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2001 Saab 9-3 L4-2.0L Turbo (B205) Vehicle Level Engine, Cooling and Exhaust Cooling System Water Pump Service and Repair

Service and Repair

To remove

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1. Open the expansion tank pressure cap to release system pressure. 2. Raise the car. 3. Connect a hose to the system drain plug and drain the coolant into a suitable receptacle.

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4. Detach the coolant pipe from the turbocharger. 5. Close the system drain plug and lower the car. 6. Remove the air hose between the air collector casing and the turbocharger intake pipe.

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7. Cut the 2 cable ties securing the main engine cables. Relieve the strain on the belt tensioner with a ratchet handle and secure the belt tensioner with a 3.5 mm drill or similar. 8. Lift the belt off the power steering pump and coolant pump pulleys.

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9. Remove the top engine cover. 10. Detach the crankcase ventilation pipe from the turbo inlet pipe and camshaft cover. Bend the pipe, to one side. Keep seals and washers safe. 11. Unplug the solenoid valve's connector. 12. Detach the solenoid valve hoses. 13. Remove the engine lifting eye. 14. Remove the bypass pipe with valve. Keep the O-ring from the connection to the turbocharger intake pipe. 15. Remove the heat shield over the exhaust manifold. 16. Detach the venting hose from the T-connection. 17. Remove the turbocharger's intake pipe, plug the turbo.

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18. Remove the power steering servo pump bolt on the right-hand side behind the belt pulley. 19. Undo the upper power steering servo pump bolt. 20. Lift up the power steering servo pump and remove the lower bolt and the 2 upper bolts on the bracket. 21. Move the power steering pump and bracket aside and secure with a cable tie or similar.

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22. Undo the hose clips and detach the hoses from the coolant pump inlet. 23. Detach the two longitudinal coolant pipes from the cylinder block. 24. Disconnect the coolant pipes from the coolant pump, keep the O-rings and move the pipes aside. 25. Loosen the coolant pump slightly.

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26. Detach the coolant pipe from the coolant pump. keep the seals. 27. Undo the coolant pump's 3 retaining bolts. 28. Carefully wiggle the coolant pump away from the mounting and from its connecting piece in the cylinder block. 29. Remove the connecting piece from the cylinder block, check its seals and change as necessary. To fit

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1. Fit the connecting piece to the cylinder block. Coat the seals with Gleitmo 805, part no. 442. 2. Fit the coolant pump in place but do not tighten it. 3. Position the coolant pipe between the coolant pump and turbocharger. Use new washers and seals. 4. Tighten the coolant pipe to the coolant pump. Tightening torque: 20 Nm

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5. Bring the two transverse coolant pipes up to the coolant pump, use new O-rings coated with non-acidic vaseline, part no. 665 or the like. 6. Tighten the coolant pump, 3 bolts. Tightening torque: 22 Nm (16.2 ft. lbs.) 7. Tighten the two transverse coolant pipes. Tightening torque: 10 Nm (7.4 ft. lbs.)

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8. Fit the power steering pump and bracket. Tightening torque: 24 Nm (17.7 ft. lbs.) 9. Fit hoses and hose clips on the coolant pump inlet. 10. Remove the plug from the turbocharger air intake. Inspect the O-ring and coat it with non-acidic vaseline, part no. 665, or the equivalent.

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11. Fit the turbocharger inlet pipe but do not tighten the V-clamp. 12. Fit the solenoid valve on the engine lifting eye. Connect the hoses to the solenoid valve. Note the markings on the hoses and the connection. 13. Fit the engine lifting eye. 14. Tighten the turbocharger's intake pipe, V-clamp. Tightening torque: 3 Nm (2.2 ft. lbs.) 15. Connect the venting hose to the T-connection.

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16. Fit the heat shield over the exhaust manifold. 17. Fit the bypass pipe and valve, use a new O-ring for the connection to the turbocharger inlet pipe. Tightening torque: 8 Nm (5.9 ft. lbs.) 18. Spray the solenoid valve connector with Kontakt 61, part no. 520, and plug it in. 19. Fit the crankcase ventilation pipe to the turbocharger intake pipe. Use new copper seals. Tightening torque: 24 Nm (17.7 ft. lbs.) Fasten the crankcase ventilation pipe to the camshaft cover, clip. 20. Fit the throttle body's cover.

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21. Raise the car and fit the coolant line to the turbocharger. Tightening torque: 25 Nm (18.4 ft. lbs.)

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22. From underneath, check that the multigroove V-belt is correctly fitted round all pulleys. 23. Check that the cooling system's drain plug is closed. Lower the car to the floor. 24. Relieve the tension on the belt tensioner with a ratchet handle and remove the catch. Make sure the belt is positioned correctly and carefully release the ratchet handle.

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25. Secure the engine's main wiring harness with cable ties. 26. Fit the air hose between the air collector casing and the turbocharger intake pipe. 27. Fill up with coolant. For the correct mixture, refer to Coolant, Specifications. Close the filler cap. 28. Fill up and bleed the system as follows: Note: A/C and ACC must be OFF. Fill the system to MAX level, fit the pressure cap, start the engine and warm it up, preferably at varying engine speeds, until the radiator fan starts. Switch off the engine and top up as necessary to the MAX level. 29. Raise the car to check for oil or coolant leakage. 30. Lower the car and top up the coolant and/or oil as necessary.
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