Saab 2000-06

Removal & Installation

Print

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Drain and recycle the engine coolant.
  4.  
  5. Disconnect or remove the following:

    Battery cables
     
    Upper engine cover
     
    Front grille
     
    Light clusters and headlamps
     
    Air deflectors by condenser
     
    Open the expansion tank pressure cap and release any overpressure
     
    Air venting hose and battery
     
    Cable ties securing wiring and battery tray

    Click image to see an enlarged view

    Fig. Disconnecting hose from throttle body, power steering fluid pipe, vent hose and radiator fan connector

     
    Hose (8) from throttle body and plug it. Remove the hose from between the charge air cooler and charge air pipe.
     
    Power steering fluid pipe (9) from the brackets on the radiator cross member and below the battery tray
     
    Vent hose (10) from the crossmember, cut cable ties and set aside
     
    Radiator fan connector (11)
     
    Power steering fluid reservoir and set aside
     

  6.  
  7. Safely raise the vehicle and remove the lower cover and air shields.
  8.  
  9. Place a receptacle under the radiator and drain the remaining coolant
  10.  
  11. Disconnect or remove the following:

    Condenser retaining bolts
     
    Lower the vehicle, disconnect the lower coolant hose the radiator and the upper coolant hose from the radiator and the thermostat housing.
     
    Vent hose from radiator
     
    Bolts securing EGR valve and set aside
     
    Condenser from radiator
     
    Cable tie from lower coolant hose.
     
    Radiator fan cowling from the radiator
     
    Clamps that secure the radiator to the radiator crossmember and remove the fan cowling
     
    Second hose from the charge air cooler
     
    A/C compressor cable from the radiator and remove the A/C pipe from the radiator crossmember
     

  12.  
  13. Lift up radiator and remove from vehicle.
  14.  

To install:

  1. To install, reverse removal procedure.
  2.  
  3. Adjust the clock in the car and press 5 times on the remote control lock/unlock button.
    NOTE
    A/C must be off

  4.  
  5. Fill with coolant, check the integrity of the system and bleed it as follows:

    Connect exhaust hoses to both the engine exhaust system and the auxiliary heater exhaust system and start the engine
     
    Start the parking heater with the diagnostic tool (Body - SID - Activate - Heater). The parking heater stops when the engine temperature has reached 80°C or on exiting the parking heater menu.
     
    Check that there is a continuous flow of coolant in the hose from the thermostat housing to the expansion tank. Rev up the engine briefly to ensure circulation of the fluid
     
    Run the engine until the thermostat has opened
     
    Shut off the engine and top up the cooling system if needed.
     

  6.  

2.3L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Loosen the expansion tank pressure cap.
  4.  
  5. Remove the front lower cover.
  6.  
  7. Drain the coolant from the radiator.
  8.  
  9. Lower the car to the floor.
  10.  
  11. Undo the hose clip on the upper radiator hose.
  12.  
  13. Remove the fan assembly
  14.  
  15. For cars with automatic transmission, also remove the connections to the oil cooler on the transmission.
  16.  
  17. Loosen the cooling system vent hose.
  18.  
  19. Unplug the A/C compressor's connector.
  20.  
  21. Loosen the lower radiator hose from the coolant pump (attached with a hose clamp at the pump).
  22.  
  23. Detach the radiator from the body.
    NOTE
    If the radiator is to be removed for some time, it should be filled with liquid and the pipe connections plugged.

  24.  

To install:


NOTE
Make sure that the hose clip on the lower radiator hose is situated as high up as possible, close to the coolant pump connection, when installing the radiator.

  1. To install, reverse removal procedure.
  2.  
  3. Switch off the A/C or ACC. Fill with coolant to the MAX level. Do not forget to close the drain plug on the radiator first.
  4.  
  5. Start the engine and run unloaded at varying engine speeds until warm and the radiator fan starts.
  6.  
  7. Turn off the engine and top up to the MAX level.
  8.  
  9. Check the oil level in the automatic gearbox and top up as necessary.
  10.  
  11. Switch off the engine. Raise the car.
  12.  
  13. Check for any leakage. Install the lower front cover.
  14.  

2.8L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Loosen the expansion tank pressure cap.
  4.  
  5. Raise the car, remove the lower spoiler shield.
  6.  
  7. Place a receptacle under the car, connect a hose and drain the cooling system.
  8.  
  9. Lower the car and remove the upper radiator member.

    Click image to see an enlarged view

    Fig. Removing radiator components

  10.  
  11. Remove the coolant hoses (5) from the radiator.
  12.  
  13. Undo the connector to the relay unit (6).
  14.  
  15. Remove the fan cowling bolts and remove the fan cowling (7).

