Cooling System V6: Removal & Installation Saab 9-3 II

To remove

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1. Take the cap off the expansion tank to release any pressure.
2. Remove «Fan cowling»(ref-275856-S35084604422007122900000)
3. Raise the car.
4. Remove the spoiler shield.
5. Place a suitable receptacle under the radiator. Connect a hose to the radiator and drain the coolant.
6. Lower the car.
7. Remove the «FRONT BUMPER SHELL»(ref-275838-S30477349582007122900000) .
8. Remove the upper cover of the radiator assembly.
9. Remove the upper radiator hose.
10. Remove the cover on both sides.
11. Undo the desiccant container from the radiator.
12. Detach the engine oil cooler hose from the radiator.
13. Aut: detach the automatic gearbox's radiator hose from the radiator using «87 92 806 REMOVAL TOOL, OIL PIPE, AUTOMATIC TRANSMISSION»(ref-275843-S37755888932007122900000) .
14. Remove the lower coolant hose from the radiator.
15. Hang up the charge air cooler and condenser using «83 95 212 STRAP»(ref-275876-S25609733142007122900000) to the radiator member stay.
16. Remove the radiator mountings from the subframe.
17. Remove the radiator from the charge air cooler and extract the radiator downwards under the car.

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1. Fit the radiator from below.
2. Hook the radiator to the charge air cooler and fasten it.
3. Fit the mountings to the subframe and the radiator pins. Tightening torque 47 Nm (35 lbf ft)
4. Remove the strap.
5. Attach the oil cooler hose.
6. Fit the desiccant container to the radiator.
7. Fit the covers.
8. Fit the lower radiator hose.
9. Aut: attach the gearbox radiator hoses.
10. Fit the upper cover of the radiator assembly.
11. Fit the upper radiator hose.
12. Fit «Fan cowling, B284»(ref-275856-S35084604422007122900000)
13. Fit the «FRONT BUMPER SHELL»(ref-275838-S30477349582007122900000) .
14. Raise the car.
15. Fit the front spoiler shield.
16. Lower the car.
17. Pressure test the cooling system; see «COOLING SYSTEM, PRESSURE TESTING»(ref-275856-S41791158062007122900000) .
18. Top up the coolant. See «BLEEDING AND CHARGING THE COOLING SYSTEM»(ref-275856-S10550426312007122900000) , B284.
19. Carry out «Procedures after reconnecting the battery»(ref-275856-S36517051262007122900000) .

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1. Remove the upper engine cover. WARNING: The cooling system is under pressure. Hot coolant and steam can escape. Open the cap slowly to release the pressure. Carelessness can cause eye and burn injuries
2. Undo the cap on the expansion tank to release pressure, retighten the cap. IMPORTANT: Take care when releasing the locking mechanism on the connector so as not to damage the connector. Pull the halves straight apart to avoid bending the pins. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275842-S26624887112007122900000) .
3. Detach the secondary air hose from the turbocharger intake manifold.
4. Remove the air cleaner casing cover and the bolts on the radiator member.
5. Detach the turbocharger intake manifold at the mass air flow sensor and remove it.
6. Lift up the heat shield and unplug the coolant temperature sensor connector.
7. Remove the sensor using 83 96 087 Sleeve.

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1. Quickly refit the temperature sensor using a new seal. Tightening torque 22 Nm (16 lbf ft) IMPORTANT: Take care when plugging in the connector so as not to damage or press out the pins/sleeves in the connector. For further information regarding connectors, refer to «CONNECTORS, HANDLING AND INSPECTION»(ref-275842-S26624887112007122900000) .
2. Plug in the sensor connector and press down the heat shield.
3. Refit the turbocharger intake manifold.
4. Fit the air cleaner casing cover and the radiator member bolts.
5. Attach the secondary air hose to the turbocharger intake manifold.
6. Replace the upper engine cover.
7. Top up coolant as necessary. See «BLEEDING AND CHARGING THE COOLING SYSTEM»(ref-275856-S10550426312007122900000) , B284.

