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Old 24th August 2009
ludichris001's Avatar
ludichris001 ludichris001 is offline
Saab Lunatic
Join Date: Sep 2007                                                
Location: Adelaide, South Aus
My Saabs: 89 900 EMS, 90 T16 900i, 2x 93 900i's
Posts: 1,478
Default a neverending story - chris's turbo 900i


after all the things i have done to this poor little car it deserves a project thread...
its a silver 5 door auto 900i that had 230,000 Kms on the clock, which i bought for $500 because of a "transmission problem".
it had no gear engagement whatsoever, which i found was due to no oil pressure.. anyway i got it towed home and pulled the whole front of the car off, the trans end plate and found a dead oil pump. i replaced the pump flushed all of the fluid put it back together and away i went!


after a few weeks of driving it around, it was running perfectly, but it soon bored me.. (too slow) so i turbocharged it....

and so it began....

started off with a stock T3, N/A fuel system and an intercooler from a toyota MR2 which i modified so it could go behind the grille (it was originally a side-mount intercooler)
fitted a 2.25" exhaust (stock one was like 2" )
i kept the EZK ignition system on the car and set boost only by the wastegate actuator. no APC...

i started off little.. 5psi... and the fuel economy went out the window.. 300kms to a full tank .. which i found out was due to still having the N/A fuel system, so i went and hunted down a complete LH2.4 system from a T16 and fuel economy came back (still kept the EZK system though).

by now i was getting bored again so i turned the boost up to 8psi...

it went like a rocket! i was very suprised at what this car could do now, but as i found, the trans didnt like it, at all.
soon came sticky gearshifts and very delayed 2-1 downshifts. i played around with band adjustments and kickdown adjustments until i got it somewhat back to the way it used to be and also started to notice the oil leaks now present from the trans.... i flushed it again which also helped a little and left it alone for a month or so...

then i got bored... again...

so i went and bought a 450x300x70 FMIC and chucked that on along with a blow off valve and an MBC.
things were looking good, i was slowly working the boost up until i had it at close to 17psi, at this point it was starting to scare me a little, i was having some fun with a few mates one night, showing off and such... i hit the accelerator, it kicked down a gear and lit the front wheels up, which almost sent me into the side of a bus at 70km/h ... i calmed down a little after that, at least until i bought some new tyres.. now that it had traction it was less "violent" when i floored it.
i was happy now. i had a excelent little car that could whoop a V6 commodore with ease (for a 4 cylinder, and especially an auto C900)

then came the time where i wanted it to go fast but also be reliable, i had little bugs and problems that showed themselves from the day i bolted the turbo on which i coughed up the $$ and fixed properly.. then i decided to get a 2.3L head and manifold. that went on in about a half a day, and i turned the boost back down to 8psi for the first 500kms, then back up to 17..

then after a few weeks of driving the trans let go, i was once again having some fun with some friends, i took off, hit full boost and heard something that sounded like i just hit the engine with a sledge hammer... i pulled over to find trans fluid POURING out from the front case.. i nursed it home and let it sit for a couple of months. i picked up a trans from a wrecker, stripped it down and replaced every bearing, seal, clutch plate, and bands, got the valve body overhauled and went over all of the gearsets ans servos etc, and repaired/replaced accordingly.. trans was fitted to the car and away i went..

then came the turbo issues that some of you may know about..
i went through 4 (i think) turbos in less than a week , all sending oil straight into the exhaust.
after a few days of research i then decided to fit a ceramic ball bearing turbo from a nissan RB20, because of the turbine size and the weight difference i basically had no turbo lag, which is ideal fo an automatic transmission.
these turbochargers have a tendency to "shatter" at higher boost levels (1 bar) so i had chosen not to go above 10psi.
along with the turbo conversion i made up a full 3 inch mandrel bent system with a supercat muffler and resonator. then soon after that i fitted a "gonzo" spiral resonator to make it quieter, which it did.

the latest addition to this car is complete LH2.4.2 + DI/APC systems from a FPT 9k 2.3T

i made up two full wiring looms from scratch, one for the LH unit and the other for the DI/APC. fitted, modified, and/or built every little thing that these systems needed made it all nice and tidy and slowly got rid of all the little issues i had with them.
(the main one being a big airflow meter problem. i will post a link to the thread if anyone is interested)

in between all of this madness i have also added to the car:
-turbo timer
-9k rims
-front and rear sway bars
-K-jet fuel pump
-K&N inverted pod filter which is now behind the L/H/F indicator/parker light
-cruise control
-two trans coolers.
-engine oil cooler, located where the air box originally was
-"sticky" fan setup (a simple system, the thermostat kicks in, both fans come on, thermostat cuts out, one fan turns off, other stays on until ignition is turned off)
-catch can (removed A/C too, catch can is now where evaporator went into heater box)
-LED parkers and interior lights
-JVC DVD head unit, sony 4" front speakers and 6x9" rears, sony 12" 1300 watt sub, modified 900 watt mono amp and clarion 120 watt 2ch amp for 6x9's
-chrome grille
-battery in the boot now...
-turbo/APC gauge (fitted gauge set to original gauge cluster, had to re wire one side.. real pain in the a#%..)

there are a few more little bits and pieces i have done, i will post them if/when i remember...

i did not want to make it loud or even look like it was modified so i have kept it looking as stock as possible - SLEEPER

it has just clocked 260,000 Kms and is still going very strong, and has still got the original N/A bottom end of engine, which has remained stock and untouched. i am currently running it at 10 psi, and it goes a lot faster than what it used to when it was running at 17 psi

i do have more plans for future improvement which i will also post when the time comes.

apologies if i have ranted on a bit too much..

will post pics asap.

any questions, just ask

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