10.10.2005: Saab NG900 Turbo Replacement

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10.10.2005: Saab NG900 Turbo Replacement

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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.

	10.10.2005 Shields down Raise the car and remove the lower shields (8 mm hex screws). If you have a 9-3, you might be able to access the radiator drain plug without removing the shield.		10.10.2005 Drained fluids Drain coolant, engine oil, and remove the oil filter.
	10.10.2005 Downpipe Disconnect the downpipe from the turbo (three 13 mm nuts). If you have a subframe brace, you might need to remove that too to allow more room to move the downpipe aside.		10.10.2005 Intake hose Disconnect the return hose from the bypass valve if you have it (my car has a BOV). Remove the rubber elbow between the airbox and the turbo inlet pipe.
	10.10.2005 Oil lines Unbolt the turbo oil feed line from the filter housing (12 mm socket), remove the oil return hose and undo the bolt that holds the turbo stay to the engine.		10.10.2005 Coolant line Undo the banjo bolt on the lower coolant line (12 mm socket). On newer cars the line goes to the water pump instead of the block. Put a catch pan under the car as there will be coolant dripping.
	10.10.2005 Coolant line Undo the banjo bolt on the upper coolant line (12 mm socket) on the left side of the engine. Don't forget the pan again.		10.10.2005 Banjo bolts Disconnect all three lines from the turbo (more coolant drips) and remove the lines if you can. On my car, I was unable to unbolt the upper coolant line.
	10.10.2005 Turbo hoses Remove the intercooler hose from the compressor housing. Unhook the BPC hoses. Unbolt the turbo inlet pipe. On T25+B204L, you might need to remove the brass BPC hose nipple to gain the access to an inlet pipe bolt.		10.10.2005 Inlet pipe Remove the turbo inlet pipe together with the metal PCV line (there are newer versions that allow you to unbolt the PCV line from the inlet pipe instead). Undo the nuts connecting the turbo to the exhaust manifold and pull the turbo down.
	10.10.2005 Old turbo The turbo is removed from the car. You can see some of the lines still attached to it.		10.10.2005 New vs old The turbo is being replaced with a recently rebuilt unit.
	10.10.2005 Old vs new Compare my old style inlet pipe to the new style (this one came from a 1999 9-3), which allows an easy access to the PCV pipe bolt.		10.10.2005 Inlet pipe With my new upgraded inlet pipe, I can bolt it to the turbo prior to installation and save myself some hassle. From this moment on, be extra clean, as even a tiny grain of sand can ruin your new turbo.
	10.10.2005 Back in Put the new turbo back in, and don't forget a new gasket for the exhaust manifold flange.		10.10.2005 Oil lines Install the oil return hose. Pour some oil into the turbo and install the oil feed line.
	10.10.2005 Banjos Start connecting the lines to the turbo. Consider new copper washers for all banjo bolts.		10.10.2005 Coolant line Connect coolant lines to the engine and tighten all six banjo bolts to 16 ft-lbs.
	10.10.2005 Manifold Tighten the nuts on the exhaust manifold (18.5 ft-lbs).		10.10.2005 Downpipe Connect the downpipe to the turbo, and re-install the subframe brace if you had to remove it.
	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.		10.10.2005 Oil filter Refit the oil filter, fill engine oil and coolant. Before starting the car, crank it with the ignition cassette harness unplugged to ensure there's enough oil in the turbo.

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