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Old 04-06-2018, 09:23 PM   #4 (permalink)
19bonestock88
Master EcoModder
 
Join Date: Jun 2016
Location: KY
Posts: 1,352

IGL - '04 Saturn Ion
Team Saturn
90 day: 56.19 mpg (US)
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When I made the intake for my Saturn I used a ported version of the stock airbox and basically made the tube from the airbox to TB as smooth as possible... I didn’t wanna draw excessively warm air but to mildly raise IATs... plus you might be able to vent PCV to open air and get that oil gunk outta your intake tract...

As for exhaust I’d just do a “lightning style” exhaust with a freer flowing muffler and as nice of bends as you can... 2.25” should be big enough... I had a setup like that on my 4.0L with a Thrush Welded muffler and it sounded great and gave a few HP...

You really should consider a tune though, getting rid of that clutch fan will be a biggie, as far as boosting mileage... plus, I hear that SCT’s 91 octane tune for the 2.3 really wakes it up... of course the X-cal isn’t too cheap...
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