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Turbo Replacement 2004 9-5 2.0T and would love some info

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3K views 40 replies 5 participants last post by  rogjan1  
#1 ·
Hey !
First of all I just wanna mention I'm new here and have owned my Saab since I got my license 3 months ago February 2023 and I love the car ! My dad is such a car person and has owned tons of older sport cars and just likes driving in general and thought a Saab would be a great first car! I totally agreed because Im literally the only one driving it as a daily in my area other than some newer 9-3s and the feel and driving experience in unique in my opinion. Me personally I wanna do the one thing my dad doesnt bother doing and thats the mechanical part and just doing things on the car by myself and putting upgrades on it and so on and i thought THIS is the perfect place to get quick and professional answers :)
I just have to say I love my Saab and the time has already come for some parts that needs replacements and so on probably from the last owner or just from age and wear.

!! As of my knowledge im NOT an expert but i really wanna try get into this and learn and do stuff myself so please throw words at me haha

Im not sure if i can talk about the whole car and what ive done to it in this post but i will do so for now so everyone that reads this understands.
This is a 2004 Saab 9-5 2.0T with original 150hp. The engine is a T7 pretty sure. The car is TUNED using the BSR Performance tuning kit and then probably should have 221-225hp?
I've replaced the Air filter to a K&N air filter.
Just replaced to new Spark Plugs and a used DIC (around 50,000km on it)
Also probably important to mention MY LAST TIME BEING AT THE GAS STATION, E10 95 FUEL WAS FILLED. If that info is any helpful ! Ive read that most saab engines could take it and not that much info about the 98

And here comes the problem. Car wont go over 3,000ish rpm. Mechanic has said that the turbo is bad and needs to be replaced. I have to be honest and say i have been driving the car here and there once in a while as its making a loud fighter jet sound under the hood when i press a bit on the gas but i have been easy on it. I know its not good for the engine but to my defense the mechanic said it should be ok and the raw fuel that gets into the cat is a tiny amount it wont hurt it. But that was before the oil pressure light has recently started showing up. Standing still and restarting the car makes it flicker and go away and maybe flicker again.
I got the oil pressure tested and they said it had ok pressure at low temps but at normal operating temperature it had 0.8 bars lower than whats recommended by them. They said this could be impacted from the type of Oil i use and they said since it is an older car it should use 5W-30 and not the 0W-30 like saab has told to be used on it Other than that theres no fault code because the light didnt come on when they were testing it and the engine runs fine in idle like its normal, but obviously as the turbo isnt really on. Mechanic has told me it might be the oil pump which ive read is the last part to go out on the engine so the easiest way to fix was to use a oil system cleaner fresh liquid type thing? You pour it in let it sit for a bit while the car is running then do an oil change. Seems easy enough and might help? Then check the pressure again. They also said this NEEDED to be done before fixing the turbo anyways so i kinda dont have a choice for now. I also wanna mention theres not really any white smoke from the exhaust so maybe the turbo isnt that worn? Might be wrong.
Also when the oil pressure light has come on the engine sounds a bit more echoey? If that makes sense? I have oil thats for sure. Mechanic has said the fuel should be good and the pump works fine. All i rememebr was the number 6. Probably how much is going into the engine at start but thats all for now.

So to end it and questions i would love answers on are:
  • Overall what can I do to my car? Is there any step by step on what to do like an example: 1. Turbo 2. Exhaust 3. Intercooler? Or do i just have to go as the car needs?
  • I need help and lots of info regarding the turbo replacement. What Turbo should i get? Should i actually go for a TD04 as many people are telling me to get? What does the 19T 15T 20T stand for ? What do i need to know about the turbo itself? LIke what cables does it have what do i need to transfer from the old to the new one and so on.
  • When and why do i need a king cobra over a normal cobra if i do?
  • SHOULD i actually replace the turbo by myself? What can go wrong? Is it hard to fix something that can go wrong during a turbo replacement?
  • Is there any parts i can add to help the engine survive just a stage 1 or 2 tune other than a easier exhaust system? Simons exhaust and a less restrictive downpipe though ive heard a down pipe is a hard and expensive process and not that worth it unless ur pushing for the max
  • Is the china turbo copies actually that bad or can a new one hold for a while?

In the end im probably just gonna have more questions as we talk about the topic but i hope thats okay as im learning ! Ive tried to include as much as possible about the car so its easier to understand my situation and the car itself and what ive done with it so far and what i can do in the future without risking the whole thing :)

Thank you!!
 
