This do88 BigPack pairs an all aluminum performance intercooler with a 2.375 inch mandrel bent charge pipe kit and replaces the OE charge air path on the automatic gearbox Saab 9-5. do88 measures the core at 11803 cm3 against 6379 cm3 for the OE unit, an 85 percent gain, with 268 CFM at 0.15 bar (2.18 psi) pressure drop against 192 CFM stock. Post intercooler air temperature fell to 32°C from 53°C under matched test conditions on do88's SuperFlow SF-1020 flow bench. CAD designed and CFD analyzed cast end tanks feed the core, the pipes carry CNC machined sensor bosses, and the kit ships with four black silicone hoses, ten stainless clamps and all mounting hardware.
Specifications
| Type | All aluminum charge air intercooler and pressure pipe kit (do88 BigPack) |
| Material | Welded aluminum core with CAD designed cast end tanks |
| Core Volume | 11803 cm³ (OE 6379 cm³), 85% larger |
| Air Flow | 268 CFM at 0.15 bar / 2.18 psi pressure drop (OE 192 CFM), 35% higher |
| Intake Air Temperature | 32°C vs 53°C OE under matched conditions, 21°C lower |
| Charge Pipes | 2.375 in (60 mm) mandrel bent aluminum with CNC machined sensor fastenings |
| Hose Color | Black |
| Hose Material | Silicone with 3 to 4 layer reinforcement |
| Included | Intercooler, charge pipes, 4 silicone hoses, 10 stainless hose clamps, mounting hardware and instructions |
| Quantity | 1 (complete kit) |
| OEM Replacement | 4966735, 4966701, 5191770, 7591936 |
| Part Number | BIG-100-S |
Documents: Installation Instructions (PDF)
This part fits:
| Year | Make | Model | Submodel |
|---|---|---|---|
| 2002 | Saab | 9-5 | 2.0T, 2.3T, Aero (Automatic) |
| 2003 | Saab | 9-5 | 2.0T, 2.3T, Aero (Automatic) |
| 2004 | Saab | 9-5 | 2.0T, 2.3T, Aero (Automatic) |
| 2005 | Saab | 9-5 | 2.0T, 2.3T, Aero (Automatic) |
| 2006 | Saab | 9-5 | 2.0T, 2.3T, Aero (Automatic) |
| 2007 | Saab | 9-5 | 2.0T, 2.3T, Aero (Automatic) |
| 2008 | Saab | 9-5 | 2.0T, 2.3T, Aero (Automatic) |
| 2009 | Saab | 9-5 | 2.0T, 2.3T, Aero (Automatic) |
| 2010 | Saab | 9-5 | 2.0T, 2.3T, Aero (Automatic) |
Shipping
- In-stock orders placed before 3 PM EST ship the same day — everything else ships within 24 hours.
- Standard, expedited, and overnight options at checkout.
- Oversized items ship by freight and take longer.
- Backordered items ship as soon as stock lands — contact us for lead times.
- International orders: prices do not include VAT, duties, or import fees. Your country charges these at import and they are the buyer’s responsibility.
Returns
- 30-day returns on new, uninstalled items in original packaging with all hardware.
- Standard returns: 8% restocking fee, buyer pays return shipping. Both waived if the item is defective or we made the error.
- Installed or used parts can’t be returned — confirm fitment before you install.
- Special orders and custom items are final sale.
- Email us for return authorization before shipping anything back.
Full details: Shipping Policy · Refund Policy
