Cooling System Components - Removal & Installation: Overview Saab 900 II

1. On turbo models, remove the charge air cooler (intercooler).
2. On all models, remove the grille.
3. Release the engine oil cooler (if equipped) and hang out of way.
4. Remove the A/C condenser from the radiator.
5. Disconnect and remove the battery. Remove the battery shelf (SENSONIC). (Scheme 1)
6. Open the drain plug and drain the coolant. Remove the cap on the expansion tank to speed up the draining.
7. On turbo models, remove the bypass hose together with the intake hose.
8. On all models, undo the upper radiator hoses from the radiator. (The top one must be removed on both B258i models.)
9. Separate the radiator fan's electrical connections.
10. Release the servo pump's oil pipe and the clips for the radiator's breather hose from the radiator crossmember and turn the oil pipe to one side.
11. Remove the 2 screws securing the radiator fan cover and lift it up.
12. On A/T models, remove the transmission cooler oil pipes by the oil cooler, remove the screw which holds the pipes to the radiator and plug the connections.
13. Remove the lower radiator hose from the radiator. Remove the clamps which hold the radiator to the radiator crossmember. Pull up the radiator from the rubber securing points so that the clips for the A/C compressor's wiring harness can be undone.
14. Lift out the radiator.

Scheme 1

1. Spread some vaseline on the radiator's rubber bushings.
2. Push down the radiator and install the clamps. Install the clips for the A/C compressor. (Scheme 2)
3. On A/T models, install the transmission cooler oil pipes to the oil cooler. Do not forget the screw which secures the pipes to the radiator. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-152389-S23846644532003020400000).
4. On all models, check that the radiator's drain plug is tightened. Install the lower radiator hose to the radiator.
5. Install the radiator fan cover over the radiator and tighten the two screws.
6. Reconnect the radiator fan and install the upper radiator hoses.
7. Install the clips for the radiator's breather hose to the radiator crossmember. Install and tighten the screw to the servo pump's oil pipe.
8. On turbo models, install the bypass hose together with the intake hose and the pressure pipe between the charge air cooler and the throttle body.
9. On all models, fill up with coolant and check that the system does not leak.
10. Install the battery shelf (SENSONIC). Install and reconnect the battery.
11. On A/T, check the oil level in the transmission and top it up if necessary.
12. On all models, install the A/C condenser.
13. Install the engine oil cooler (if equipped).
14. Install the grille.
15. On turbo models, install the charge air cooler.
16. Bleed the system as follows: Fill the system to the MAX level, install the pressure cap. Start the engine and run until warm, preferably at varying speeds, until the radiator fan starts. Remove the pressure cap and fill up to MAX again. Install the pressure cap and let the engine run at varying speeds until the radiator fan has started a further three times. Switch off the engine and fill up to MAX again if necessary.

Scheme 2

1. Lift up the car and remove the spoilers. (Scheme 3)
2. Undo the pipe connections.
3. Remove the screws securing the oil cooler and remove the oil cooler.

1. Push the oil cooler up into its correct position and tighten the screws. (Scheme 3)
2. Install the oil pipes. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-152389-S23846644532003020400000).
3. Install the spoilers and lower the car.
4. Check the oil level and top up if necessary.

Scheme 3

1. Undo the grille and remove the horn. (Scheme 4)
2. Remove the direction indicators and the headlamps and separate the electrical connections.
3. Lift up the car and remove the spoilers. Disconnect the outdoor temperature sensor's electrical connection and the washer hose.
4. Remove the bumper's securing screws and pull the bumper forward.
5. Undo the hoses from the charge air cooler and remove the charge air cooler.

1. Hang up the charge air cooler in its place, be careful with the positioning of the plastic foam seams and the rubber bushings on the left-hand side. Install the hoses. (Scheme 4)
2. Tighten the screws securing the charge air cooler.
3. Install the bumper and tighten the bolts.
4. Reconnect the outdoor temperature sensor's electrical connection and the washer hose. Install the spoilers. Lower the car.
5. Reconnect the electrical connections. Install the headlamps and the direction indicators.
6. Install the horn and the grille.

Scheme 4