SAAB 900 DO88 Intercooler Installation

Yeah, it's big. And that's a good thing. DO88's front-mounted intercooler is just what your Classic 900 needs to get more air/fuel into the engine when you spin up the turbo. See how it goes together, and what makes this the perfect time for bumper repair.
DO88 Intercooler Kit: www.do88.se/sv/artiklar/fmic-...
SEM Bumper Coater 39273 Charcoal Metallic

[@GrantArmitage]

Best Classic 900 content on youtube. Keep up the great work Lee!

[@LeeKelso]

Wow, thanks!

[@TheDurk96]

Thanks Lee, great video! A/C gone on my 900 as well, haven't missed it!

[@t1mpetti]

Thank You, Lee!

[@czteryczteryczteryczterycz6019]

Great video

[@ryannicol8863]

Brilliant video!

[@LeeKelso]

Glad you liked it! Having driven with it in place for a while now, I'm convinced it was worth the effort. I later installed a larger turbo and the ability to move even more air is important.

[@adaermelgar5376]

i have a DO88 intercooler w/ the "big pack" pipes on m y NG 9-3 (06) ... i know i know.. I KNOW not an OG 900..But i vouch for DO88... not only did the full "Big Pack" kit fit like a glove, ( its was one of my 1st DIYs on said 9-3 )but i havent had a single cooling issues in the 5 years ive had it. it fit like a glove... DO88 is quality.. And like this OG 900, my NG 9--3 looks stock with the DO88 intercooler... i got it because im going with the sleeper dad car look ;P

[@markc.4883]

Now that you deleted the compressor, delete the condenser....panel it off with a door built in and you get a huge under the hood storage area!! I'd post a pic, but you know....can't do that here! You can also do a remote oil filter while your in there, upgrade that small cooler, use a Chevy V8 oil filter and increase your oil capacity to almost 6 quarts......;-)

[@johartmann9408]

The cooling capacity of the do88 intercooler is fantastic, but the removal of the air conditioning, headlight wipers and the original towing eyes should be considered carefully. With the space gained in the engine compartment, however, a number of things can be implemented (battery, intake modifications, etc.).

[@LeeKelso]

I agree, especially on a limited production car like a Commemorative Edition. However, my car has a salvage title and accident repair history so its not a candidate to be elevated to top-notch collector car status. That's why I don't feel bad about sympathetic, performance oriented modifications. An update to t-5 ignition system is next.

[@FinishPlayer]

You gotta get rid of the tow hooks? Damn those are so useful, with my saabs front end apart we pulled the car into the barn with the tractor using those, at least they give you new hook.

[@LeeKelso]

I too was a bit suspect about cutting those off. My SAAB has been hauled on a flatbed more than once, so I get your concern. But, the alternative they provide seems more than adequate.

[@FinishPlayer]

@@LeeKelso It'll certainly do the job, i'm just hoping i don't need to carry the front end in the air with a tractor in the future, the hooks being right on the bumper made it easy to do so.

[@czteryczteryczteryczterycz6019]

Is there a workaround with headlight wipers? Could i make it work with them still attached or is it impossible?

[@RetrocarStyle]

NICE!! I always wondered if you could run the Do88 intercooler with A/C. Also any plans to feature the burgundy convertible in any videos??

[@LeeKelso]

A couple of people have asked about that car, so yes. It's a real survivor. Very clean with just a few minor needs here and there.

[@RetrocarStyle]

@@LeeKelso I look forward to some featured episodes.

[@charliefortenberry3510]

Thanks for this! Did you find it opened up the space where the old intercooler went? Thinking about alternative air filter placements to go with Modern Classic Saab’s battery relocation kit.

[@LeeKelso]

I had not thought of that, but yes there is more space available. I have a high-flow filter in the original canister. I kinda like keeping it the snorkel draws cool air from outside the engine bay. Love the idea of moving the battery to that site. Jordan, what do you think?

[@kaisertrinityt.m.i.s1607]

Very nice, i have seen the kit and didnt bought it because i thought, that you have to cut something off under the front bumper. aside that i have something on my saab thats hugely worrieng me. Now under the car, there are 4 points where you can lift up your car, but the front one on the co-driver side was so badly corroded that it almost broke when i lift up my saab and is now halfway bow inside. when i was checking it, i discovered that the entire thunnel where the entry-cover-plates and hald of the seat is screwed on has rust on it, semengly on the ENTIRE LENGHT.... now what should i do? cut all out?

