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Viggen Intercooler |
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| Installation Summary -
Radiator coolant must be drained to install new lower radiator
hose. A new passenger side hose is required but it is possible to use the
existing drivers side hose by removing the clamp that holds it to the
engine block and sliding the hose down and retightening. The old
intercooler is removed and the Viggen Intercooler is installed in the same
location with the same bolts. The installations of the Viggen Intercooler
does not require the moving or relocation of any other parts or pipes
other then the ones mentioned. Part Numbers For Ordering From Dealer Viggen Intercooler: 4729521 Passenger's Side Hose: 4729950 Driver's Side Hose: 4729968 (Not Required - See Bottom) Lower Radiator Hose: 4963872 I highly recommend this upgrade, it is well worth the effort and cost. There is a noticeable increase in power and spool-up is quicker. On Maptun's website they indicate that there is a 10 HP increase. I have also seen verification of this on Saab Net where someone posted a before and after dyno. There was an increase of 11 horsepower 12 nm of torque. Using some string I measured the distance from the turbo exit to the throttle body transition casting, the total length was 10'9" with stock setup. With the Viggen Intercooler the length was reduced by 25% to 8'2", plus a reduction of approximately 260 degrees of bends. Viggen Intercooler Dimentions: Core: 167.5mm high Core: 555mm length exposed to air flow Core: 56.5mm deep. Cost: $175 Intercooler, $100 Each Side Hose, $11 Radiator Hose Time: 4 hr Difficulty: Moderate |
  
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| Full Installation Instructions-
This installation is for installing the Viggen intercooler with the
new passenger side hose and reusing the driver's side hose (Number 6
pictured to the right). Begin by jacking up the front and removing the
bumper (Bumper instructions written under Tips). The next step is to
remove the stock intercooler, start by first removing the pipes from the
turbo to intercooler (2,3,4) and then take the intercooler to throttle
body pipes (5,6,7) off by remove the clamps (11) that secure them to the
throttle body transition casting. There is also a metal clamp on part (6)
which secures it to the engine block (not pictured). This clamp needs to
be removed from the engine block and the hose because it will not be
reused for the reinstallation. The stock intercooler is held in place by only two bolts on either side. All pipes are held in place by circular pipe clamps (11,12) that can be loosened with a flat head screwdriver or a hex socket. Two pipe clamps (11) need to be saved from this removal to be reused on the new passenger side pipe unless new clamps were purchased. All parts of the driver's side hose with be reinstalled in the same layout as pictured here (5,6,7). |
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| With the stock intercooler removed
the next step is to drain the radiator fluid. The drain is located on the
driver's side at the bottom of the radiator. There is a hex wrench screw
that must be loosened to allow the fluid to pore out. First remove the cap
to the radiator fluid chamber to equalize the pressure during the drain.
As soon as the screw is loosened radiator fluid will pore out of the hex
hole in the screw. I used a plastic trash bag to catch the fluid because
it is not possible to position a bucked directly under the spout. A small
hose might work well but there is not much room to maneuver beneath the
spout. The trash bag worked rather well without much spilling
Once the radiator fluid has drained remove the lower radiator hose on the passenger side and install the new one. I suggest using new pipe clamps because they will be easier to tighten in the confined space. Don't refill the radiator fluid yet, it is easier to install the turbo exit pipe when the radiator hose is empty. |
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| The installation of the Viggen intercooler is next. Reattach the bolts on either side of the Viggen intercooler |
 
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