Saab 2000-06

Removal & Installation

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9-3



2.8L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Drain and recycle the engine coolant.
  6.  
  7. Raise the car. Remove the bolt from the coolant pipe mounting on the front of the engine.
  8.  
  9. Slightly loosen the rear bolt holding the coolant pipe to the engine block.
  10.  
  11. Lower the car. Remove the battery and battery cover.
  12.  
  13. Move the coolant reservoir aside. Remove the upper and lower heat shield of the catalytic converter.

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    Fig. Disconnecting the cable duct



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    Fig. Removing thermostat and components

  14.  
  15. Disconnect the cable duct (9) from the gearbox and move the duct aside.
  16.  
  17. Remove the bolt (10) holding the coolant pipe to the radiator assembly.
  18.  
  19. Disconnect the pipe (11) from the thermostat housing. Collect any spill.
  20.  
  21. Detach the coolant pipe (12) running from the thermostat housing to the radiator.
  22.  
  23. Remove the thermostat housing (13). For A/T vehicles: At the same time, press the coolant pipe to the radiator forward.
  24.  

To install:

  1. Clean gasket residue from the sealing surface of the engine block.
  2.  
  3. Install the thermostat housing using a new seal. Fasten the seal with vaseline on the engine block. Tighten bolts to: 7 ft. lbs. (10 Nm).
  4.  
  5. Attach the coolant pipe using a new O-ring lightly coated with vaseline. Do not tighten the bolt until the front mounting is fitted.
  6.  
  7. Attach the pipe to the heater assembly using a new O-ring lightly coated with vaseline.
  8.  
  9. To complete installation, reverse remaining removal procedure.
  10.  
  11. Fill cooling system and check for leaks.
  12.  

2000-2002 Model


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Fig. Identifying thermostat components

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the engine cover.
  6.  
  7. Raise the car and remove the bottom cover.
  8.  
  9. Drain and recycle the engine coolant.
  10.  
  11. Remove the coolant hoses (4) from the thermostat housing.
  12.  
  13. Remove the thermostat housing cover with thermostat.
  14.  
  15. To install, reverse removal procedure.
  16.  
  17. Use a new thermostat housing gasket. Tighten bolts to: 6 ft. lbs. (8 Nm).
  18.  
  19. Connect exhaust hoses to both engine exhaust system and auxiliary heater exhaust system and start the engine.
    NOTE
    A/C must be shut off.

  20.  
  21. Fill coolant, check for system leaks and bleed as follows:

    Start the parking heater with the diagnostics tool (Body, SID, Activate, Heater). The parking heater shuts off when the engine reaches 80°C or if one leaves the parking heater menu. Check that there is a continuous coolant flow in the hose from the thermostat housing to the expansion tank. Run the engine until the thermostat has opened.
     

  22.  

2003-06 Model (Except 2.8L Engine)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the expansion tank cap.
  6.  
  7. Raise the car and remove front spoiler shield.
  8.  
  9. Drain and recycle the engine coolant. Close the drain cock.
  10.  
  11. Install the remove front spoiler shield and lower the car.

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    Fig. Disconnecting level sensor



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    Fig. Disconnecting vacuum hose

  12.  
  13. Disconnect the level sensor connector (8) and the expansion tank from the mounting on the body and set aside.
  14.  
  15. Disconnect the vacuum hose (9) from the vacuum pump.
  16.  
  17. Remove the cover on the thermostat housing and set aside.
  18.  
  19. Remove the thermostat.
  20.  

To install:

  1. Clean the sealing surfaces. Lubricate the new thermostat seal sparingly with Vaseline, non-acidic and fit the thermostat to the thermostat housing.
  2.  
  3. Install thermostat and tighten bolts to: 7 ft. lbs. (10 Nm).
  4.  
  5. To complete installation, reverse remaining removal procedure.
  6.  
  7. Fill cooling system and check for leaks.
  8.  

9-5



2.3L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the expansion tank cap.
  6.  
  7. Raise the car and remove front cover.
  8.  
  9. Drain and recycle the engine coolant.

