Intake Manifold and Throttle Body The installation of the intake manifold from a naturally aspirated version was not as straight forward as I would have liked, but it yielded more of an increase than I expected.     Here is the intake manifold off of a non-turbo, NA 1994 9000 CS. The theory is that the significantly larger manifold will allow better air flow and increase the horsepower. As you can see from the picture, the difference in size is huge. I have to say though that this was not as straight forward as I would have liked. The real PITA was the fuel rail. The stock non-turbo is round and much smaller. This would be totally unacceptable for my application since the goal is to add horsepower, not reduce it. So, I had to install the turbo fuel rail on the non-turbo intake manifold that had different mounting points. I had to make my own brackets - :-( I had also switched to the fuel rail from a '98 CSE which has a larger fuel pressure regulator (still 3.0 bar) and allows for quicker fuel dump when you snap the throttle plate closed. And of course this is a part that never fails, so I had to basically get the trolls at the Saab factory to make one for me which took forever. There were also numerous other bits that needed to be changed also - motor oil dipstick/tube needed to be longer, different mounts for wiring harness, differnet AIC valve, different vacuum connections, additional mounting braces, hose clamps now needed to be added since this baby was going to be highly pressurized. The tip is that if you are going to do this, make sure you get every little bit you can at the scrap yard so that you can make this as easy as possible. Unfortunately for me, the donor car had damaged some of the pieces I needed so I had to buy them from the dealer ($$$$).   Click to enlarge       This is the new intake installed in the car. This thing looks much bigger than the stock unit and provides significantly better flow, provided you have already addressed other flow restrictions in the "system".   Click to enlarge       The work that Dave at SPG9 has done on the inner throttle body is real clean and opens up the throttle nicely. This piece combined with my other modifications will open up the air flow and let the engine breathe deeply.   Click to enlarge       Another added benefit on installing this manifold is that it has two places where there are rubber isolation bushing. You say, "ya, so what?" Well, these bushing also help to prevent heat sink from heating up the manifold and thus the intake charge. After several dyno runs, you could still place your hand on the intake where as you would burn it good if you touched the engine   Click to enlarge       OK, here are the "big green" injectors revealed. There has been much discussion about these injectors and a lot of mystery too. The resistance is: stock inj--11.9 ohm, green inj---12.5 ohm. The injector rating is 465cc. The first part number is the Bosch part number and the second part number is the Volvo part number. Now the question everyone will ask, "where did you get them and how much did they cost?" Well, the cost was nothing, "Freebie" and I cannot reveal they source. However, these can be special ordered from the Volvo dealer for about $120USD each.   Click to enlarge       This is a high pressure one-way valve that replaces that stock valve that is know to fail when running high boost pressures. We got this one from Trent Saab in the UK for £40 or about $65 USD delivered. Given the information on the piece, you could probably find it less expensive elsewhere. It looks like the rating says that its good to 16 Bar which should just handle the pressure of my turbo - ;-) On Trent's site that say "Trent SAAB has just developed a replacement PCV check valve for all turbo cars (including 9-3, 9-5). This component is aerospace specification and is essential for any modified engine. The standard Saab item is prone to failure after a relatively short time, and when this happens the crankcase becomes pressurised, leading to dramatic oil loss through the oil filler tube. These T-Power units are made from 7075 alloy with stainless steel and brass internals and pressure-tested up to 11 bar. And help build that vital boost just that little bit quicker!" I got it mainly because I was interested in the part and was tired of the other overpriced pieces from the dealer failing.   Click to enlarge       Working with Dave at Group 9 Performance, he was able to develop this more affordable alternative to the Trent valve. It is pretty trick and adjustable. Contact Dave for pricing and more information.   Click to enlarge