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B2190 Saab 9-3 I

Cooling System (Mechanical) 22 illustrations ~1613 words

High Speed Radiator Fan Relay 1. Short to B+

Identifying High Speed Radiator Fan Relay 1 Circuit. Scheme 130

Scheme 130: Identifying High Speed Radiator Fan Relay 1 Circuit
Scheme 130: Identifying High Speed Radiator Fan Relay 1 Circuit

Fault symptoms

  1. The radiator fan runs at high speed continuously (also with ignition OFF).
  2. Battery is discharged.
  3. Radiator fan does not operate at high speed, which may lead to engine overheating.

Conditions

Control module output is monitored and if there is a short-circuit to ground/B+ or in the relay circuit, a diagnostic trouble code will be generated.

Diagnostic help

The output from the control module can be activated using the diagnostics instrument.

Radiator Fan Operation Circuit. Scheme 131

Scheme 131: Radiator Fan Operation Circuit
Scheme 131: Radiator Fan Operation Circuit

Fault symptoms

Radiator fan operation defective

Diagnostic help

The relay outputs can be activated using the diagnostics instrument, as also can the low -speed and high-speed functions.

If no information on coolant temperature is available, the low -speed function will start.

Check the wiring

Jiggle the wiring harness at several points and in different directions to reveal intermittent breaks and short -circuits in the wiring harness. Observe the multimeter, test lamp or diagnostic instrument while doing this.

Removing The Bypass Hose Together With The Intake Hose (Turbo). Scheme 132

Scheme 132: Removing The Bypass Hose Together With The Intake Hose (Turbo)
Scheme 132: Removing The Bypass Hose Together With The Intake Hose (Turbo)

Scheme 133

Scheme 133
Scheme 133

Scheme 134

Scheme 134
Scheme 134
  1. Remove the «charge air cooler»(ref-206764-S04877323922005112600000).
  2. Remove the front grille.
  3. Detach the oil cooler (certain cars) and suspend it so that the hoses will not be damaged.
  4. Detach the condenser from the radiator (A/C).
  5. Note the radio code if applicable. Disconnect the vent hose and remove the battery.
  6. Open the drain plug and drain the coolant. Unscrew the expansion tank filler cap to speed this up.
  7. Remove the bypass hose together with the intake hose (turbo).
  8. Detach the upper radiator hoses from the radiator. (Scheme 133): Detaching The Upper Radiator Hoses From The Radiator
  9. Unplug the radiator fan electric connections.
  10. Detach the servo pump's oil pipe and the clips for the radiator's venting hose from the radiator crossmember and bend the oil pipe aside.
  11. Remove the radiator fan cowling (2 bolts) and lift it up.
  12. Remove the gearbox oil pipes at the oil cooler, remove the bolt securing the pipes to the cooler and plug the connections (aut.).
  13. Remove the lower radiator hose from the radiator. Remove the clamps securing the radiator to its crossmember and pull the radiator up and out of the rubber mountings so that the clip for the A/C compressor's cable can be removed. (Scheme 134): Removing Lower Radiator Hose From Radiator
  14. Lift out the radiator.

Attaching Lower Radiator Hose To Radiator. Scheme 135

Scheme 135: Attaching Lower Radiator Hose To Radiator
Scheme 135: Attaching Lower Radiator Hose To Radiator

