SAAB WIS ONLINE

Coolant pump

Coolant pump

To remove

Warning

The turbocharger can be hot and great care must be observed.


Warning

The cooling system is under pressure. Hot coolant and steam can escape.

- Open the cap slowly to release the pressure.

- Carelessness can cause eye and burn injuries



1. Slacken the turbo pipe (A) and move it to one side.


2. Remove the heat shield (B).

3. Remove the connectors (H) to the oxygen sensors (D).

4. Remove the oxygen sensors (D).

5. Remove the nuts (C) between the turbo and the catalytic converter (G).

Important

When removing the nuts of the catalytic converter, it is important to hold the removal tool vertically against the flange. The stud and nut can easily be broken off if they are subjected to a skew loading. Use 82 92 484 Removal tool, door hinge.


6. Remove the oil delivery pipe's (O) upper banjo bolt (K).


7. Undo the expansion tank cap (I).


8. Unplug the connector (J) from the mass air flow sensor.

9. Undo the connector from the air cleaner cap (S).

10. Remove the cover (S) from the air filter housing (X).


11. Remove the air filter (U).

12. Detach the inlet air hose (V) from the air filter housing (X).

13. Remove the air filter housing (X).

14. Remove the inlet hose to the turbocharger and cover the turbocharger inlet.

Important

Take care to ensure that the AC pressure sensor is not damaged when the air filter housing is removed.


15. Remove the upper screw (A) to the water pump.


16. Raise the car.

17. Remove the front right wheel.

18. Remove the Spoiler shield, front .

19. Remove the right Wing liner, front . CV: Remove Chassis reinforcement, front subframe, CV, Z19DTH/DTR, A20NFT/LHU

20. Remove the exhaust pipe (E) from the catalytic converter (G).


21. Remove the lower bracket (F) from the catalytic converter (G).

22. Remove the catalytic converter (G) from the car.

23. Drain coolant from the radiator's drain cock.

24. Mark the direction of rotation, relieve the multigroove belt and remove it using 83 96 095 Belt circuit relieving tool .

25. Remove the stabiliser stay (P) between the turbo and the engine block.


26. Remove the temperature sensor (N) from the thermostat housing (L).

27. Undo the thermostat housing (L) from the engine block (3 bolts).

28. Move the thermostat housing (L) to one side together with the coolant pipe.

29. Remove the oil delivery pipe's (O) lower banjo bolt (M).

30. Remove the oil delivery pipe (O) and its gaskets.

31. Remove the banjo bolts (D) from the turbo and thermostat housing.


32. Remove the return fluid pipe (C).

33. Remove the oil return pipe (E).

34. Remove the lower bolt (B) to the water pump in the timing cover.

35. Place a receptacle under the car and connect a hose to the coolant pump drain cock. Open the cock and drain the coolant pump.

36. Remove the coolant pump cover (A).

37. Position and fit 83 96 103 Coolant pump holder tool to secure the balancer shaft pinion.

38. Remove the bolts (B) from the timing cover (D).


39. Remove the bolts (A) from the pinion (C). Use a magnetic socket to remove the bolts (A) from the holder.

40. Move the coolant pipe (F) out of the way and remove the coolant pump.

Important

It is normal for a very small amount of coolant to pass via the coolant pump shaft seal in order to lubricate it.




To fit


1. Clean and fit new O-rings on the coolant pipe, lubricate sparingly with Vaseline, non-acidic .

2. Clean the connections on the thermostat housing, fit a new seal and fit the water pipe.

3. Fit the stud to the coolant pump driver using 83 96 103 Holding tool for changing water pump from the tool kit.

4. Fit the coolant pump with new seal, sparingly lubricated with Vaseline, non-acidic , by guiding in the stud through one of the holes in the balancer shaft sprocket.