    Click image to see an enlarged view

    Fig. Removing condenser, upper radiator mounting and radiator

  16.  
  17. Remove the condenser bolts and lift the condenser (8) from the radiator.
  18.  
  19. Remove the upper radiator mounting (9).
  20.  
  21. Remove the rubber pads (10) and springs from the radiator.
  22.  
  23. Lift up and remove the radiator (11).
  24.  

To install:

  1. To install, reverse removal procedure.
  2.  
  3. Pressure test cooling system.
  4.  

3.0L Engines



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Loosen the expansion tank pressure cap.
  4.  
  5. Raise the car. Remove the front lower cover.
  6.  
  7. Drain the coolant from the radiator.
  8.  
  9. Lower the car to the floor.
  10.  
  11. Unplug the connectors and remove the radiator fan.
  12.  
  13. Detach the upper venting hose from the radiator.
  14.  
  15. Loosen the upper oil pipe from the automatic transmission.
  16.  
  17. Detach the inlet and outlet hoses from the radiator and the upper hose from the pipe to the thermostat.
  18.  
  19. Loosen the lower oil pipe from the automatic transmission.
  20.  
  21. Remove the radiator brackets from the radiator member and lift out the radiator.
    NOTE
    If the radiator is to be removed for some time, it should be filled with liquid and the pipe connections plugged.

  22.  

To install:

  1. To install, reverse removal procedure.
  2.  
  3. Tighten the A/T lower and upper oil pipe to: 20 ft. lbs. (27 Nm). Change the sealing washers before fitting. Grease the washers with vaseline.
  4.  
  5. Fill with coolant. Do not forget to close the drain plug on the radiator first.
  6.  
  7. Vent the cooling system as follows:

    Fill the system to the MAX level and close the lid of the expansion tank. Start the engine and run unloaded until warm at varying engine speeds until the radiator fan starts. Open the lid of the expansion tank and top up to the MAX level. Close the expansion tank lid and let the engine run at varying engine speeds until the radiator fan has started three more times. Switch off the engine and top up as necessary to the MAX level.
     

  8.  
  9. Raise the car. Check for any leakage. Fit the lower front cover.
  10.  

Except 2.8L Engine



  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Loosen the expansion tank pressure cap.
    WARNING
    Ensure that you do not place the top radiator bracket on the battery positive terminal, otherwise there is a risk of short-circuit/fire.

  4.  
  5. Remove the upper engine cover, insulation and battery cover.
  6.  
  7. Raise the car and remove engine/spoiler shield.
  8.  
  9. Place a suitable receptacle under the radiator. Connect a hose to the radiator and drain the coolant.
  10.  
  11. Remove the turbocharger delivery pipe hose and the pipe screw from the radiator.
  12.  
  13. Lower the vehicle and remove the front bumper shell.
  14.  
  15. Remove the right-hand headlight.
  16.  
  17. Disconnect the A/C pipe mounting and boost pressure valve from the radiator member.
  18.  
  19. Remove the upper radiator member.
  20.  
  21. Remove the turbocharger delivery hose from the throttle body, the clip from the coolant hose and the turbocharger delivery pipe from the fan cowling. Remove the pipe and hose completely.
  22.  
  23. Remove the turbo delivery pipe and hose from the turbocharger outlet.
  24.  
  25. Remove the upper radiator hose.
  26.  
  27. Remove the air exhaust hose from the radiator.
  28.  
  29. Remove the radiator pipe to the reservoir from the engine, two mountings, and the hose from the manifold.
  30.  
  31. Remove the upper radiator mounting and rubber bushings.
  32.  
  33. Hold away the A/C hose using Strap (83 95 212).
  34.  
  35. Remove the electrical connection from the fan cowling.
  36.  
  37. Remove the bolts and lift up the fan cowling.
  38.  
  39. Remove the cover.
  40.  
  41. Remove the intake manifold from the air cleaner can (air intake in front of radiator).
  42.  
  43. Remove the turbocharger delivery pipe with hose.
  44.  
  45. Undo the desiccant container from the radiator.
  46.  
  47. Remove the lower coolant hose from the radiator.
  48.  
  49. Hang up the charge air cooler and condenser using Strap (83 95 212) to the radiator member stay.
  50.  
  51. Remove the radiator mountings from the subframe.
  52.  
  53. Remove the radiator from the charge air cooler and extract the radiator downwards under the car.
  54.  

To install:


NOTE
To reduce the risk of hoses mounted on the delivery side of the turbocharger coming loose due to low friction at high air pressure, the hoses and connecting pieces must be cleaned thoroughly before fitting. Use a rag dampened with 93 160 907 Motip Dupli cleaning agent to wipe clean inside the ends of the hoses. Clean the connecting pieces as well. If hose clips are rusty or damaged, they must be replaced so the correct clamping force is maintained.

  1. To install, reverse removal procedure.
  2.  
  3. Pressure test cooling system.
  4.  

 
label.common.footer.alt.autozoneLogo