This project has been a long time coming for me. I originally had plans to boost the old Sunfire GT I had until that went up, sold off most of the LD9 parts
and decided to update to something with a little more aftermarket support. I ended up with this 04’ 1SV Base 5-speed with about 50K on it. Almost immediately
I knew which route I was going… Saab Kit
Being a Member of J-Bom there was already lots of experience with this kit. I have to give props to Chad (cadwz24) and Todd (tmanz24) for hooking me up with
part numbers and tons of advice on how to take full advantage of this setup.
Anyway on with more pics then ever needed to be taken.... Full Saab Kit Install on 2004 Cavalier
Some Parts I started with:
I traded my old sunfire for this half started Saab kit:
TD04L-14T Saab (Mitsubishi) turbo
Turbo manifold w/Air Induction
Saab 370cc Injectors
Oil feed and return lines
Coolant feed and return lines
Stock Saab charge pipe piece
Stock Saab TB adapter piece
Brandoson Downpipe
Random gaskets and things
Better Pic of the lines
370cc Saab Injectors
Turbo
2” E-bay intercooler
E-bay Couplers/L-Bend Pipe kit
Radiator Hose Tee – From jagsthatrun.com
My room right before the start of the project, things were getting crazy
The Good Part – The Kit Install
I figured I would get the hard part out of the way first so I dropped the pan so the return line could be drilled
Drilled a pilot hole
I liked the angle so I went ahead and started to drill return sized (17/32”) hole. I was about 90% thru when the drill started to buck. I gave the drill full throttle
and pushed a little harder. Yup i knew it was going to happen.
That’s what happens when you buy the cheapest bit you can find and have a heavy duty 1/2” chuck Milwaukee Drill.
The hole was almost done and didn’t look that bad
Block – 1 Me – 0
But I had something for it…. A little carbide action
I worked from the inside and just cleaned out the material so the hole was clear
I think it turned out fine..Next on to the oil Feed plug
If you look close at that allen… she ist straight anymore…
But I had something for that in my bag o tricks too…
A little heat and the plug came right out.
After that things went a little more smoothly
Looks like there might be room back here for something….
This ones no good
But this one will work just fine
Turbo mounted up
Turbo underside
Oil Feed and manifold brace
Oil Return
Upper Radiator hose spliced w/Tee and using OEM coolant feed line, Coolant return was into the closest Heater core line(no Pic)
Next Came the Downpipe/Exhaust
Now the Brandoson downpipe is a good piece don’t get me wrong but, I had to “convince” it to actually fit. It was hitting on the up-facing thermostat hose barb.
Ball-Peen “convincing”
O2 bung
First time MIG welding bear with me on these welds
Making some smoke
Bungs welded
2.5” Collector – Magnaflow Cat – 6”Flex Pipe
I think the welds came out ok
Rest of turbo back together
All done….
On to Front End - Intercooler and Charge pipes
04’ Bare Front end (maybe just for reference)
Needed to ditch the stock washer bottle…and pick up this (off of a toyota tercel/paseo). Props to Jay Van (qwik2k2z24)
Mounting Intercooler
Charge Pipes - all 2”
Starting from throttle body – Stock Saab piece
To Exhaust L-Bend
Drivers Fender
Up Front
Passenger Fender
Under Engine – used stock Saab charge pipe cut to fit
Then upward
Front with test fit nose on
Moved and modified PCM bracket
Turbo back shots
Gay makeshift defiantly not permanent filter
Finished Engine bay
Interior
All torn up
Gauge Supply
Guages installed – Autometer Ultra lite boost, Stewart Warner ele. Oil Pressure, AEM UEGO Wideband (I know not really needed, only thing left over from the LD9 project)
Guages (dark)
Full Dash
Clean Engine Bay
So that’s what I have. The whole project wasn’t all that bad. It took maybe 3-4 hours a day by myself in my garage for a week after work.
I think it turned out well. She has ran perfect from the very first start-up.
I Love how stock the car looks from the outside.
Im excited to get to the track. All I want out of this is a 13.9 slip…that’s all I’ve ever really wanted. I’m thinking this will get me there.
The final pic is the only one that really matters
Made this just to make some noise, I love the way it sounds video dosnt do it justice.
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If anyone needs Saab Numbers or some help I should be able to help ya out, let me know.