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1. Drain the coolant. See «DRAINING, COOLING SYSTEM»(ref-275856-S12898389582007122900000) .
2. Remove the bolt from the coolant pipe mounting on the front of the engine.
3. Slightly loosen the rear bolt holding the coolant pipe to the engine block.
4. Lower the car.
5. Remove the battery and «BATTERY COVER, BOTTOM, B284 (2006)»(ref-275860-S10461848692007122900000) or «BATTERY COVER, BOTTOM (2007)»(ref-279916-S39619585692008021800000) .
6. Move the coolant reservoir aside.
7. Remove the upper heat shield of the catalytic converter.
8. Remove the lower heat shield of the catalytic converter.
9. Detach the cable duct from the gearbox and move the duct aside.
10. Remove the bolt holding the coolant pipe to the radiator assembly.
11. Detach the pipe from the thermostat housing. Collect any spill.
12. Detach the coolant pipe running from the thermostat housing to the radiator.
13. Remove the thermostat housing. Aut: At the same time, press the coolant pipe to the radiator forward.

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1. Clean gasket residue from the sealing surface of the engine block.
2. Fit the thermostat housing using a new seal. Fasten the seal with Vaseline on the engine block. Tightening torque 10 Nm (7 lbf ft)
3. Attach the coolant pipe using a new O-ring lightly coated with Vaseline. Do not tighten the bolt until the front mounting is fitted.
4. Attach the pipe to the heater assembly using a new O-ring lightly coated with Vaseline.
5. Fit the bolt holding the coolant pipe to the radiator assembly.
6. Fit the cable duct to the gearbox.
7. Raise the car.
8. Fit the bolt of the coolant pipe mounting.
9. Tighten the bolt of the heater assembly pipe.
10. Lower the car.
11. Tighten the bolt of the coolant pipe to the thermostat housing.
12. Pressure test the cooling system, see «COOLING SYSTEM, PRESSURE TESTING»(ref-275856-S41791158062007122900000) .
13. Fit the lower heat shield of the catalytic converter.
14. Fit the upper heat shield of the catalytic converter.
15. Fit the coolant reservoir.
16. Fit «BATTERY COVER, BOTTOM, B284 (2006)»(ref-275860-S10461848692007122900000) or «BATTERY COVER, BOTTOM (2007)»(ref-279916-S39619585692008021800000) .
17. Fit the battery.
18. Top up the coolant. See «BLEEDING AND CHARGING THE COOLING SYSTEM»(ref-275856-S10550426312007122900000) , B284.
19. Carry out «Procedures after reconnecting the battery»(ref-275856-S36517051262007122900000) .

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1. Take the cap off the expansion tank to release any pressure.
2. Raise the car.
3. Undo the right-hand side of the spoiler shield.
4. Place a suitable receptacle under the radiator. Connect a hose to the radiator and drain the coolant. Close the cock and refit the spoiler shield.
5. CV: Remove «Chassis reinforcement, front subframe, CV»(ref-275876-S05650643942007122900000)
6. Fit «83 96 145 Centering tool, subframe - engine»(ref-275876-S33252037272007122900000) and «83 96 152 Centering tool, power train»(ref-275876-S00358376022007122900000) with «32 025 059 SUPPORT»(ref-275856-S04420248902007122900000) . First remove the two long supports. Relieve the load on the engine.
7. Lower the car.
8. Detach the turbocharger intake hose.
9. Remove the air cleaner casing cover.
10. Remove the air cleaner. Detach the intake hose and remove the air cleaner casing.
11. Remove the engine pad from the body and bracket.
12. Remove the engine bracket. NOTE: The lower hole is slotted.
13. Loosen the bolts of the coolant pump pulley slightly.
14. Unload the drive belt tensioner using a 1/2" puller and remove the belt from the coolant pump pulley.
15. Remove the pulley.
16. Remove the coolant pump.