Scheme 136

Scheme 136
Scheme 136
  1. Smear the radiator's rubber bushes with vaseline.
  2. Introduce the radiator into position and fit the clamps. Refit the clip for the A/C compressor cable.
  3. Attach the gearbox oil pipes to the oil cooler (aut.). Tightening torque: 25 Nm (18.5 lbf ft) Do not forget the bolt securing the pipes to the radiator.
  4. Check that the radiator drain plug is tightened. Tightening torque: 4 Nm (3 lbf ft) Attach the lower radiator hose to the radiator.
  5. Position the radiator fan cowling on the radiator and tighten the 2 bolts.
  6. Connect the radiator fan and attach the upper radiator hoses.
  7. Fit the clips for the radiator's venting hose to the radiator crossmember and fit the servo pump's oil pipe. (Scheme 136): Fitting Clips For Radiator's Venting Hose To Radiator Crossmember And Fitting Servo Pump's Oil Pipe
  8. Fit the bypass hose together with the intake hose and delivery pipe between the charge air cooler and throttle body (turbo).
  9. Fill up with coolant and check the system for leaks.
  10. Fit and reconnect the battery.
  11. Check the gearbox oil level and top up as necessary (aut.).
  12. Fit the condenser (A/C).
  13. Fit the oil cooler (certain cars).
  14. Refit the grille.
  15. Fit the charge air cooler (turbo).
  16. Fill up and bleed the system as follows: NOTE: A/C and ACC must be OFF. Fill the system up to the MAX level, fit the pressure cap, start the engine and warm it up at varying RPM until the radiator fan starts. Switch off the engine and top up as necessary to the MAX level.
  17. Set the car clock and radio code where applicable. Calibrate the ACC.

Scheme 137

Scheme 137: To Remove
Scheme 137: To Remove

Scheme 138

Scheme 138
Scheme 138

Scheme 139

Scheme 139
Scheme 139

Scheme 140

Scheme 140
Scheme 140

Scheme 141

Scheme 141
Scheme 141

Scheme 142

Scheme 142
Scheme 142

Scheme 143

Scheme 143
Scheme 143
  1. Disconnect the vent hose from the battery. Disconnect the positive and negative battery cables and remove the battery. Note the radio code where applicable. (Scheme 138): Unplugging Radiator Fan Electric Connections
  2. Unplug the radiator fan electric connections.
  3. Remove the top engine cover.
  4. Remove the charge air pipe and bypass pipe with valve, keep the O -ring from the connection to the turbocharger intake pipe.
  5. Remove the heat shield over the exhaust manifold.
  6. Remove the power steering system's fluid reservoir.
  7. Undo the oil pipe for the power steering servo pump, the clip for the A/C expansion tank and the clip for the radiator vent hose from the radiator crossmember and bend the oil pipe to one side.
  8. Remove the bracket from the battery tray and bend it aside.
  9. Remove the radiator fan cowling, 2 bolts. Tilt the radiator fan cowling, twist up and lift out. (Scheme 140): Removing Radiator Fan Cowling
  10. Place a receptacle under the car and remove the gearbox oil pipe on the oil cooler. Remove the screw securing the pipe to the cooler and plug the connections (aut). (Scheme 141): Removing The Gearbox Oil Pipe On The Oil Cooler
  11. Remove the front grille. (Scheme 142): Removing Front Grille
  12. Remove headlamps and light clusters.
  13. Remove the 2 air shields.
  14. Remove the horn.
  15. Open the expansion tank pressure cap to release system pressure.
  16. Raise the car.
  17. Remove the lower air shields. (Scheme 143): Removing The Lower Air Shields
  18. Drain the coolant by connecting a hose and opening the drain plug. Collect the coolant in a suitable receptacle.
  19. Tighten the drain plug.
  20. Unbolt the bottom of the charge air cooler, 2 bolts. (Scheme 144): Unbolting Bottom Of Oil Cooler
  21. Unbolt the bottom of the oil cooler, 3 bolts. Bend the oil cooler aside and secure with a cable tie or similar.
  22. Unbolt the bottom of the condenser, 2 bolts.
  23. Detach the outlet hose from the turbocharger. (Scheme 145): Detaching Outlet Hose From Turbocharger
  24. Detach the outlet hose from the charge air cooler.
  25. Lower the car to the floor.
  26. Detach the upper hose from the radiator.
  27. Detach the lower hose from the radiator.
  28. Remove the clips securing the radiator to the radiator crossmember and pull the radiator up out of the rubber mountings.
  29. Unhook the condenser from the mountings on the radiator. (Scheme 146): Unhooking Condenser From Mountings On Radiator
  30. Tilt the radiator away from the radiator crossmember and disconnect the vent from the expansion tank.
  31. Cut off the clip securing the A/C compressor cable to the radiator.
  32. Lift out the radiator.

