Cooling System, Petrol: Removal & Installation Saab 9-3 I

To Remove

1. Raise the car and remove the spoiler shields.
2. Undo the pipe connections (PAD connection).
3. Undo the oil cooler retaining bolts and remove the oil cooler.

Collect the oil in a receptacle.

1. Remove the electric connection from the level sensor.
2. Remove the level sensor.

Fitting Level Sensor. Scheme 7

1. Fit the level sensor.
2. Plug in the level sensor connector.

1. Open the expansion tank pressure cap and release the overpressure, then tighten the pressure cap.
2. Remove the cover and delivery pipe between the charge air cooler and throttle body (turbo).
3. Unplug the temperature sensor connector and remove the sensor.

Scheme 8

1. Fit the temperature sensor. Tightening torque: 6 Nm (4.5 lbf ft) (Scheme 23): Fitting Temperature Sensor Plug in the connector.
2. Fit the delivery pipe between the charge air cooler and throttle body (turbo).
3. Fill up with coolant and check the system for leaks.

Scheme 9

1. Remove the radiator fan.
2. Cut the cables to the resistor. (Scheme 24): Identifying Resistor Cables
3. Fit shrink tubing from the wiring harness repair kit, part no. (16) 86 12 079. Solder the leads to the new resistor. Heat the shrink tubing so that it shrinks over the soldered connections. IMPORTANT: Be sure to get the colors right.
4. Fit the radiator fan.

Scheme 10

Scheme 11

1. Unscrew the drain plug and drain the coolant. Remove the expansion tank pressure cap to speed this up.
2. Remove the air cleaner. (Scheme 25): Removing Air Cleaner
3. Detach the intake hose and plug the pipe (turbo).
4. Remove the bypass hose and the delivery pipe between the charge air cooler and throttle body (turbo).
5. Relieve the belt tensioner of tension using a ratchet handle extension and insert a 6 mm drill bit or the like in the hole (Scheme 25)
6. Remove the power steering pump with bracket and suspend it from the radiator crossmember.
7. Detach the coolant hoses and pipes from the pump. see scheme 125: Removing Coolant Hoses And Pipes From Pump
8. Undo the screw securing the coolant pipe in the front left corner of the engine.
9. Remove the throttle body hose from the coolant pipe and undo the thermostat housing bolts. Move the pipes aside.
10. Remove the solenoid valve and move it to one side (turbo). see scheme 126: Removing Solenoid Valve (Turbo)
11. Remove the coolant pump.
12. Remove the sleeve with O -rings and unbolt the coolant pump from the pump housing.

Scheme 12

1. Clean the mating surfaces and bolt the coolant pump to the pump housing.
2. Lubricate the O -rings with non-acidic vaseline and fit the sleeve together with the pump.
3. Refit the solenoid valve (turbo).
4. Attach the coolant hose to the throttle body and refit the thermostat housing bolts.
5. Fit the coolant pipe retaining bolt in the front left corner of the engine.
6. Connect the coolant hoses and coolant pipes to the coolant pump.
7. Refit the power steering pump with bracket and fit the belt. see scheme 129: Installing Power Steering Pump With Bracket
8. Relieve the belt tensioner with a ratchet handle extension and remove the drill bit.
9. Fit the delivery pipe between the charge air cooler and throttle body and refit the bypass hose (turbo).
10. Refit the intake hose (turbo) and fit the air cleaner.
11. Make sure that the radiator drain plug is tightened. Fill up with coolant and check the system for leaks.
12. 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.

Scheme 13

Scheme 14

Scheme 15

Scheme 16

Scheme 17

Scheme 18

1. Open the expansion tank pressure cap to release system pressure. see scheme 130: Identifying Expansion Tank Pressure Cap
2. Raise the car.
3. Connect a hose to the system drain plug and drain the coolant into a suitable receptacle.
4. Detach the coolant pipe from the turbocharger. see scheme 131: Removing Coolant Pipe From The Turbocharger
5. Close the system drain plug and lower the car.
6. Remove the air hose between the air collector casing and the turbocharger intake pipe.
7. Cut the 2 cable ties securing the main engine cables. Relieve the strain on the belt tensioner with a ratchet handle and secure the belt tensioner with a 3.5 mm drill or similar. see scheme 132: Relieving The Strain On The Belt Tensioner With A Ratchet Handle
8. Lift the belt off the power steering pump and coolant pump pulleys.
9. Remove the top engine cover.
10. Detach the crankcase ventilation pipe from the turbo inlet pipe and camshaft cover. Bend the pipe to one side. Keep seals and washers safe.
11. Unplug the solenoid valve's connector.
12. Detach the solenoid valve hoses.
13. Remove the engine lifting eye.
14. Remove the bypass pipe with valve. Keep the O -ring from the connection to the turbocharger intake pipe.
15. Remove the heat shield over the exhaust manifold.
16. Detach the venting hose from the T -connection.
17. Remove the turbocharger's intake pipe, plug the turbo.
18. Remove the power steering servo pump bolt on the right -hand side behind the belt pulley. see scheme 134: Removing The Power Steering Servo Pump Bolt
19. Undo the upper power steering servo pump bolt.
20. Lift up the power steering servo pump and remove the lower bolt and the 2 upper bolts on the bracket.
21. Move the power steering pump and bracket aside and secure with a cable tie or similar.
22. Undo the hose clips and detach the hoses from the coolant pump inlet. see scheme 135: Removing Hose Clips And Detaching The Hoses From The Coolant Pump Inlet
23. Detach the two longitudinal coolant pipes from the cylinder block.
24. Disconnect the coolant pipes from the coolant pump, keep the O -rings and move the pipes aside.
25. Loosen the coolant pump slightly.
26. Detach the coolant pipe from the coolant pump. Keep the seals. see scheme 136: Detaching The Coolant Pipe From The Coolant Pump
27. Undo the coolant pump's 3 retaining bolts.
28. Carefully wiggle the coolant pump away from the mounting and from its connecting piece in the cylinder block.
29. Remove the connecting piece from the cylinder block, check its seals and change as necessary.

