Intercooler upgrade on the 1996 Saab 900. Parts from MP Performance.

Tools:

  • 16 mm socket: bumper bolts;
  • 10 mm socket: old intercooler bolts;
  • 8 mm socket: headlight wiper nuts and lower shield screws;
  • 7 mm socket: hose clamp screws;
  • long socket extensions;
  • ratchet handle;
  • flat screwdriver;
  • Torx T25 screwdriver;
  • hacksaw and files;
  • sharp knife;
  • measuring tools;
  • car jacks and stands or ramps.
23.05.2005
Grille

Raise the front of the car and open the hood. Remove the grille by detaching two tabs on top.
23.05.2005
Blinker

Undo the Torx T25 screw on the turn signal assembly, remove the housing and unplug the wires.
23.05.2005
Headlight

Remove the headlights (three Torx T25 screws). Unplug the wires, use a flat screwdriver to release the locking tab on the harness.
23.05.2005
Wiper

Lift the covers over the nuts on the headlight wiper arms and remove the arms (8 mm socket). Detach the washer fluid hose from the bumper (there is a couple of metal tabs holding it).
23.05.2005
Lower shields

Remove the plastic shields from below. Each side is held by half a dozen screws with a 8 mm hex head.
23.05.2005
Foglight

Unplug the wires from the foglights.
23.05.2005
Sensor

Detach the temperature sensor under the bumper. That horrible rusty thing is the license plate holder.
23.05.2005
Screw

Remove the Torx T25 screw under the fender (one on each side).
23.05.2005
Bumper bolts

Undo two long bumper bolts located next to the headlight wipers (16 mm socket).
23.05.2005
Bumper

Pull the bumper forward and remove it from the car. Mind the sides of the bumper cover while pulling: there are latches on each side that you need to release.
23.05.2005
Intercooler

The intercooler is held by two long (and likely rusty) bolts. Use a 10 mm socket to remove those. Both hoses are attached on the driver's side, the clamps can be released through the headlight opening with either a 7 mm socket or a flat screwdriver (and a lot of rust solvent).
23.05.2005
Old intercooler

Remove the intercooler from the car. Detach the hoses from the delivery pipe and the turbo.
23.05.2005
Old vs new

The old intercooler was a two-pass design, the new one is a cross-flow.
23.05.2005
Old vs new

The upgraded intercooler core is made by Spearco and has a 3"x7" cross section with a flow area of 5.30 square inches. This is 60% more than a cross-flow Viggen intercooler has, and 4 times more than my base unit. There are also 5 times more fins for a much greater cooling capacity.
23.05.2005
Old vs new

The end tanks are made by MP. You can see an extra weld spot: this was a discounted defective unit. I had to take it to an alloy welder for repair first. We've found four pinholes in the welds. The regular units should not have these problems, but it never hurts to do a pressure test. Also check for metal shavings in the end tanks: I had a lot of those.
23.05.2005
Old vs new

The newer intercoolers MP sells now have additional grooves machined on the inlet pipes to help secure the hoses better. Mine didn't have that, and the pipes were unequal length, but then again, I knew what I was getting, and it's hard to complain considering the discount they offered.
23.05.2005
Lower radiator hose

The 900 models have an older lower radiator hose that gets in the way of the intercooler inlet hose. It has to be replaced by a new design (Saab part #4963872).
23.05.2005
Draining coolant

With the intercooler removed, you now have the access to the radiator drain plug. Use a piece of aluminium foil to form a trough gutter and drain the coolant into a clean bucket so you can reuse it later (assuming your coolant does not require replacement yet).
23.05.2005
900 vs 9-3

Here's the old hose next to the new style hose provided by MP. They supply used hoses, and unfortunately this one had a crack on the back. I've noticed it too late and had to reinstall the old hose since it was a holiday and the dealership was closed.
23.05.2005
Coolant tank

To not make my coolant drain a total waste of time, I cleaned the coolant expansion tank (it looks rather dirty on this picture). A quarter cup of rice, some soap water and 10 minutes of vigorous shaking made it shine like new! If you do that, wash it well: you don't want any rice in your coolant pipes ;).
23.05.2005
Old inlet pipe

Normally, the intercooler is supplied with Viggen hoses which are almost a direct fit. The custom made piping would've been even better. Unfortunately, I had neither, since my intercooler didn't come with any, and the stores were closed. So I decided to make the most of the stuff I had.
23.05.2005
Test fit

I had one extra elbow that helped to form the inlet section. The test fit looks promising.
23.05.2005
Inlet hose

The intercooler is put in place and the turbo hose is attached. This actually looks better than the Viggen hose, as the Viggen elbow forms a nasty bend on the T25 turbo, because the T25 is angled differently. And there's enough clearance even with the original radiator hose.
23.05.2005
Radiator fan

The new hose did not fit with the radiator fan frame, so I had to cut a corner of the frame off.
23.05.2005
Fan installed

The fan is attached with two screws at the top. Everything seems to fit well. Make sure all clamps are very tight, especially if you used soap or another lubricant to put them on. You don't want any of those to come off on the road.
23.05.2005
Hose

This is the hose from the intercooler to the delivery pipe. It had to be extended an inch and a half. The clamps are easier to reach from under the car.
05.11.2005
New hoses

This is an updated hose arrangement used with a Mitsubishi TD04 turbo (aka "Viggen turbo").
05.11.2005
Turbo pipes

The compressor outlet on TD04 is angled differently, which allows for a shorter hose.
23.05.2005
Zip ties

The intercooler is not bolted on like the old unit, but it's held by the hoses quite firmly and is not going anywhere. I added strong zip ties on each side, as well as a couple of rubber strips to prevent it from rubbing against the radiator.
05.11.2005
No bumper

A view of the intercooler with the bumper removed.
05.11.2005
Bumper on

The bumper is a rather close fit. Leave the intercooler sticking out too far, and it will rub against the bumper rail.
23.05.2005
Coolant

Time to fill the coolant.
23.05.2005
Installed

Install the lower shields, headlights and grille. The only sore spot left is my rusty license plate holder, which also blocks the intercooler.
23.05.2005
License plate

The finished install: the plate has been replaced and attached higher, and the intercooler is seen through the opening in the bumper.

  [expand all]

 

 

 
Copyright © 2000-2013 Dmitry Platonoff
All rights reserved.