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    Fig. Loosen the hose clamp on the upper radiator hose (6) mounting



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    Fig. Removing thermostat housing components

  10.  
  11. Lower the car to the floor. Loosen the hose clamp on the upper radiator hose mounting at the thermostat housing. Move the hose to one side.
  12.  
  13. Undo the ground connection and bracket (8) for the coolant pipe by the thermostat housing.
  14.  
  15. Slacken the upper bolt (9) for the thermostat housing and remove the lower bolt (9).
  16.  
  17. Remove the thermostat housing and thermostat.

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    Fig. Removing the thermostat housing (10) and thermostat (10)

  18.  

To install:

  1. Check and clean the sealing surfaces. Grease the rubber seal lightly with non-acidic vaseline.
  2.  
  3. When fitting the thermostat, ensure that the vent hole is at the top (thermostat marking -TOP-).
  4.  
  5. Install thermostat housing, tighten bolts to:16 ft. lbs. (22 Nm).
  6.  
  7. Install the ground cable and the coolant pipe bracket. Apply acid-free vaseline to both sides of the ground connection.
  8.  
  9. To complete installation, reverse remaining removal procedure.
  10.  
  11. Fill with coolant. Do not forget to close the drain plug on the radiator first.
  12.  
  13. Check for coolant leakage. Start the engine, set the heat to max. and run the engine until warm.
  14.  
  15. Switch off the engine. Check the coolant level.
  16.  

3.0L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Remove the expansion tank cap.
  6.  
  7. Raise the car and remove lower front cover.
  8.  
  9. Drain and recycle the engine coolant.
  10.  
  11. Lower the car to the floor. Remove upper engine cover.
  12.  
  13. Remove the upper intake manifold. Remove the middle intake manifold. Remove the lower intake manifold. Refer to Intake Manifold in this section.

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    Fig. Removing mass air flow sensor (10), turbo intake pipe (11), the dipstick (12) and the pipe (12) going to the thermostat

  14.  
  15. Remove the mass air flow sensor and hose.
  16.  
  17. Detach the turbo's intake pipe and move it towards the charge air cooler. Also detach the turbo bypass pipe and the connection to the crankcase breather pipe.
  18.  
  19. Remove the dipstick and the pipe going to the thermostat.
  20.  
  21. Remove the thermostat and thermostat housing.
  22.  

To install:

  1. Check and clean the sealing surfaces.
  2.  
  3. Install a new O-ring to the thermostat and its connecting pipe. Coat the O-ring with a little non-acidic vaseline to facilitate assembly.
  4.  
  5. Install the thermostat and its connecting pipe. Tighten to: 15 ft. lbs. (20 Nm).
  6.  
  7. Install the dipstick.
  8.  
  9. Install the turbo intake pipe. Also fit the turbo bypass pipe and the crankcase breather pipe connection. Tighten the following to specification:

    Turbo/intake pipe, V-clamp: 2 ft. lbs. (3 Nm)
     
    Bypass pipe/intake pipe, bolt: 6 ft. lbs. (8 Nm)
     
    Bypass pipe, hose clip: 6 ft. lbs. (8 Nm)
     
    Crankcase breather pipe: 18 ft. lbs. (24 Nm)
     

  10.  
  11. Install the mass air flow sensor and hose.
  12.  
  13. Install the intake manifolds. Check the O-ring and coat it with non-acidic vaseline. Refer to Intake Manifold in this section.
  14.  
  15. Fill with coolant. Do not forget to close the drain plug on the radiator first.
  16.  
  17. Vent the cooling system as follows:

    Fill the system to the MAX level, close the expansion tank filler cap, start the engine and warm it up at varying speeds until the radiator fan starts. Open the expansion tank filler cap and fill up again to the MAX level. Close the cap and run the engine at varying throttle openings until the radiator fan has started three more times. Switch off the engine and top up as necessary to the MAX level.
     

  18.  
  19. Raise the car. Check for any leakage. Fit the lower front cover.
  20.  
  21. Lower the car to the floor. Install the upper engine cover.
  22.  

 
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