Boost gauge installation on a 1996 Saab 900. This should work for most T5 cars. For T7, see this guide.
17.04.2004
The kit

A Cyberdyne Ultragage boost/vacuum gauge kit (part #A213E061Y) bought on eBay. It contains a gauge, a sender, some tubing and other supplies.
05.11.2005
Vacuum line

Locate the vacuum line going from the throttle body to the bypass valve.
05.11.2005
Tap

Tap into the line (or replace the hose to keep a spare handy) and insert a tee.
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Sender

Connect the sender unit and attach it into a secure spot. Tie the cable so it doesn't dangle around.
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Fuse box

Undo the 10 mm nut holding the fuse box. Lift the box and move it aside.
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Firewall

Locate the wire cluster going throught the firewall next to the clutch cable (or the clutch line). Unwrap the tape and cut the zip tie around it.
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Lower panel

Undo Torx T25 screws on the lower panel. Unscrew the OBD II connector.
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Fuse box

More screws around the fuses. Finally, a 10 mm bolt at the bottom, and the trim panel comes off.
05.11.2005
Fuse box

Removing the fuze box is not absolutely necessary, but it gives you more room to do the wiring. Three Torx T25 screws.
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Wire cluster

The rubber gaiter securing the wire cluster is found next to the clutch pedal.
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Pipe

Push a piece of PVC pipe between the wires and the rubber sleeve so it comes out on the engine side.
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Wire

Slide the sender unit signal wire through and remove the pipe. Zip-tie and wrap the rubber sleeve on the engine side.
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More wires

Connect a piece of wire to the ground nut under the dash. Connect another wire to the cigarette lighter fuse for a source of switched power. It is a good idea to have the battery disconnected prior to this.
05.11.2005
Dash

Many 2"1/16 gauges will fit right in, but you will need to cut the plastic inside the headlight switch socket. I decided to pop the dashboard to attach the display from the rear. Follow this guide for dashboard removal.
05.11.2005
Wiring

Trim and crimp the wires from the sender, as well as your power and ground lines.
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Gauge

Attach mating connectors to the gauge display unit.
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Test run

Connect the wires, double check everything and do a test run. After you start the car, you should see 15-16 Hg of vacuum at idle.
05.11.2005
Headlight switch

The headlight switch will rest inside the dashboard set to the "headlights on" position. Saab DRLs run the headlights full on anyway, so it won't make much difference.
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Wrapped

Wrap the switch into something so it doesn't rattle inside the dash.
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Finished

Job complete. The gauge is nicely illuminated at night.
07.03.2006
On

It's clearly visible in the bright sun.
07.03.2006
Off

Nice and stealthy when the car is shut off.

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