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Had two 9-3 hot aero in family (older one not the SS) one was remapped by BSR and had a downpipe and something else, 265bhp? Most economical petrol car we've ever had (if driven normal), got up to 46mpg on longer 60 mph A roads. Long term average for it I think was 34 mpg? Mate has a 1.6 focus petrol, thats all that gets lol and it has maybe 90bhp?
Bulkhead cracking can be stopped if you get a sub frame brace for the front (upper and lower bracing, again BSR/Abbott etc make these things), we only got one of them because price and I think the other was a nightmare to fit, you have to roll the back of the subframe down and take the rack out in order to fit it, maybe dashboard out too. Eventually it cracked and it wasn't in an area that could be cost effectively repaired.
Don't quote me but I think the 3 door versions suffer from it less, also 2.3 viggen models have a factory lower brace (thin steel tubing but better than nothing).
Go for the full fat 2.3 aero 265, more of a cruiser than absolute speed, soft suspension, ancient dynamics (came out in like 1997? and facelifted beyond hell). Have one in the family, not built as well as old school saabs, but still better than other GM stuff.
Engine wise rarely ever go wrong, coil pack get the genuine saab one or go home, ALL others will just randomly misfire and half throw a code within weeks/months, experience of saabs for many years, don't skimp on coil pack cassette.
Rear suspension has pretty crumby little bushs that go fairly often (likely more down to aftermarket parts not being that good). Budget spending a grand in the first year to take care of all the little things.
Oh gearbox cables/linkage are very sloppy compared to 9-3 and 9-3SS, might not annoy you but the gearboxs suffer as you are on the brink of nearly money shifting it all the time.