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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.
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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.
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