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10.10.2005: Intercooler hose
Fit the intercooler hose on the turbo, intake elbow and the BPC hoses. Connect the bypass valve return hose, as well as the PCV line.

Garrett T25 turbocharger replacement performed on a 1996 Saab 900. The procedure is more or less similar for all Saabs using the B204-B235 engine families. Use new copper crush washers for all banjo bolts. It is also a good idea to get a new oil feed line, or at least clean the old one from sludge and deposits.

This article describes replacing a stock turbocharger with another OEM unit. For upgrade information, refer to this document.

Tools and supplies:

  • 13 mm wrench and socket (downpipe and turbo nuts);
  • 12 mm wrench and socket (banjo bolts);
  • 10 mm wrench (turbo inlet pipe);
  • 8 mm socket (shield screws);
  • 7 mm socket (hose clamps), or flat screwdriver;
  • large pliers (oil return hose clamps);
  • torque wrench;
  • ratchet handle;
  • ramps or jacks and stands;
  • fresh oil and coolant.


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