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Intercooler install – Removing the bumper

Intercooler install – Removing the bumper

This is an photo journey of my installation of a new intercooler in my Saab 9-3 (1999, RHD). The standard one makes the air flow back and forth in the intercooler, but I’m installing a bigger cross flow intercooler to cool the intake air and to increase the flow of air to the engine.

To install the new intercooler, the old intercooler needs to be removed and for that to happen, the bumper needs to come off. This section of the install will just focus on the bumper removal.

This is how the car looks at the start. You’ll need to have the bonnet (hood) up so that you can get into the engine bay.

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The next two pictures show the piping going to the intercooler (not very clearly).

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When I’m working on the car like this, I always have my ipad open and handy with a tutorial ready to go. It makes things a lot easier.

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The first part to come off is the front grill. There are two clips at the top of it that hold it on. The clips pinch together and then you can lift the grill off.

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From the top looking down at the right hand side of the car (facing it), you can the screw that holds the right side front light assembly.

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Remove the screw and then light assembly pulls forward.

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Pinch the sides of the clip together to release the whole unit and put it aside.

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Next is the actual headlight. Looking from the top down, you can see the two screws holding in the top of the light. Remove these screws.

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Once those two are out, there is a third screw on a metal bracket on the side of the unit. Undo this screw and pull the light forward.

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Once pulled out, undo the clips holding the wiring to the light.

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My bumper has driving lights and therefore I’ll need to unplug them before taking the bumper off. The following shot is the plug from the bottom, looking up.

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The next wire to unplug is the temperature sensor in the bumper itself. 

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It disconnects easily by pulling the clip out.

 

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Once all the electronics have been removed, the bumper is only held on with two large bolts. These are on either side of the radiator, located on the metal frame of the bumper.

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Remove these bolts.

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I also have a bit of a body kit thing – like a skirt that goes into the bumper. It has a screw holding it to the car, so that needs to be undone. There is also one on the bottom (photo looking up from the ground) that needs to be removed.

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Once all the above have been removed, the bumper can now be pulled forward from the car evenly.

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More car pictures

It’s been a while since I’ve posted some nice photos, so I thought I’d put some up…

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Turbo Troubleshooting

Okay, I know it’s been ages since I’ve posted, but I will be making a bunch of posts soon making up for it. : )

However, first off I need to post about some troubles I’m having with my turbo so I can go through my trouble shooting steps. Once I find the problem, I’ll post how it was fixed so it will help in future.

But first, the problems…

The above picture is the oil residue I found in the pipe that goes from the air intake tube to the BPV. In order, it goes air box, main intake tube and then turbo air inlet. This pipe comes off the side of the main intake tube. Although blurry, it shows pretty clearly that there is a bit of oil in there. I don’t think this is a good sign.

This shows clearly where the pipe comes from (not so much my explanation above :p ) – in this picture it is detached and sitting near where it joins the main intake tube.

This is also a bit of a grim picture. This is where the main intake tube is connected to the turbo intake pipe. There is a fair bit of oil here as well and I’m starting to think cause for concern. The other end of the pipe (not shown) connected to the air box (filter).

This is the side view of the metal tube that bolts onto the turbo itself. This tube leads to the cold side fan (as opposed to the fan that faces the exhaust). The main intake tube fits on here and it’s pretty obvious to see that there is an oil residue here as well. The bolt in the front of the picture holds the breather tube on which runs to the engine. The connector where it goes to the engine (near the throttle body – ish) has a lot of oil residue on it as well.

This is the view straight down the metal air intake to the turbo. The pipe itself doesn’t seem too messy, but you can see some pretty recent oil on the edge of the pipe there.

This is the panoramic shot. 🙂  From left to right you can pretty clearly see: The metal intake pipe to turbo with oil on the side of it, it bolts to the turbo housing itself which seems to be okay. Moving to the right you can see where the manifold bolts on and then the downpipe – both look okay with no visible leaks – sure, they aren’t gleaming and shiny or anything, but okay. Underneath all of that, you can see the wastegate housing with the lever that opens and shuts it (rusty but working fine). Right down below you can see the blue silicon elbow that takes the turboed air to the intercooler. It’s tight – no leaks there.

Probably not that relevant, but just in case, here is the area around the throttle body with the cover removed. The IAC (I think it’s called?) is on the left there and outwardly seems to be in fine condition. I can clean that, but I don’t think it’s the main cause of the problem. I have also checked that silicon hoses and such are in place – just in case.

And finally this is the under car view looking up at the turbo area. From the top of the picture down (which is left to right on the car) – Blue silicon elbow going to the intercooler. It’s connected to the turbo housing. Next you can see what I think is the oil pipe in to the turbo? Looks a bit crappy… Next is where the turbo cold side fan attached to the other fan and the waste gate, etc – the waste gate lever/actuator is on the right hand side there. And lastly at the bottom you can see where the exhaust bolts on. There’s a lovely white stain there… don’t know what that’s from….

Okay, that’s all the photos for now. I’ll putting it out there to help solve my problems and I’ll see what the diagnosis is. I’ll post later as to what the result was.

 

 

 
 

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Some photos of my car

I have a lot of photos here of the interior of the car and the engine bay, but I have realised that I haven’t got pictures of how it looks on the outside! So, here are a couple….

 

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