New exhaust manifolds for Saab 900 Turbo (-93)
17.10.2025
The exhaust manifold on the Saab 900 Turbo with the B202 is somewhat poorly designed compared to the naturally aspirated version, and it was modified at least once during its construction. However, this did not really solve the problems at the time, as it continued to tend to crack between the individual cylinders. In severe cases, the stud bolts on the cylinder head have even broken off in early turbos.
Originally, the manifolds were given larger holes on the outside during the modification to allow for more thermal expansion, but this was not entirely sufficient. The fastening with long stud bolts and spacer sleeves also serves this purpose. After discussions with experienced workshops and mechanics, we came to the conclusion that all holes in the manifold should be oversized in order to get the tearing problem under control.
We had been planning to reproduce the manifold for quite some time. New manifolds have been unavailable for what feels like forever, and used parts are usually cracked or, in the worst case, broken into two pieces. After some searching, we found a small foundry that was able to produce the manifolds for us in small batches at a reasonable price. After delivering samples and the cylinder head, the manufacturer created and tested 3D models, then produced a prototype. We then installed and tested this prototype in our car. Subsequently, minor changes were made to reduce the problem with thermal expansion and simplify installation.
To make installation easier, we offer flange bolts and copper nuts with a smaller wrench size for the turbo connection; the original parts are very fiddly to remove due to the limited space.
Incidentally, to remove and install the manifold, it is sufficient to remove the upper right engine mount and hang or support the engine. At the time, Saab specified the removal of the distributor and turbocharger in its workshop manuals. This is not necessary.
The new manifolds for the classic Saab 900 Turbo are now available in our shop under the number 1003815.
Suitable for the following vehicles:
- Saab 900 Turbo (-93) with B202 engine
