is excessively corroded outer sill (2.4.A.3)
Offside Rear Suspension component mounting prescribed area is excessively corroded outer sill (2.4.A.3)
Offside Rear Anti-roll bar linkage ball joint dust cover excessively damaged so that it no longer prevents the ingress of dirt (2.4.G.2)


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 Post subject: Re: 9-5 Aero HOT
PostPosted: Thu Apr 05, 2018 12:20 pm 
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Joined: Tue Aug 16, 2016 11:38 pm
Posts: 88
Location: Cheltenham
Car Models: saab 9-5 Aero HOT 2003
Haven't posted for a long time.

I have swapped the side lights for LED's
Swapped the Reverse Lights for LED's
Changed all the interior lights for LED's
Getting a New exhaust and had some rust repaired on one of the arches.

I have a nice camera now so images will be uploaded soon!


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 Post subject: Re: 9-5 Aero HOT
PostPosted: Thu Apr 05, 2018 12:48 pm 
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Joined: Wed Jan 18, 2012 5:24 pm
Posts: 7355
Location: Wigan, Lancashire
Car Models: 99L, 9000cse, Panda, Octavia estate and far too many 9-5s.
Looking forward to some pics, as them's the rulz.

As for the exhaust, unless it needs replacing I'd save yourself some money and postpone this. The OE exhaust is good for 300+bhp and is not a restriction. A stainless steel exhaust will make it sound different (better, if not too loud, in my opinion) but won't really make a difference. For much less than the cost of a SS exhaust you could make enquires with Saabnoob on this forum about a cheeky Stg1 remap which will make the car more interesting.

And just so I don't seem to be a boring old fogie, which I am, my 9-5 is at Stage3 and a bit and I've only recently got a SS cat-back system put on it for the sound and that bits of the old one were getting very crusty.

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 Post subject: Re: 9-5 Aero HOT
PostPosted: Thu Apr 05, 2018 9:23 pm 
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Joined: Tue Aug 16, 2016 11:38 pm
Posts: 88
Location: Cheltenham
Car Models: saab 9-5 Aero HOT 2003
I am incredibly immature and want a loud exhaust.
It is actually already at Stage 1 I failed to mention that so my fault.
Also my exhaust is incredibly crusty atm. So I thought I may as well get a nice fancy new one. :)


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 Post subject: Re: 9-5 Aero HOT
PostPosted: Thu Apr 05, 2018 11:01 pm 
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Joined: Sun Nov 02, 2014 6:27 pm
Posts: 541
Location: Bristol, UK
Car Models: '09 9-5 Turbo Edition St3 Noob
guffers158 wrote:
I am incredibly immature and want a loud exhaust.
It is actually already at Stage 1 I failed to mention that so my fault.
Also my exhaust is incredibly crusty atm. So I thought I may as well get a nice fancy new one. :)



Pics brother, else you are likely to be shot! :wink:


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 Post subject: Re: 9-5 Aero HOT
PostPosted: Thu Apr 05, 2018 11:46 pm 
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Joined: Wed Jan 18, 2012 5:24 pm
Posts: 7355
Location: Wigan, Lancashire
Car Models: 99L, 9000cse, Panda, Octavia estate and far too many 9-5s.
guffers158 wrote:
I am incredibly immature and want a loud exhaust.
It is actually already at Stage 1 I failed to mention that so my fault.
Also my exhaust is incredibly crusty atm. So I thought I may as well get a nice fancy new one. :)

:D
Hmm, toss up between loud and an Albert666 downpipe. Not an easy choice

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 Post subject: Re: 9-5 Aero HOT
PostPosted: Sun Apr 08, 2018 12:21 pm 
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Joined: Tue Aug 16, 2016 11:38 pm
Posts: 88
Location: Cheltenham
Car Models: saab 9-5 Aero HOT 2003
I am getting an Albert666 Exhaust (That's the plan anyway). It'll just be a straight through with Sports Cat