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1. Clean the sealing surfaces.
2. Fit the pump. Tightening torque: 10 Nm (7 lbf ft).
3. Fit the pulley.
4. Fit the drive belt.
5. Tighten the bolts on the pulley to torque. Tightening torque: 12 Nm (9 lbf ft).
6. Fit the engine bracket. Tightening torque, M10: 42 Nm (31 lbf ft) Tightening torque, M12: 93 Nm (69 lbf ft)
7. Fit the engine pad to the body and bracket using «32 025 063 Special box spanner»(ref-275843-S42625165892007122900000) . Tightening torque to body: 50 Nm + 180° (37 lbf ft + 180°). Tightening torque to engine mounting: 45 Nm + 90° (33 lbf ft+ 90°).
8. Fit the air cleaner casing and connect the intake hose. Fit the air cleaner.
9. Fit the air cleaner casing cover.
10. Fit the turbocharger inlet hose.
11. Raise the car.
12. Remove «83 96 145 Centering tool, subframe - engine»(ref-275876-S33252037272007122900000) and «83 96 152 Centering tool, power train»(ref-275876-S00358376022007122900000) with «32 025 059 SUPPORT»(ref-275856-S04420248902007122900000) .
13. CV: Fit «Chassis reinforcement, front subframe, CV»(ref-275876-S05650643942007122900000) .
14. Fit the spoiler shield.
15. Lower the car.
16. Carry out «Test pressurize the cooling system»(ref-275856-S41791158062007122900000) and «BLEEDING AND CHARGING THE COOLING SYSTEM»(ref-275856-S10550426312007122900000) , B284.

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1. Remove the «BATTERY (2006)»(ref-275860-S17428070512007122900000) or «BATTERY (2007)»(ref-279916-S20608419722008021800000) .
2. Remove «BATTERY COVER, BOTTOM, B284E»(ref-275860-S10461848692007122900000) or «BATTERY COVER, BOTTOM (2007)»(ref-279916-S39619585692008021800000) .
3. Remove «UPPER RADIATOR MEMBER, B284E»(ref-275838-S39889916672007122900000) .
4. Remove the mass air flow sensor connector.
5. Detach the secondary air pipe, the delivery hose from the turbocharger intake manifold and the crankcase ventilation pipes.
6. Detach the turbocharger intake manifold from the air cleaner casing cover and the turbocharger.
7. Remove the upper radiator mounting.
8. Unplug the radiator fan connectors and detach the wiring harness from the fan cowling.
9. Remove the bolt of the lower turbocharger delivery pipe.
10. Fit the fan cowling bolts.
11. Press the radiator assembly forward and remove the fan cowling.

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1. Press the radiator assembly forward and position the fan cowling.
2. Fit the fan cowling bolts.
3. Fit the bolt of the lower turbocharger delivery pipe.
4. Plug in the radiator fan connectors and attach the wiring harness to the fan cowling.
5. Fit the upper radiator mounting.
6. Attach the turbocharger intake manifold to the turbocharger and the air cleaner casing cover.
7. Attach the secondary air pipe, delivery hose to the turbocharger intake manifold and the crankcase ventilation pipes.
8. Fit the mass air flow sensor connector.
9. Fit «UPPER RADIATOR MEMBER, B284E»(ref-275838-S39889916672007122900000) .
10. Fit «BATTERY COVER, BOTTOM, B284E (2006)»(ref-275860-S10461848692007122900000) or «BATTERY COVER, BOTTOM (2007)»(ref-279916-S39619585692008021800000) .
11. Fit the «BATTERY (2006)»(ref-275860-S17428070512007122900000) or «BATTERY (2007)»(ref-279916-S20608419722008021800000) .

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1. Undo the cap on the expansion tank and release the pressure.
2. Raise the car.
3. Loosen and move aside the right section of the spoiler shield.
4. Place a receptacle under the car, connect a hose and drain the cooling system.
5. Lower the car.
6. Remove the bolts of the turbocharger intake manifold on the radiator member, the hose clip and the pipe connection of the secondary air injection pump.
7. Remove the air cleaner casing cover.
8. Detach the pipe of the mass air flow sensor.
9. Remove the hose's clamps.
10. 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-275856-S41791158062007122900000) .
3. Attach the pipe of the mass air flow sensor. Fit the bolts of the turbocharger intake manifold on the radiator member, the hose clip and the pipe connection of the secondary air injection pump.
4. Fit the lid to the air filter housing.
5. Raise the car.
6. Fit the spoiler shield.
7. Top up coolant. See «Bleeding and charging the cooling system»(ref-275856-S10550426312007122900000) , B284.