Scheme 19

Scheme 20

Scheme 21

Scheme 22

Scheme 23

Scheme 24

Scheme 25

1. Fit the connecting piece to the cylinder block. Coat the seals with Gleitmo 805, part no. 30 06 442. see scheme 137: Fitting The Connecting Piece To The Cylinder Block
2. Fit the coolant pump in place but do not tighten it.
3. Position the coolant pipe between the coolant pump and turbocharger. Use new washers and seals.
4. Tighten the coolant pipe to the coolant pump. Tightening torque: 20 Nm
5. Bring the two transverse coolant pipes up to the coolant pump, use new O -rings coated with non -acidic vaseline, part no. 30 06 665 or the like. see scheme 138: Installing Two Transverse Coolant Pipes Up To The Coolant Pump
6. Tighten the coolant pump, 3 bolts. Tightening torque: 22 Nm (16.2 lbf ft)
7. Tighten the two transverse coolant pipes. Tightening torque: 10 Nm (7.4 lbf ft)
8. Fit the power steering pump and bracket. Tightening torque: 24 Nm (17.7 lbf ft) see scheme 139: Fitting The Power Steering Pump And Bracket
9. Fit hoses and hose clips on the coolant pump inlet.
10. Remove the plug from the turbocharger air intake. Inspect the O -ring and coat it with non-acidic vaseline, part no. 30 06 665, or the equivalent.
11. Fit the turbocharger inlet pipe but do not tighten the V -clamp.
12. Fit the solenoid valve on the engine lifting eye. Connect the hoses to the solenoid valve. Note the markings on the hoses and the connection.
13. Fit the engine lifting eye.
14. Tighten the turbocharger's intake pipe, V-clamp. Tightening torque: 3 Nm (2.2 lbf ft)
15. Connect the venting hose to the T-connection.
16. Fit the heat shield over the exhaust manifold. see scheme 141: Fitting The Heat Shield Over The Exhaust Manifold
17. Fit the bypass pipe and valve, use a new O -ring for the connection to the turbocharger inlet pipe. Tightening torque: 8 Nm (5.9 lbf ft)
18. Spray the solenoid valve connector with Kontakt 61, part no. 30 04 520, and plug it in.
19. Fit the crankcase ventilation pipe to the turbocharger intake pipe. Use new copper seals. Tightening torque: 24 Nm (17.7 lbf ft) Fasten the crankcase ventilation pipe to the camshaft cover, clip.
20. Fit the throttle body's cover.
21. Raise the car and fit the coolant line to the turbocharger. Tightening torque: 25 Nm (18.4 lbf ft) see scheme 142: Fitting The Coolant Line To The Turbocharger
22. From underneath, check that the multigroove V-belt is correctly fitted round all pulleys. see scheme 143: Checking That The Multigroove V-Belt Is Correctly Fitted
23. Check that the cooling system's drain plug is closed. Lower the car to the floor.
24. Relieve the tension on the belt tensioner with a ratchet handle and remove the catch. Make sure the belt is positioned correctly and carefully release the ratchet handle.
25. Secure the engine's main wiring harness with cable ties. see scheme 144: Securing The Engine's Main Wiring Harness With Cable Ties
26. Fit the air hose between the air collector casing and the turbocharger intake pipe.
27. Fill up with coolant. For the correct mixture, see «COOLING SYSTEM»(ref-206764-S36753404882005112600000). Close the filler cap.
28. Fill up and bleed the system as follows: NOTE: A/C and ACC must be OFF. Fill the system to MAX level, fit the pressure cap, start the engine and warm it up, preferably at varying engine speeds, until the radiator fan starts. Switch off the engine and top up as necessary to the MAX level.
29. Raise the car to check for oil or coolant leakage.
30. Lower the car and top up the coolant and/or oil as necessary.

Identifying Motor, LH Radiator Fan (4-Cyl). Scheme 26

Identifying Motor, LH Radiator Fan (V6). Scheme 27

Identifying Coolant Temperature Sensor, Instrument (45). Scheme 28

Identifying Relay, 2-Speed Radiator Fan, High Speed (81). Scheme 29

Identifying Relay, 2-Speed Radiator Fan, Low Speed (155). Scheme 30