5. Insert the coolant pump (A) bolts, the two rear bolts and the lower bolt through the timing cover.


6. Lower the car.

7. Insert and tighten the coolant pump (A) bolts, the two rear screws and the lower screw through the timing cover.

8. Raise the car.

9. Tighten the coolant pump's (A) bolts.

Tightening torque, short bolts 22 Nm (16 lbf ft).

Tightening torque, long bolt 25 Nm (18 lbf ft).

10. Position the oil delivery pipe (O) with new gaskets.


11. Fit the lower banjo bolt (M).

Tightening torque 35 Nm (26 lbf ft)

12. Fit the coolant pipe to the pump and fit the thermostat (L).

Tightening torque 10 Nm (7 lbf ft)

13. Fit the temperature sensor (N) to the thermostat housing (L).

Tightening torque 20 Nm (15 lbf ft)

14. Fit the coolant pipe (C) and tighten the banjo bolt (D).

15. Fit the oil return pipe (E).

Tightening torque 10 Nm (7 lbf ft)

16. Fit the stabiliser stay (P) between the turbo and the engine block.

Tightening torque, nut: 50 Nm (37 lbf ft)

Tightening torque, screw: 58 Nm (43 lbf ft)

17. Move up the catalytic converter (G) and pass it in towards the turbo connection (C).


18. Insert the bolts for the lower bracket (F) of the catalytic converter (G) without tightening them, they should just guide the position of the catalytic converter (G).

19. Lower the car.

20. Lubricate the turbocharger studs with 30 20 971 Screw-thread paste

21. Fit the nuts (C) between the turbo and the catalytic converter.

Tightening torque 50 Nm (37 lbf ft)

22. Fit the oil delivery pipe's (O) upper banjo bolt (K) with a new seal.

Tightening torque 45 Nm (33 lbf ft).


23. Raise the car.

24. Tighten the lower bracket (F) of the catalytic converter (G).

Tightening torque 58 Nm (43 lbf ft)


25. Fit the exhaust pipe (E) to the catalytic converter (G).

Tightening torque 35 Nm (26 lbf ft)

26. Lower the car.

27. Apply a thin coating of 30 20 971 screw thread paste to the threads.

28. Fit both sensors (D).

Tightening torque 42 Nm (31 lbf ft)

Important

Make sure that the oxygen sensor cables are not twined or damaged.


29. Fit the connectors (H) to the sensors (D).

Important

Make sure that no cables are pinched or chafed.


30. Fit the heat shield (B).

Tightening torque 10 Nm (7 lbf ft)

31. Fit the turbo pipe (A).

Tightening torque 22 Nm (16 lbf ft)

32. Fit the bolt (A) to the coolant pump.


33. Raise the car.

34. Remove the stud and fit the bolts (A) to the balancer shaft pinion (C) using a 10mm magnetic socket.

Tightening torque 8 Nm (6 lbf ft)

Note

It may be necessary to remove the fixing tool for access before finally tightening with a torque wrench.



35. Fit the cover on the timing cover with a new gasket and tighten the bolts (B).

Tightening torque 10 Nm (7 lbf ft)

36. Fit the multigroove belt in the direction of rotation noted earlier, making sure it is positioned correctly over the pulleys. Use 83 96 095 Belt circuit relieving tool .

37. Close the radiator drain. CV: Fit Chassis reinforcement, front subframe, CV, Z19DTH/DTR, A20NFT/LHU .

38. Lower the car.

39. Fit the air filter housing (X) and connect the intake hose (V).


40. Fit the filter (U) and the air filter housing cover (S).

Important

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.



41. Fit the turbocharger inlet hose.

42. Plug in the mass air flow sensor connector (J).

43. Connect the connector to the air filter housing cover (S).

44. Top up coolant, see Cooling system, draining and filling, LHU/A20NFT .

45. Check for coolant leaks.

46. Raise the car.

47. Fit the right-hand Wing liner, front .

48. Fit the Spoiler shield, front .

49. Lower the car.

50. Check the coolant level and top up as necessary.