#4 · (Edited)
It’s a problem if the oil pressure warning light comes on as it’s probably only 8psi or so - not at all good for the engine. Before thinking about any mods I’d investigate that first. Oil pump, oil pump pickup screen, worn connecting rod or crankshaft bearings, etc. could be the cause. And the “loud fighter jet” sound can’t at all be good. If the turbo is self-destructing it could be sending metal fragments into the engine.

Not revving over 3000 could be mechanical or more likely it’s in limp home mode requiring resetting of the throttle body at a minimum.

Unfortunately, you have a few issues but I’d be most concerned about oil pressure.
 
#7 ·
Thank u so much for info ! Is there any symptoms for it being a specific part like the oil pump or the pickup screen? Is it a chance its only the sensor or probably not since the mechanic has checked the pressure so it cant be the sensor then right? Most of the parts you're mentioning are unknown to me and i have no idea how to get to them or if i need any special equipment for it but i think as soon as i get into it im gonna get the idea and pickup rather quick. Is it hard checking the parts you mentioned myself?
 
#5 ·
The job to replace the turbo is not that hard and you really can't do anything that will cause issues other than not prime the turbo with oil and make sure you pump up the oil pressure by turning over the engine with no plugs in it until the oil pressure builds befor eyou start it.

the TD04 is the better turbo for the 9-5, I'd get one of those. Get the stock one. If you have the Garrett then you'll need to change over the coolant lines from one with a TD04 or get the adapter rings that you can get on ebay.

you really only need the king cobra if you want to tune it to get the max HP.

A couple of things to make the job easier:
  • try to find get the studs out of the top of the turbo where it meets the exhaust manifold, using two nuts locked together, that way you don't have to take the exhausst manifold off (which requires removing some other stuff)
  • unbolt the oil drain from the turbo, you will take it out after the turbo is out and put it in before the turbo goes back
  • like I said, take the plugs out and crank the engine until the oil pressure comes up to normal after you put the turbo in, then put the plugs back and start the car.
  • if the turbo leaked a lot of oil make sure you clean out the intercooler and y ou're going to make a lot of smoke when the exhaust gets hot. you'll have to take it for a ride, do it in the dark.
you really don't need to add much to go to stage 1, better flow for stage 2 is necessary. But take that in steps.

I've not done one of the china turbos, I actually took some TD04's from junkyards and used those. They are quite robust.
 
#8 ·
The job to replace the turbo is not that hard and you really can't do anything that will cause issues other than not prime the turbo with oil and make sure you pump up the oil pressure by turning over the engine with no plugs in it until the oil pressure builds befor eyou start it.

the TD04 is the better turbo for the 9-5, I'd get one of those. Get the stock one. If you have the Garrett then you'll need to change over the coolant lines from one with a TD04 or get the adapter rings that you can get on ebay.

you really only need the king cobra if you want to tune it to get the max HP.

A couple of things to make the job easier:
  • try to find get the studs out of the top of the turbo where it meets the exhaust manifold, using two nuts locked together, that way you don't have to take the exhausst manifold off (which requires removing some other stuff)
  • unbolt the oil drain from the turbo, you will take it out after the turbo is out and put it in before the turbo goes back
  • like I said, take the plugs out and crank the engine until the oil pressure comes up to normal after you put the turbo in, then put the plugs back and start the car.
  • if the turbo leaked a lot of oil make sure you clean out the intercooler and y ou're going to make a lot of smoke when the exhaust gets hot. you'll have to take it for a ride, do it in the dark.
you really don't need to add much to go to stage 1, better flow for stage 2 is necessary. But take that in steps.

I've not done one of the china turbos, I actually took some TD04's from junkyards and used those. They are quite robust.
Hey and thank you !
What does priming the turbo mean? I guess its actually oiling it before use so it isnt running raw or dry. Does this need to be done regardless of used or new turbo? What do I need to check the oil pressure and possible for u to show or explain where its done? Turning the engine with no plugs do you mean no sparkplugs and coil or just no sparkplugs or is it something else maybe? And i guess this is all done after the new turbo is installed?

I've seen when looking around on the TD04 it got the numbers 15t, 19t or 20t, does that matter and what it is and what should I get? The size of the compressor wheel? I know its a Garrett turbo in it now and its most likely the original small one though im unsure of the name but you probably know which one it is. Whats the stock TD04? What does the coolant line look like for the TD04 and does it go straight on my car ? Whats everything i need to change over to a TD04 that works with the car?

What does the king cobra do or do better than the original one?