The window rollers broke so I took the window apart and replaced the green rollers and lubed it up with loads of Mobil Grease 28. Works better than ever.
Right so here are pics.
LED's that I swapped for the standard dash lights. Too green though so I will be swapping them for white ones.
Image

Interior Lights swapped for LED's also Green puddle lights because I am a sap.
Image

Reverse lights swapped, No. plate lights and side lights swapped for LED's
Image
Image

Car in Cornwall. Handles are very faded and she is a bit tatty tbh. But I like it!
Image

Check out those awesome Editing skillz!
As it wasn't the summer holidays the A roads around Bude were pretty much empty, thus some very spirited driving occurred. Can't believe how well this car handles with some good tyres. (The gf wasn't too impressed.)


Last edited by guffers158 on Fri Apr 13, 2018 12:38 pm, edited 4 times in total.

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 Post subject: Re: 9-5 Aero HOT
PostPosted: Sun Apr 08, 2018 1:31 pm 
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Joined: Wed Jan 18, 2012 5:24 pm
Posts: 7355
Location: Wigan, Lancashire
Car Models: 99L, 9000cse, Panda, Octavia estate and far too many 9-5s.
guffers158 wrote:
Interior Lights swapped for LED's also Green puddle lights because I am a sap.
Image

No sap involved. I did my interior lights with green LEDs as well.
The LEDs look brighter than mine. where did you get them?

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 Post subject: Re: 9-5 Aero HOT
PostPosted: Sun Apr 08, 2018 4:45 pm 
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Joined: Tue Aug 16, 2016 11:38 pm
Posts: 88
Location: Cheltenham
Car Models: saab 9-5 Aero HOT 2003
DeeDub8 wrote:
guffers158 wrote:
Interior Lights swapped for LED's also Green puddle lights because I am a sap.

No sap involved. I did my interior lights with green LEDs as well.
The LEDs look brighter than mine. where did you get them?


My chums think otherwise but they don't have a Saab (HAHAHA) :twisted:

I got them from Amazon. Don't know if they sell them anymore, here is the link
http://amzn.eu/0yjQ8Er


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 Post subject: Re: 9-5 Aero HOT
PostPosted: Wed Apr 25, 2018 9:18 am 
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Joined: Tue Aug 16, 2016 11:38 pm
Posts: 88
Location: Cheltenham
Car Models: saab 9-5 Aero HOT 2003
Ok so I bought a few more LED's as the Green LED's were a bit harsh behind all the displays. I also bought some to go behind the instrument cluster. Turns out on the Aero the instrument cluster has surface mount LED and not incadescent bulbs. So no need to change. A
Also changed the Top Mounts on the Old mans Saab 9-3 TTiD.
Pic of the car on the moor. Not that great but it was a lovely evening in the Pennines.
Image

Saab 9-3
Image

Full Dashboard off of car to get to instrument cluster
Image

Instrument Cluster.
Image

Behind the Dashboard. So many wires, made me slightly uncomfortable.
Image


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 Post subject: Re: 9-5 Aero HOT
PostPosted: Wed Apr 25, 2018 10:16 am 
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Joined: Sun Aug 15, 2004 9:39 am
Posts: 41731
Location: SW Herts
Car Models: 2007 9-5 Aero est. 300hp Hirsch. 9-3 2010 9-3 Carlsson
If you do change the instrument panel, you will need to get a Tech 2 to the site. The panel is included in the security network. The car won’t start if it’s not married!!

But otherwise the dashboard mess looks very familiar, :D

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 Post subject: Re: 9-5 Aero HOT
PostPosted: Mon Apr 30, 2018 8:35 am 
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Joined: Tue Aug 16, 2016 11:38 pm
Posts: 88
Location: Cheltenham
Car Models: saab 9-5 Aero HOT 2003
Dropped the car of at Alan's last night. He said it'll be done in the next couple of days. :D


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