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I did this job last year on my 1998 900SE. There are excellent instructions with pics at the platonoff DIY site. Google 'photo platonoff' and look at the 'NG900 turbo upgrade' link. I followed these instructions and they worked like a charm (with a few modifications).
First off, the TD04 fits to your existing hot side (downpipe). It takes a different fitting on the inlet side, though. There are custom-made after-market parts (expensive!) for this but I got lucky with the dismantler. There are also differences in the oil and coolant lines on the Mitsu turbo.
First, I got my TD04 off a Viggen wreck. There's a Volvo/Saab dismantler in Rancho Cordova, CA (google them). I got them to send me the Viggen turbo inlet pipe (this goes from your air box to the turbo). They also sent me all the oil and coolant lines and (more importantly) banjo bolts. I paid around $400 delivered and sold my old T25 turbocharger (still functional) on ebay for $280.
I simply cut the rubber hose between the airbox and turbo at an angle to accomodate the longer Viggen 'cobra' inlet pipe. The fit is so tight it holds without a clamp (I clamped it anyway). If you're using the Viggen inlet pipe (#30584297), you'll also need to ask the dismantler for the hard ventilation line and banjo bolts that go between the the top of the inlet pipe and the back of the engine valve cover. You'll also need to get the bypass hose (#4753869) that goes from the inlet pipe to the blowoff valve. This connects to the BOV with rubber hose and clamps and to the inlet pipe with a small metal bolt and clamp. Make sure you get a new o-ring for between this aluminum hose and the inlet pipe (#7987415). One of your BPC valve hoses goes to the nipple on the top of the inlet pipe (near the vent line). I had to step down the line to get it to fit snug. Make sure you hook up the other two BPC valve lines to the nipples on the wastegate and turbo compressor housing. People recommend new 6mm ID silicone lines (cheap on ebay).
I had all the banjo bolts from the stock T25 and TD04 oil and coolant lines, so I used additional copper washers (as suggested on the platonoff site) to get tight seals. The coolant return between the turbo and engine is a rubber hose that is too big on the TD04. You have to really clamp it good to get it to work.
I think that's about it. I've been running it exactly 12 months now with no issues. One thing you should know is that upgrading to this turbo without computer modifications does not add noticeable HP or torque. The stock programming on a Trionic 5 doesn't know what to do with the larger turbo. Performance doesn't suffer; actually seems better, esp at speed and higher RPMs.
I'm finally getting my computer upgrade (should arrive tomorrow). It's a jakstollperformance stage 4 designed for the Mitsu TD04. You also need upgraded intercooler, and larger downpipe and exhaust to run this. It's supposed to be about 255hp at the wheels and 290 torque. I'll post once I have it installed and run a dyno.
Good luck!
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