We have a new home on Github! Go right ahead to bookmark and contribute... Or stay here if you like 2000's websites.

[expand all] 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36 37 38 [index]
Click to see the next picture
17.09.2008: Reinforcement
Secure all the clamps and attach the reinforcement plate at the front. Tighten to 50 ft-lbs.

Complete exhaust system replacement on a 1999 Saab 9-5 (applies to all four cylinder 9-5 models). The original exhaust rusted through, and is now replaced with a three inch straight through system built by Jak Stoll. It is made of 3" aluminized steel piping and includes a downpipe, sport catalitic converter, two flex joints, resonator and a rear muffler.

Jak's fabrication quality got better over the years. The welds and transitions were much smoother than on the NG900 downpipe I bought from him a few years ago. Other than his choice of a resonator, I didn't really have anothing to complain about. The fit was nearly flawless too. He actually mentioned that he doesn't have a jig for 9-5 exhausts at his shop. Instead, he gets his mother in-law's Aero up on the lift and makes a tailored job every time. I suppose this kind of dedication had to pay off ;].


  • 22 mm (7/8") crowfoot socket: O2 sensors (or specialized O2 sensor socket);
  • 14 mm socket: reinforcement panel, exhaust clamps and joints (could differ depending on the supplier);
  • 13 mm socket or wrench: downpipe to turbo nuts;
  • flat screwdriver: O2 sensor connectors;
  • torque wrench;
  • ramps and jack stands;
  • anti-seize lubricant;
  • exhaust sealant.


Copyright © 2000-2013 Dmitry Platonoff
All rights reserved.