Scheme 144

Scheme 144: To Fit
Scheme 144: To Fit

Scheme 145

Scheme 145
Scheme 145

Scheme 146

Scheme 146
Scheme 146

Scheme 147

Scheme 147
Scheme 147

Scheme 148

Scheme 148
Scheme 148

Scheme 149

Scheme 149
Scheme 149

Scheme 150

Scheme 150
Scheme 150

Scheme 151

Scheme 151
Scheme 151
  1. Lubricate the radiator upper rubber bushes with non -acidic vaseline, part no. 30 06 665, or the equivalent.
  2. Lift the radiator into place but do not press it home.
  3. Fit the bleed hose to the expansion tank. (Scheme 147): Fitting Bleed Hose To Expansion Tank
  4. Hook the condenser onto the mountings on the radiator.
  5. Press the radiator home and fasten the 2 clips that secure the radiator to the radiator member.
  6. Fasten the A/C compressor's lead to the radiator with a new clip. (Scheme 148): Fastening The A/C Compressor's Lead To Radiator
  7. Attach the radiator's lower hose.
  8. Attach the turbocharger's outlet hose and the charge air cooler's outlet hose.
  9. Raise the car.
  10. Bolt the bottom of the condenser in place, 2 bolts. (Scheme 149): Bolting Bottom Of Condenser In Place
  11. Remove the cable tie and fit the oil cooler, 3 bolts.
  12. Bolt the bottom of the charge air cooler in place, 2 bolts.
  13. Fit the two lower air shields. (Scheme 150): Fitting Two Lower Air Shields
  14. Make sure the cooling system drain plug is tight. Fit the lower air shields and lower the car.
  15. Fit both air shields (by the side of the condenser). (Scheme 151): Fitting Both Air Shields (By The Side Of The Condenser)
  16. Fit the light clusters and headlamps.
  17. Fit the horn and front grille.
  18. Attach the gearbox oil pipes to the oil cooler (aut.). Tightening torque 25 Nm (19 lbf ft) see scheme 73: Attaching Gearbox Oil Pipes To Oil Cooler
  19. Fit the screw securing the pipe to the radiator Tightening torques
  20. Lift the radiator fan cowling into place and fit the 2 bolts. see scheme 74: Lifting Radiator Fan Cowling Into Place And Fitting 2 Bolts
  21. Attach the radiator's upper hose.
  22. Mount the bracket on the battery tray.
  23. Fit the power steering system's fluid reservoir.
  24. Fit the oil pipe for the power steering servo pump and the clips for the radiator vent hose as well as the clip for the A/C expansion tank.
  25. Plug in the radiator fan's plugs.
  26. Fit the heat shield over the exhaust manifold. see scheme 75: Fitting Heat Shield Over Exhaust Manifold
  27. Fit the charge air pipe.
  28. Fit the bypass pipe with valve. Use a new O -ring for the connection to the turbocharger intake pipe.
  29. Fit the top engine cover.
  30. Fit the battery and connect its vent hose.
  31. Fill up with coolant. For the correct mixture, see «COOLING SYSTEM»(ref-206764-S36753404882005112600000). Close the filler cap.
  32. Bleed the system as follows: NOTE: A/C and ACC must be OFF. Fill the cooling system to MAX level. Close the cap on the expansion tank, start the engine and warm it up at various engine speeds until the radiator fan starts. Carefully open the cap and top up to MAX.
  33. Raise the car to check for oil or coolant leakage.
  34. Lower the car and top up with coolant / transmission fluid (aut) as necessary
  35. Set the clock and radio code where applicable.

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