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2001 Aero 2.3l rebuild update
Posted by saabsince 93b [Email] (# 972) [Profile/Gallery] (more from saabsince 93b) on Fri, 9 Mar 2012 08:36:24

I have about 5000 miles on my 2001 Aero since the complete rebuild, and I love it. I am running a JZW stage 1 tune and I love the performance. I have a ScanGauge installed and have gotten as high as 295 on the HP reading. I am not at all sure how accurate this may be, but with the earlier stock engine the most I could get was 225-230. As for the performance overall it is really terrific.

A little history. I had a scored piston and had to do a rebuild or put in an old used engine. I opted for the rebuild. Walter Wong, of The Right Solution pulled the engine for me, and stipped the block and the head.

I brought these pieces to Martin Davidson in Reseda who had a great reputation as a very good machine shop. I had him put in Woosner forged pistons that I ordered, and a lightweight aluminum flywheel from Genuninesaab. We also removed the balance shafts and chains. You do have to plug the oil passages when removing the balance shafts to keep your oil pressure up where it should be.

The flywheel is 11 pounds rather than 25 for the stock one. The responsiveness is amazing with the less rotating mass. The flywheel is a Spec aluminum one.

Martin did all the machining and blueprintting. We also balanced everything including crank, flywheel, clutch.

I did all the while we are in there things like oil pressure switch, cps, oil pump, water pump, hoses, center engine mount clutch and clutch lines.

Also rebuilt the turbo with a kit I bought on-line. That was a surprisingly easy fix.

Sure I paid a bit more than the 80,000 mile engine I was going to install, but I have a new engine and turbo and who knows....at least 275HP, certainly somewhere between there and 300.

I bought a used ECU on eBay for $25 and shipped it to John Williams at JZW and he did a stage one and the open SID. Open SID is great as I can keep an eye on the mass air sensor and other ECU parameters.

Bottom line is the Aero is amazing with these mods. and I hope to get lots of good miles out of it.

What about those balance shafts......well I am surprised at how little the difference is.....there is a difference, but not much. Idles fine and it has some areas of coarseness, but very little different.
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