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1. Even out the break surface.
2. Fit the new mounting on the flange. IMPORTANT: Be careful not to damage the radiator end when drilling the hole.
3. Drill holes through the mounting and flange using a 4 mm bit.
4. Remove the mounting from the flange. Fit the nut in the mounting.
5. Fit the mounting to the flange with washer and bolt. Tightening torque 3.5 Nm (2.5 lbf ft)
6. Fit the upper rubber supports to the radiator.

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The cooling system is the pressurized type with crossflow radiator and expansion tank. The cooling system includes engine oil cooling, turbocharger cooling and automatic transmission fluid cooling.

The coolant pump, which is a radial pump, is located on the left side of the engine. It is driven by the crankshaft via the poly-V-belt circuit.

The thermostat is a traditional wax thermostat. It is situated on the exhaust side in a housing on the right hand side of the engine. The thermostat starts to open at 82°C and is fully open at 95°C. The opening stroke is 9 mm.

The expansion tank is located on the left side of the engine compartment. The tank is connected to the thermostat housing, the turbocharger and the highest point of the cylinder head. The latter connections serve to ventilate the cooling system. The connection from the turbocharger cools the turbocharger through the thermosyphon effect when the engine is off. The coolant filler cap also houses a relief valve, which opens at 1.4 bar.

When the engine is off, coolant circulates in the turbocharger in the same direction as when the engine is running. This occurs with the help of the thermosyphon principle. After the engine has been run hard, a boiling/bubbling noise may be audible. This is completely normal.

The car is equipped with electric radiator fans that are located behind the radiator. These fans can be run at 4 different speeds and are controlled by ECM.

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The car has two radiator fans located behind the radiator. The fans have 11 vanes and a diameter of 320 mm. The fans can be run at four different speeds, depending on the engine temperature and A/C pressure.

RADIATOR FANS SPECIFICATIONS

The radiator fans have their own relay box. Communication between the ECM and fan relay box is enabled by wiring via the UEC.

The fans are controlled by ECM through the following input signals

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1. Coolant temperature
2. A/C pressure
3. Exhaust temperature (calculated in ECM)

Radiator fan relay box (706) is supplied with +30 from UEC to pins 3 and 6, and is grounded to G30A from pins 5 and 2.

3 leads lead from the ECM via the UEC to the relay box. These leads are connected to pins 1, 4 and 7 on the relay box. The four fan speeds are controlled by the grounding of these three leads.

The radiator fans start in the following cases

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1. Temperature logic: Fan speed 1 is engaged when the coolant temperature reaches 102°C and is disengaged when the temperature has dropped to 98°C. Fan speed 2 is engaged when the coolant temperature reaches 105°C and returns to fans speed 1 when the temperature has dropped to 101°C. Fan speed 3 is engaged when the coolant temperature reaches 112°C and returns to fans speed 2 when the temperature has dropped to 108°C. Fan speed 4 is engaged when the coolant temperature reaches 116°C and returns to fans speed 3 when the temperature has dropped to 112°C.
2. A/C pressure logic Stage 1 on the radiator fans starts at an A/C pressure over 1100 kPa and stops at a pressure below 800 kPa. Stage 2 on the radiator fans starts at an A/C pressure over 1700 kPa and returns to stage 1 at a pressure of 1400 kPa. Stage 3 on the radiator fans starts at an A/C pressure over 2000 kPa and returns to stage 2 at a pressure of 1800 kPa. Stage 4 on the radiator fans starts at an A/C pressure over 2300 kPa and returns to stage 3 at a pressure of 2100 kPa. If the temperature of the automatic transmission fluid rises to 140°C, the radiator fans will start at speed 4, irrespective of the temperature of the engine or pressure of the A/C system. Once the transmission temperature has dropped to 130°C, the fans will return to obeying the normal logic. If the temperature signal is missing, the radiator fans will run constantly at full speed, i.e. stage 4.

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With the ignition switch turned to ON, ECM will use the following information on the bus

1. Coolant temperature (bus from ECM)
2. A/C pressure
3. A/C system status (active/inactive)
4. Exhaust temperature (calculated in ECM)

This information is used by ECM to control starting and stopping the radiator fans.