Cooling System 4-CYL: Removal & Installation Saab 9-3 II

To Remove

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1. Undo the expansion tank cap and release the pressure.
2. Remove the upper engine cover.
3. Remove the battery cover and release the cables from the battery.
4. Remove the battery cooling pipe and release it from its catch.
5. Disconnect the charge air pipe from the throttle body and the pipe's upper mounting from the fan cowling.
6. Release the connector and hose from the pressure/temperature sensor on the charge air pipe.
7. Raise the car.
8. Remove «FRONT SPOILER SHIELD»(ref-275838-S05457380322007122900000) .
9. Place a receptacle under the car, connect a hose and drain the cooling system.
10. Detach the charge air hose from the charge air pipe on the left side.
11. Remove the lower charge air pipe bracket from the fan cowling.
12. Detach the charge air hose from the charge air pipe on the right side. Move the hose aside.
13. Remove the dryer filter bolts from the radiator.
14. Lower the car.
15. Lift away the intake manifold with hose.
16. Remove the upper coolant hose from the radiator.
17. Detach the expansion tank hose.
18. Auto: Remove the dust protector to the upper pipe, turn «87 92 806 REMOVAL TOOL, OIL PIPE AUTOMATIC TRANSMISSION»(ref-275852-S07498375782007122900000) . slightly and remove the upper connection. Undo the pipe from the clip at the same time.
19. Remove the upper fan cowling bolts.
20. Remove the upper bolts - intercooler - radiator.
21. Undo and fold up the cover over the radiator core. Guide down two «83 95 212 STRAPS»(ref-275852-S36283635012007122900000) to hang up the fan cowling and charge air cooler respectively together with the condenser.
22. Raise the car.
23. Tighten «83 95 212 STRAPS»(ref-275852-S36283635012007122900000) .
24. Remove the lower radiator connection.
25. Auto: Remove the dust protector and the pipe from the oil cooler. Use «87 92 806 REMOVAL TOOL, OIL PIPE, AUTOMATIC TRANSMISSION»(ref-275852-S07498375782007122900000) .
26. Unhook the intercooler and condenser from the radiator.
27. Unhook the fan cowling from the radiator.
28. Remove the lower radiator mounting from the subframe.
29. Carefully lower the radiator.

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1. Remove the expansion tank cap.
2. Raise the car.
3. Remove «FRONT SPOILER SHIELD»(ref-275838-S05457380322007122900000) .
4. Take a receptacle, open the drain cock and drain the cooling system.
5. Close the drain cock.
6. Fit «FRONT SPOILER SHIELD»(ref-275838-S05457380322007122900000) .
7. Lower the car.
8. Detach the level sensor connector and the expansion tank from the mounting on the body and move aside.
9. Detach the vacuum hose from the vacuum pump.
10. Remove the cover on the thermostat housing and move aside.
11. Remove the thermostat.

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1. Clean the sealing surfaces.
2. Lubricate the new thermostat seal sparingly with Vaseline, non-acidic and fit the thermostat to the thermostat housing.
3. Refit the thermostat cover and fit the screws. Tightening torque 10 Nm (7 lbf ft).
4. Connect the vacuum hose to the vacuum pump.
5. Put in place the expansion tank and fit it to the body.
6. Plug in the level sensor connector.
7. Fill with coolant to approx. 20 mm above the mark on the expansion tank.

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1. Carefully undo the cap on the expansion tank to release the pressure.
2. Unplug the connectors for the oxygen sensors and temperature sensor and carefully lower the cables.
3. Unplug the connector from the mass air flow sensor.
4. Detach the hose from the mass air flow sensor.
5. Remove the cover on the air cleaner casing.
6. Remove the filter element.
7. Detach the inlet air hose from the air cleaner casing.
8. Remove the air cleaner casing. IMPORTANT: Take care to ensure that the AC pressure sensor is not damaged when the air filter housing is removed.
9. Remove the inlet hose to the turbocharger, cover the turbocharger inlet.
10. Remove the upper bolt for the water pump in the timing cover and engine block.
11. Remove the heat shield over the turbocharger.
12. Remove the upper oxygen sensor.
13. Remove the nuts for the catalytic converter connection with the turbocharger.
14. Undo the bolt for the turbocharger oil delivery pipe.
15. Raise the car slightly.
16. Remove the front right wheel.
17. Lift the car a little more.
18. Remove «FRONT SPOILER SHIELD»(ref-275838-S05457380322007122900000) .
19. Remove right wing liner. CV: Remove «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
20. Place a receptacle under the car, connect a hose to the radiator and drain the coolant.
21. Remove the lower bolt for the water pump in the timing cover and engine block.
22. Place a receptacle under the car and connect a hose to the coolant pump drain cock. Open the cock and drain the coolant pump.
23. Mark the direction of rotation, relieve the multi-groove belt and remove it using «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275852-S01220740802007122900000) .
24. Remove the lower turbocharger pressure pipe.
25. Remove «FRONT EXHAUST PIPE»(ref-275846-S02149158502007122900000) .
26. Remove the heat shield over the steering gear.
27. Remove the heat shield over the catalytic converter.
28. Remove the lower oxygen sensor.
29. Remove the catalytic converter bracket from the engine block and the catalytic converter.
30. Remove the catalytic converter.
31. Remove the turbocharger coolant pipe from the thermostat housing and the turbocharger.
32. Remove the bolts on the thermostat housing.
33. Remove the coolant pump cover from the timing cover.
34. Position and fit «83 96 103 COOLANT PUMP HOLDER TOOL B207»(ref-275852-S34603891282007122900000) to secure the balancer shaft pinion.
35. Remove the pinion bolts. Use a magnetic socket to remove the bolts from the holder.
36. Remove the bolts on the back of the coolant pump.
37. Move aside the thermostat housing with pipe and remove the coolant pump. IMPORTANT: It is normal for a very small amount of coolant to pass via the coolant pump shaft seal in order to lubricate it.
38. Remove the water pipe from the thermostat housing.

