Saturn Coupes/Sedans/Wagons 1991-1998 Repair Guide

Hoses

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INSPECTION



See Figures 1, 2, 3 and 4

Upper and lower radiator hoses, along with the heater hoses, should be checked for deterioration, leaks and loose hose clamps at least every 15,000 miles (24,000 km). It is also wise to check the hoses periodically in early spring and at the beginning of fall or winter, when you are performing other maintenance. A quick visual inspection could discover a weakened hose which might have left you stranded if it had remained unrepaired.

Whenever you are checking the hoses, make sure the engine and cooling system are cold. Visually inspect for cracking, rotting or collapsed hoses, and replace as necessary. Run your hand along the length of the hose. If a weak or swollen spot is noted when squeezing the hose wall, the hose should be replaced.



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Fig. Fig. 1: The cracks developing along this hose are a result of age-related hardening



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Fig. Fig. 2: A hose clamp that is too tight can cause older hoses to separate and tear on either side of the clamp



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Fig. Fig. 3: A soft spongy hose (identifiable by the swollen section) will eventually burst and should be replaced



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Fig. Fig. 4: Hoses are likely to deteriorate from the inside if the cooling system is not periodically flushed

REMOVAL & INSTALLATION



See Figures 5 and 6


CAUTION
Disconnect the negative battery cable or fan motor wiring harness connector before replacing any radiator/heater hose. The fan may come ON, under certain circumstances, even though the ignition is OFF.

  1. Remove the surge tank pressure cap.
  2.  


CAUTION
Never remove the pressure cap while the engine is running or personal injury from scalding hot coolant or steam may result. If possible, wait until the engine has cooled to remove the pressure cap. If this is not possible, wrap a thick cloth around the pressure cap and turn it slowly to the first stop. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, press down on the cap with the cloth, then turn the cap and remove it.If removing just the upper radiator hose, only a little coolant must be drained. To remove hoses positioned lower on the engine, such as a lower radiator hose, the entire cooling system must be emptied.

  1. Position a suitable container under the radiator and block, then drain the coolant by opening the radiator drain and removing the engine drain plug. The engine drain plug is a bolt which can be removed with a ratchet and socket or wrench. To open the radiator drain, grasp the plug firmly and turn counterclockwise until loosened, then use a small prybar to dislodge the plug and large rubber gasket. Make sure the plug is fully loosened before prying to prevent plug or radiator damage.
  2.  


CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant may be reused unless it is contaminated or several years old.

  1. Loosen the hose clamps at each end of the hose requiring replacement. Clamps are usually either of the spring tension type (which require pliers to squeeze the tabs and loosen) or of the screw tension type (which require screw or hex drivers to loosen). Pull the clamps back on the hose away from the connection.
  2.  
  3. Twist, pull and slide the hose off the fitting, taking care not to damage the neck of the component from which the hose is being removed.
  4.  

If the hose is stuck at the connection, do not try to insert a screwdriver or other sharp tool under the hose end in an effort to free it, as the connection and/or hose may become damaged. Heater connections especially may be easily damaged by such a procedure. If the hose is to be replaced, use a single-edged razor blade to make a slice along the portion of the hose which is stuck on the connection, perpendicular to the end of the hose. Do not cut deep, so as to prevent damaging the connection. The hose can then be peeled from the connection and discarded.

  1. Clean both hose mounting connections. Inspect the condition of the hose clamps and replace them, if necessary.
  2.  

To install:
  1. Dip the ends of the new hose into clean engine coolant to ease installation.
  2.  
  3. Slide the hose clamps over the replacement hose and slide the hose ends over the connections into position.
  4.  
  5. Position and secure the clamps at least 0.12 in. (3mm) from the ends of the hose. Make sure they are located beyond the raised bead of the connector.
  6.  
  7. Close the radiator or engine drains and properly refill the cooling system with the clean drained engine coolant or a suitable mixture of ethylene glycol coolant and water.
  8.  
  9. If available, install a pressure tester and check for leaks. If a pressure tester is not available, run the engine until normal operating temperature is reached (allowing the system to naturally pressurize), then check for leaks.
  10.  


CAUTION
If you are checking for leaks with the system at normal operating temperature, BE EXTREMELY CAREFUL not to touch any moving or hot engine parts. Once operating temperature has been reached, shut the engine OFF, and check for leaks around the hose fittings and connections which were removed earlier.

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Fig. Fig. 5: Hose and cooling system routing-SOHC engine



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Fig. Fig. 6: Hose and cooling system routing-DOHC engine


 
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