Cooling System Components - Removal & Installation Saab 900 I

1. Drain the coolant. Remove the distributor cap.
2. Slacken the hose clips and remove the radiator hoses.
3. Disconnect the electrical leads to the fan and the thermostatic switch. Remove the coil. Disconnect the hose to the expansion tank and the air intake to the air cleaner.
4. Remove the two bolts in the upper radiator member. Lift the radiator out of the car, pulling the top of the radiator slightly backwards. (Scheme 5)

Scheme 5

1. Guide the radiator studs into the holes in the radiator member. Fit the retaining bolts. (Scheme 6)
2. Connect the radiator hoses and electrical leads. Refit the coil and distributor cap.
3. Fit the air cleaner intake.
4. Fill up with coolant and bleed the system.

Scheme 6

Removal (Turbo APC Cars Only)

1. Drain the coolant into a suitable receptacle.
2. Remove the air intake (1981-1984 models).
3. Disconnect the bottom radiator hose.
4. Remove the ignition coil.
5. Remove the APC valve and switch assembly.
6. Disconnect the top radiator hose.
7. Remove the turbo pressure (discharge) pipe.
8. Disconnect the expansion tank hose.
9. Disconnect the electrical leads at the thermostatic switch.
10. Remove the fan (remove both fans for cars with AC).
11. Remove the radiator.
12. Remove the rubber bush from the radiator.
13. Remove the fan lower securing bolt.

To install, reverse removal procedure.

Removal (B201 Turbo Engines Through 1985)

1. Remove the radiator grille. (Scheme 7)
2. Remove the left headlight.
3. Remove the wiper motor (leaving leads attached).
4. Undo the four screws securing the oil cooler to the radiator (two at top and two at bottom).
5. Detach the hydraulic hoses from the cooler. (Scheme 8)

Scheme 7

Scheme 8

To install, reverse removal procedure.

Removal (B202 Turbo 1984-93 & B201 Turbo 1986-93)

1. Remove the left light cluster.
2. Remove the baffle plate. (Scheme 9)
3. Remove the left headlight.
4. Remove the spoiler grille for the oil cooler.
5. Remove the nut from the bolt in the radiator member. (Scheme 10) Remove the bolt from underneath the radiator member. (Scheme 11)
6. Remove the six bolts securing the shroud and cooler to the body.
7. Lower the shroud and remove it from the oil cooler. (Scheme 12)
8. Disconnect the hydraulic hoses from the oil cooler. (Scheme 13)

Scheme 9

Scheme 10

Scheme 11

Scheme 12

Scheme 13

1. Connect the hydraulic hoses to the oil cooler. (Scheme 14)
2. Insert the cooler in the shroud.
3. Fit the shroud leaving the bolts slack.
4. Insert the bolt in the radiator member from underneath, fit the nut and then tighten the shroud-securing bolts.
5. Refit the spoiler grille.
6. Pull the hydraulic hoses forward such that they run straight up from the oil cooler.
7. Fit the headlight.
8. Fit the baffle plate.
9. Fit the light cluster.

Scheme 14

Layout

Air-cooled variant for cars with ME, FE and AU specifications, and all 1984-93 B202 turbo engines. Water-cooled variant (all other models). (Scheme 15)

Air-cooled variant with thermostat for 1985-93 cars with B202 engine and USA, CA or JA specifications. (Scheme 16)

Scheme 15

Scheme 16

Note. Applies to 1984-93 B202 turbo engines and 1986-93 B201 turbo engines.

1. Remove the following: The mounting plate between the radiator member and intercooler. On 1986-93 models, the plastic shroud between the radiator member and intercooler. (Scheme 17) The bolt securing the intercooler to the radiator member.
2. Remove both turbo pressure pipes.
3. Lift out the intercooler.

Scheme 17

To install, reverse removal procedure.

Changing Thermostat

1. Undo the cap on the expansion tank to release the pressure.
2. Replace the cap securely.
3. Remove the securing bolts for the thermostat housing.
4. Change the thermostat (fit a new gasket).
5. Refit the thermostat housing.
6. Run the engine up to normal operating temperature and then top up the coolant as necessary.

REPLACEMENT OF COOLANT

Note. During the 1983 model year, a coolant was introduced which needs changing only once every three years. The color of this coolant is green. The reason for the coolant having to be changed is due to the anti-corrosion additives being gradually consumed.

1. Remove the cap from the expansion tank.
2. Drain the coolant through the valve on the radiator and the drain plug in the engine block. NOTE: To drain the system completely, i.e. coolant in the bottom radiator hose and lower section of the radiator, the bottom hose must be disconnected from the radiator. It is not possible to drain the heating system completely.
3. Close the drain valve and tighten the drain plug. Refill the system with coolant (50% Saab Original Coolant and 50% clean water). The system holds approximately 10 liters. Open the bleeder nipple on the thermostat housing until coolant starts to flow through the nipple.
4. Start the engine and run it up to normal operating temperature. Let it run at a moderate speed and with the temperature control for the heating system set to maximum. Top up the system as the air is expelled.

Draining Coolant From Engine Block

Note. Applies to 1985-93 B201 engine.

Drain the coolant through the lower plug (2) in the cap. The upper plug (3) can be removed for fitting of an immersion heater. (Scheme 18)

Scheme 18

EXPANSION TANK

The liquid in the expansion tank does not circulate in the cooling system. The tank is connected to the water pump and the upper left section of the radiator to enable air to be evacuated from the upper section of the radiator.

1. Drain the coolant.
2. Remove the "V" belt.
3. Remove the pulley.
4. Remove the bolts and lift off the pump.

1. Clean the mating surfaces and fit a new gasket. Apply gasket sealant.
2. Refit the pump.
3. Refit the pulley.
4. Refit the "V" belt.
5. Fill the system with coolant.

TORQUE SPECIFICATIONS

Torque specifications are not available from manufacturer.