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1. Clean and fit new O-rings on the coolant pipe, lubricate sparingly with Vaseline, non-acidic.
2. Clean the connections on the thermostat housing, fit a new seal and fit the water pipe.
3. Fit the stud to the coolant pump driver using «83 96 103 HOLDING TOOL FOR CHANGING WATER PUMP, B207»(ref-275852-S34603891282007122900000) from the tool kit.
4. Fit the coolant pump with new seal, sparingly lubricated with Vaseline, non-acidic, by guiding in the stud through one of the holes in the balancer shaft sprocket.
5. Insert the coolant pump bolts, the two rear bolts and the lower bolt through the timing cover.
6. Lower the car.
7. Insert and tighten the upper bolt through the timing cover.
8. Raise the car.
9. Tighten the coolant pump bolts. Tightening torque, short bolts 20 Nm (15 lbf ft). Tightening torque, long bolts 25 Nm (18 lbf ft).
10. Fit the coolant pipe to the pump and fit the thermostat. Tightening torque 10 Nm (7 lbf ft)
11. Fit the coolant pipe between the turbocharger and the thermostat housing with new seals. Tightening torque 20 Nm (15 lbf ft).
12. Lift up the catalytic converter, position its bracket to the studs on the engine block and position the catalytic converter to the turbocharger connection.
13. Insert the catalytic converter bracket bolts into the engine block and new nuts on the studs.
14. Lower the car.
15. Lubricate the turbocharger studs with 30 20 971 Screw-thread paste .
16. Fit the catalytic converter with new nuts so that it is firmly against the turbocharger. Tightening torque 10 Nm (7 lbf ft)
17. Tighten the turbocharger oil delivery pipe using new seals. Grip the pipe so that it does not rotate. Tightening torque 15 Nm (11 lbf ft)
18. Raise the car.
19. Tighten the catalytic converter nuts and bolts a last time. Tightening torque, bolts: 25 Nm (18.5 lbf ft)
20. Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the lower oxygen sensor. Tightening torque 40 Nm (30 lbf ft). IMPORTANT: Make sure that the oxygen sensor cables are not twined or damaged.
21. Lift up the oxygen sensor cable. IMPORTANT: Make sure that no cables are pinched or chafed.
22. Fit the heat shield onto the catalytic converter.
23. Fit the heat shield over the steering gear.
24. Clean the joint on the catalytic converter and the pipe connection to the front silencer. Mount the joint clamp.
25. Fit the front pipe with a new gasket, new nuts and rubber mountings. Lubricate the studs with 30 20 971 Screw-thread paste.
26. Move over the joint clamp so that the pipe ends are in the middle of the clamp.
27. Tighten the joint with the catalytic converter. Tightening torque 25 Nm (18.5 lbf ft).
28. Tighten the joint clamp nuts. Tightening torque 40 Nm (30 lbf ft).
29. Remove the stud and fit the bolts to the balancer shaft pinion using a 10 mm magnetic socket. Tightening torque, pinion 8 Nm (6 lbf ft), bearing 8 Nm (6 lbf ft). NOTE: It may be necessary to remove the fixing tool for access before finally tightening with a torque wrench.
30. Fit the cover on the timing cover with a new gasket. Tightening torque 8 Nm (6 lbf ft).
31. Fit the multigroove belt in the direction of rotation noted earlier, making sure it is positioned correctly over the pulleys. Use «83 96 095 BELT CIRCUIT RELIEVING TOOL B207»(ref-275852-S01220740802007122900000) .
32. Fit the lower turbocharger delivery pipe.
33. Close the radiator drain. CV: Fit «CHASSIS REINFORCEMENT, FRONT SUBFRAME, CV, PETROL»(ref-275876-S05650643942007122900000) .
34. Lower the car.
35. Lubricate the threads sparingly with 30 20 971 Screw-thread paste and fit the upper oxygen sensor. Tightening torque 40 Nm (30 lbf ft).
36. Plug in and secure the oxygen sensor connector.
37. Fit the turbocharger heat shield. Tightening torque 20 Nm (15 lbf ft).
38. Fit the air cleaner casing and connect the inlet hose.
39. Fit the filter and the air cleaner casing cover.
40. Fit the turbocharger inlet hose.
41. Plug in the mass air flow sensor connector.
42. Fill with coolant to approx. 20 mm above the mark on the expansion tank.
43. Check for coolant leaks.
44. Raise the car.
45. Fit «FRONT WING LINER»(ref-275838-S09185847162007122900000) .
46. Fit «FRONT SPOILER SHIELD»(ref-275838-S05457380322007122900000) .
47. Lower the car.
48. Check the coolant level and top up as necessary.

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1. Undo the expansion tank cap and release the pressure.
2. Remove the upper engine cover.
3. Remove the «FRONT SPOILER SHIELD»(ref-275838-S05457380322007122900000) .
4. Place a receptacle under the car, connect a hose and drain the cooling system.
5. Remove the hose's clamps.
6. Remove the radiator hose.

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1. Position the radiator hose.
2. Fit the radiator hose clamps. Pressure test the cooling system, see «COOLING SYSTEM, PRESSURE TESTING»(ref-275852-S33395671202007122900000) .
3. Replace the upper engine cover.
4. Fit the «FRONT SPOILER SHIELD»(ref-275838-S05457380322007122900000) .
5. Fill with coolant to approx. 20 mm above the mark on the expansion tank.