[@LeeKelso]

Send me photos of its condition and we'll put them up on SAAB Talk LIVE and ask experts in the community for their input.

[@kaisertrinityt.m.i.s1607]

@@LeeKelso i can try but when and how? neither i use facebook, Whatsapp or any of that. all i can use is via my Gmail Account if thats ok to you.

[@kaisertrinityt.m.i.s1607]

@@LeeKelso alright, i made some photos, how can i give them to you?

[@jayschuon8330]

Lee, love the content ! Did you notice a difference with the DO88 intercooler when compared to a stock car ?

[@LeeKelso]

Yes. It's subtle, but feels as though the engine breathes better and pulls stronger into higher RPM's. I'm not sure you'd sense a significant difference with lazy in-town motoring, but when you take your SAAB out to play it's more apparent. Seems even more noticeable after the T-5 conversion.

[@Terensu-desu]

Any recommended alternatives to the DO88? That looks great and really compelling, but I don't want to cut away on my 900 CE.

[@LeeKelso]

I think it's worth a little metal surgery. The engine breathes so much better, and the replacement towing plate is more than sturdy enough to do the job.

[@Achilles3588]

Nice vid Lee. Curious...whatcha gonna do with the old intercooler? Asking for a friend...

[@LeeKelso]

It's sitting on the shelf. Happy to send it your way for just the cost of postage.

[@Dodgingsimulator]

Hey I have a question my brother just bought one of these and it won't go into first or second and I'm convinced that it's that dogbone shift coupler but I don't see it and help would be great I've been over schematic 20 times and I just don't see it

[@LeeKelso]

It could very well be the problem. Mine split and left me with just 3rd gear. The coupler you mentioned links the shift rod coming out of the transmission to the linkage rod from the cabin. It's a chunk of rubber bonded to metal plates with two threaded studs extending from the top and bottom. I believe there are 7 or 8mm lock nuts securing the shift linkage to the transmission rod. The Bentley manual has instructions on how to align the shift linkage with the rod from the transmission. I simply used a drill bit through the alignment holes in the cabin holding the shifter into position, and another drill bit that fit through a groove on the back of the transmission through an alignment hole on the trans rod. A little fussy at first, but it all makes sense and is a quick repair. I now carry a spare coupler in the boot.

[@JS-yj7ow]

Aw man, I shouldn’t have watched this, now I want to do this to my ‘92! But seriously, you have me thinking. And what about that pretty maroon vert sitting in the background? Yours? Always loved that color And what are you doing with your AC over pressure valve. I could use one.

[@LeeKelso]

That Ruby C900 is a great find. A tip about an estate sale of an elderly SAAB collector led me to buy two C900 convertibles. Sold one, kept Ruby. 94 that is amazingly clean, original, low miles and no dash cracks. Sadly, it's an auto. But, I'm leaving it a slushbox because I like tossing the keys to friends and asking them join us for weekend convertible cruises.

[@1873Winchester]

Good video, I didn't know you had to give up the wipers when doing this. That means for me I won't be doing the do88 intercooler on my car. Is your car a manual by the way? I haven't seen a skid plate on a saab 900 here, but on american cars they seem common. My workshop manual says it's for automatics, but see no reason it cannot fit a manual? I like the idea of one, seems like it would help aerodynamically.

[@LeeKelso]

Yes, mine is a manual. All the SAAB's I've owned have a skid plate so maybe it's a USA thing? Giving up the headlamp wipers was no problem for me, I believe the performance benefit is well worth it. Personal choice, of course.

[@1873Winchester]

@@LeeKelso I'm in Finland and while I don't drive this in winter anymore (to save it from the salt) autumns still get very wet and dark and the wipers for the headlights are such a useful feature I could not give them up. And they look cool of course!

[@larsjrgensen5975]

I think it depends on what year the car is from, my Danish 1991 manual had a skid plate on it and it has saved me atleast once.

[@austinvitoux]

Oooh, AC delete aka weight reduction for more "go fast"