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

 

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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.

 

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

 

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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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05.11.2005: 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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05.11.2005: Fuse box
Undo the 10 mm nut holding the fuse box. Lift the box and move it aside.

 

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05.11.2005: 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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05.11.2005: Lower panel
Undo Torx T25 screws on the lower panel. Unscrew the OBD II connector.

 

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

 

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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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05.11.2005: Wire cluster
The rubber gaiter securing the wire cluster is found next to the clutch pedal.

 

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05.11.2005: 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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05.11.2005: 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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05.11.2005: 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.

 

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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.

 

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05.11.2005: Wiring
Trim and crimp the wires from the sender, as well as your power and ground lines.

 

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05.11.2005: Gauge
Attach mating connectors to the gauge display unit.

 

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05.11.2005: 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.

 

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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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05.11.2005: Wrapped
Wrap the switch into something so it doesn't rattle inside the dash.

 

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05.11.2005: Finished
Job complete. The gauge is nicely illuminated at night.

 

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07.03.2006: On
It's clearly visible in the bright sun.

 

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07.03.2006: Off
Nice and stealthy when the car is shut off.

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