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

Removal (4-Cyl)

1. Open the drain plug and drain out the coolant. Remove the cap to the expansion tank to speed up the draining.
2. On turbo models, remove the cover over the throttle body.
3. Undo the bypass hose and the pressure pipe between the charge air cooler and the throttle body. (Scheme 5)
4. On all models, undo the screw which holds the coolant pipe to the coolant pump.
5. Undo the screw which holds the coolant pipe in the engine's front left-hand corner.
6. Remove the hose to the throttle body's pre-heating and remove the screws which hold the coolant pipe to the thermostat housing.
7. Remove the cover of the thermostat housing and remove the thermostat.

Scheme 5

1. Install the thermostat and the cover of the thermostat housing. (Scheme 6)
2. Install the coolant pipe, using a new "O" ring, to the coolant pump without tightening the screw.
3. Install the screw in the corner of the engine and the screws securing the coolant pipe to the thermostat housing but do not tighten them.
4. When the pipe is fixed at all points you can tighten the screws.
5. Reconnect the hose to the throttle body's pre-heating.
6. Check that the radiator's drain plug is tightened, fill up with coolant and check that the system does not leak.
7. On turbo models, install the pressure pipe between the charge air cooler and the throttle body. Install the bypass hose.

Scheme 6

Removal (V6)

1. Open the drain plug and drain out the coolant. Remove the cap of the expansion tank to speed up the draining.
2. Undo and turn the upper inlet pipe to one side and cover the engine's intake ports.
3. Undo the middle intake pipe and move it slightly. NOTE: There is quite a lot of coolant left in the engine. Always have a receptacle under the engine when you work on the radiator system.
4. Remove the upper radiator hose from the engine. (Scheme 7)
5. Pull out the dipstick.
6. Remove the screw which holds the coolant pipe and the lifting eye and carefully pull out the pipe.
7. Remove the cover of the thermostat housing, complete with thermostat.

Scheme 7

1. Clean the sealing surfaces. Install the cover of the thermostat housing, complete with thermostat. (Scheme 8)
2. Install new "O" rings on the coolant pipe and install it into the cover of the thermostat housing.
3. Install the screw which holds the coolant pipe and the lifting eye.
4. Install the dipstick and install the upper radiator hose to the engine.
5. Install and tighten the middle intake pipe. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-152389-S23846644532003020400000).
6. Install and tighten the upper intake pipe.
7. Top up with coolant and check that the system does not leak.
8. 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 8

REPLACEMENT OF COOLANT

Note. It is not possible to drain the coolant completely from a V6 engine. A large amount of coolant remains in the engine.

1. Open the drain plug and drain out the coolant. Remove the cap of the expansion tank to speed up the draining. (Scheme 9)
2. Tighten the drain plug by hand.
3. Mix Saab Original Coolant and water 50:50 in a receptacle.
4. Pour the coolant into the expansion tank.
5. Install the pressure cap and run the engine warm. Check the systems for leaks and top up if necessary.

Scheme 9

1. Open the drain plug and drain out the coolant. Remove the cap of the expansion tank to speed up the draining.
2. Undo the upper radiator hoses from the expansion tank.
3. Disconnect the level sensor's electrical connection (certain models).
4. Remove the screw securing the expansion tank.
5. Lift up the expansion tank and undo the lower radiator hose.

Scheme 10

1. Install the lower radiator hose to the expansion tank and position the expansion tank.
2. Install the screw securing the expansion tank and reconnect the level sensor's electrical connection (certain models).
3. Reconnect the upper radiator hoses.
4. Check that the radiator's drain plug is tightened, fill up with coolant and check that the system does not leak.
5. Bleed the system as follows: Fill the system to 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 11

1. Open the drain plug and drain out the coolant. Remove the cap of the expansion tank to speed up the draining.
2. Remove the air cleaner. (Scheme 12)
3. On turbo models, undo the intake hose and plug the pipe.
4. Remove the bypass hose and remove the pressure pipe between the charge air cooler and the throttle body.
5. On all models, release the tension on the belt tensioner with an extension to a ratchet and install a 6-mm drill in the hole.
6. Undo the steering servo pump with its console and hang it up on the radiator crossmember.
7. Undo the coolant hoses and the pipes on the pump.
8. Undo the screw which holds the coolant pipe to the front left-hand corner of the engine.
9. Remove the hose to the throttle body from the coolant pipe and undo the screws on the thermostat housing. Move the pipes to one side.
10. On turbo models, remove the boost pressure control valve and move it to one side.
11. On all models, remove the coolant pump.
12. Remove the sleeve with the "O" rings and remove the coolant pump housing.

Scheme 12

1. Clean the sealing surfaces. Install the coolant pump to the pump housing. (Scheme 13)
2. Lubricate the "O" rings with acid-free vaseline. Install the sleeve together with the pump.
3. On turbo models, install the boost pressure control valve.
4. On all models, nstall the coolant hose to the throttle body and install the screws on the thermostat housing.
5. Install the screw which holds the coolant pipe to the front left-hand corner of the engine.
6. Reconnect the coolant hoses and pipes to the coolant pump.
7. Install the steering servo pump with its bracket and put the belt back.
8. Release the tension on the belt tensioner with an extension to a ratchet and remove the drill.
9. On turbo models, install the pressure pipe between the charge air cooler and the throttle body. Install the bypass hose. Install the intake hose.
10. On all models, install the air cleaner.
11. Check that the radiator's drain plug is tightened. Fill with coolant and check that the system does not leak.

Scheme 13

1. Open the drain plug and drain out the coolant. Remove the cap to the expansion tank to speed up the draining.
2. Remove the air cleaner complete with hoses. (Scheme 14)
3. Release the tension on the belt tensioner by turning the securing screw on the belt tensioner with a 15-mm open-ended spanner. Remove the belt from the coolant pump's pulley and slowly let the belt tensioner go back.
4. Remove the belt tensioner and remove the servo pump's pulley.
5. Remove the coolant pump's pulley (the motor must be pressed to the left in the car, use the motor console as support).
6. Remove the cam belt cover.
7. Remove the coolant pump. NOTE: There is quite a lot of coolant left in the engine, always place a receptacle under the car in which to collect it when you work on the radiator system.

Scheme 14

1. Clean the sealing surfaces and install a new "O" ring. (Scheme 15)
2. Apply acid-free vaseline to the sealing surfaces and the "O" ring. Install the coolant pump.
3. Install the cam belt cover.
4. Install the coolant pump's pulley (the motor must be pressed to the left of the car, use the motor console as support).
5. Install the servo pump's pulley. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-152389-S23846644532003020400000).
6. Install the belt tensioner.
7. Release the tension on the belt tensioner by turning the securing screw on the belt tensioner with a 15-mm open-ended spanner forwards in the car. Put the belt back on the coolant pump's pulley and check the position of the other pulleys. Slowly let the belt tensioner go back.
8. Install the air cleaner complete with hoses.
9. Check that the radiator's drain plug is tightened, fill up with coolant and check that the system does not leak.
10. 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 top up to the MAX level. Install the pressure cap and run the engine at varying speeds until the radiator fan has started a further three times. Switch off the engine and top up to the MAX level, if necessary.

Scheme 15