Does it hurt the engine cranking without the said plugs and does this drain the battery? What is normal oil pressure? Is it the same number for every car or does every car have a unique number?
How do I see if the turbo has been leaking? Or does it just do that if its not working properly. The turbo has been bad now for maybe a month and ive never seen it leak oil on the ground not even when driving so i dont know if that says anything. How do i clean the intercooler if needed? Isnt it placed behind the radiator or somewhere between?

Thank you again and sorry for tons of questions !
 
#6 ·
Hi and welcome.

I'd start with replace oil pressure sensor.
Then I change oil to 5W-30 Dexos2 grade oil.
Remove your fancy K&N ASAP and replace it to original air filter.
Check air intake hoses inc IC carefully and to throttle body and try to open exhaust from turbo for checking if exhaust is clogged.
Which spark plugs you use now?

If all these are OK, then you might consider to replace turbo.
 
#9 ·
Hi and thanks !
Is it a chance that it is the oil pressure sensor as the mechanics already checked that it has bad pressure?
Why should i use 5w-30 over 0w-30?
I remember reason i changed airfilter was because on the BSR website it mentioned that a less restrictive air filter could help feed the car with the air that it needed for the stage 1 though now its not there now so i dont know if thats not needed anymore.
Isnt the K&N filter worth it or isnt the engine powerful enough to need it yet?
When opening the air intake hoses what am i looking for? Same with exhaust from the turbo.
Not sure which ones are in it right now but I'll ask them on Monday
 
#10 ·
If you have bad oil pressure, it could be symptom of wrong viscosity oil.
If new oil will not help, I'd take oil pan out and check oil intake screen and intake pipe carefully.

Original air intake including original air filter is good up to 500hp.
K/N is good for seller's bank account, but bad for engine, despite what BSR says. There are several dynamometer results for this.

You are not needed new turbo yet, so keep your money in your pocket.

Typically air hoses are misplaced or clamps are loose and pressurized air leaks out.
 
#11 ·
Alright thank you !
Gonna ask them which spark plugs they put in tomorrow and then first thing im gonna do is prep up for the oil flush ! Then its getting a turbo and changing it and in my head it seems pretty straight forward, Kinda like building a PC when you look at it it seems like its tons of parts that needs to fit but when youre used to it u can easily name every part and you know which cables go where.
If I ever come to the point of removing the oil pan is it easy to locate the intake screen and pipe? One thing is im pretty sure it isnt leaking at least so lets hope thats not the case.

Should I just get another the garrett turbo and do you know which model it is and wait on the TD04?
What should i look for when buying a used turbo?

Do i just check the air hoses around the turbo and intake area? Are they hard to get to and are any under the car?
 
#25 ·
Just in and out, very simple, if you arent familiar with spark plug re and re then you might be best off using a torque wrench so you don't over tighten until you get a feel for how tight the spark plugs should be, you have to careful when tightening them in the aluminum head.

I just watched your video, I think you have noisy accessory pulley bearings on the serpentine belt.
 
#27 ·
I was also wondering about this. I just got my car back from the mechanic and im seeing this thing and i feel like i havent seen it before? Its some oil there and when ive looked up the cars engine bay on google i find out theres something supposed to be there i dont have? Is this normal or am i missing something?
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#29 ·
ahh alright thank you ! Just found out its the original spark plugs that the manual books tells u to use and the whining doesnt start before the engine gets to normal temperature. Also realised smoke comes from the right side of the radiator like faint smoke you barely see it. Idk if you know what that is?
 
#35 ·
Right now I just want to get the oil and turbo fixed. After that I was I wanna start looking at exhausts and similar small upgrades to start off.
But my main goal is to just have it easy tuned and work on it here and there but at levels where it’s safe for the engine if that makes sense
 
#37 ·
That’s the td04 right? And it’s safe for the 2.0? What extra or what do I need to change compared to the garret one that stands in it?
I’m thinking of starting with the system flush next week and see if that helps. What bars should the oil pressure be at when idling and in rpms?
 
#40 ·
You might need bigger turbo when you go higher than original can.
I personally drove almost 10 years 2006 9-5 Aero manual which had 315WHP and 479Nm.
It had stock turbo fuel pressure and intake, bigger injectors and full 3" exhaust.
 
#41 ·
Oh wow that’s mad
We got this car around august 2021 and it wasn’t until first now something needed a change which was the spark plugs and had a gap of 1.7mm which then ruined the coil haha. Then now turbo. But before us there was only 1 family that’s owned it since it was new which I think is really positive tho the turbo felt a bit behind from the start. We did get it for around 1500 euros but at first was just brakes so felt good about the car !