RBatsch said:
So I could fit a KC on my Viggen?
Yes. You will need either a 2006+ 9-5 TD04HL-15T (with the 15mm short intake neck) or have your pre-2006 TD04HL-15T intake neck machined down by 15mm. I purchased a used TD04HL-15T from ebay for $65, removed the compressor housing, and sent it to Nick at GS to have machined down. You can see the intake neck difference here:
You will then need a 2006+ "KING" Cobra pipe of course. You will need to have some threads pressed into the crank case inlet for the crank case vent banjo bolt.
Finally, you will need to shorten the crank case inlet hard line as the crank case inlet is a few mm off. I did this by removing the 90 bend before the banjo fitting and added a 130 degree bend rubber hose (Saab part #: 91-89-465 - $6) inline to line things up correctly, as seen here:
You can purchase a pre-machined housing and KC with pressed in threaded crank case inlet from GS here:
http://www.genuinesaab.com/catalog/product_info.php?cPath=47_53&products_id=471
RBatsch said:
When you say taking the turbo out wasn't that bad....do you have to disassemble the turbine, or just the housing?
You actually have to remove both the exhaust and intake housings. You must remove the exhaust housing first to be able to get to the 3+" snap ring holding the compressor housing in. The exhaust housing is easy to take off, just removed the clamp and then a couple whacks with a rubber mallot and it comes apart. The intake housing is easy as well, however you need a snap ring tool capable to taking off a 3+" snap ring. I purchased a Snap-On Tools snap ring plier for $24 shipped:
http://buy1.snapon.com/catalog/item.asp?search=true&item_ID=70072&PartNo=SRPC9090A&group_id=771&supersede=&store=snapon-store&tool=all
Steps required:
1. Drain coolant
2. Drain oil and remove oil filter.
3. Remove old cobra pipe
4. Remove downpipe (don't forget to unplug the O2 sensors!)
5. Remove the oil hard line from turbo*
6. Remove both coolant hard lines from Turbo*. Don't get freaked out by the banjo bolt going into the waterpump....it will come out with a slight wiggle.
7. Remove the oil drain neck from the turbo (2 bolts)
8. Remove the turbo from the exhaust manifold
9. Remove exhaust housing from Turbo (see above)
10. Remove snap ring holding compressor housing on (WEAR SAFETY GLASSES!!!!!) and seperate the housing.
* with the limited room to get those banjo bolts on the hard lines out, I suggest getting a 12mm thin & stubby/shorty open end wrench. I picked up this one from Napa which worked very well:
http://www.napaonline.com/NOLViewer/Pages/Detail.aspx?R=99024&ShowPics=1
(this guy would work as well:
http://www.napaonline.com/NOLViewer/Pages/Detail.aspx?R=96615&ShowPics=1)
To make the install complete you will need:
1. New Turbo to exhaust manifold gasket
2. New rubber seal (black) from KC outlet to Turbo inlet.
3. New rubber seal (teal) for the dump valve air inlet to the KC
4. All new copper washers for all banjo bolts. I suggest getting these from GS as they are 1/10th the price as getting them from saab.
5. New exhaust lock nuts for the DP and turbo-to-exhaust manifold. I used very nice VW copper exhaust lock nuts (VW Part #: N-902-002-01), At only $1.50 each from VW, they are 1/5th the price as getting from Saab and much nicer as you will see. You will need 7 of these. If you end up needing new Studs, you can use VW part number N-044-411-5 (M8x1.25x35), again 1/5th the price than getting from Saab.
6. 1 new oil filter, 1 drain plug washer, and new oil
7. 1 gallon of Saab coolant and 1 gallon of distilled water.
8. New oil drain neck-to-Turbo gasket (Saab Part #: 90-490-305 - $2.19)
RBatsch said:
Are you running staged software and I assume you have a Viggen?
Robert
No software yet, I wanted to get all my HW first. I plan on going with the Nordic Stage 4. Yes, I have a Viggen...2000 Silver 5-door.