SAAB WIS ONLINE

(260-2538) Leakage from the coolant pump

Symptom: Coolant leakage at the coolant pump.

TECHNICAL SERVICE BULLETIN
Bulletin Nbr: 260-2538
Date: ........... Mars 2005
Market: all
Leakage from the coolant pump

Cars affected

Saab 9-5 M05 within Vehicle Identification Number range 53502502 - 53521624 with engine variant B235 and B205.

Background

There have been instances where the O-ring on the coolant pipe to the coolant pump does not fully fulfil the technical requirements. In some cases this can result in leakage of coolant from the O-ring. In some cases the coolant pump has been replaced unnecessarily to rectify the leakage. It is the defective O-ring which should be replaced.

In the case of customer complaint, the following procedure must be carried out.

Symptom description

Coolant leakage at the coolant pump.



Parts required

30 551 913 O-ring (new material)

90 490 362 O-ring

79 87 415 O-ring (CA 30588378)

40-12 799 124 Coolant Saab longlife 4 l (approx. 3 litres are required when replacing the O-ring)

(CA: 10953464 DEX-COOL 3.87 L)

Procedure

To remove


1. Place protection over the front of the car.

2. Open the expansion tank cap and release the overpressure.


3. Raise the car.

4. Remove the lower front cover.

5. Drain the coolant.

6. Lower the car.

7. Remove the air hose from the turbocharger intake manifold.


8. Detach the crankcase ventilation pipe from the turbocharger intake manifold and the camshaft cover.


9. Remove the connector from the solenoid valve.

10. Remove the engine's lifting eye.

11. Detach the turbocharger solenoid valve and move it aside.

12. Remove the bypass pipe with the valve.

Note

There is an O-ring where the bypass pipe is attached to the turbocharger intake manifold.


13. Remove the exhaust manifold heat shield. The heat shield is secured with a nut and two clips on the underside.


14. Remove the turbocharger intake manifold and detach the hose from the turbocharger solenoid valve.

15. Plug the turbocharger intake with a plastic or similar material plug to prevent small parts from being dropped into the turbocharger during this operation.

16. Detach both longitudinal coolant pipes from the cylinder block and the thermostat housing.


17. Detach both coolant pipes from the coolant pump.


To fit


1. Raise the car and close the drain cock.

2. Fit the lower front cover.

3. Lower the car.

4. Fit both longitudinal coolant pipes to the coolant pump. Use the new O-ring, grease with Vaseline.

Tightening torque 10 Nm (7 lbf ft)


5. Fit both longitudinal coolant pipes to the cylinder block and the thermostat housing.


6. Pressure test the cooling system.

7. Remove the plug from the turbocharger intake. Connect the hose from the turbocharger solenoid valve and then fit the intake manifold. Use a new O-ring greased with Vaseline. Check that the lifting eye hole fits.


8. Fit the exhaust manifold heat shield.

Tightening torque 20 Nm (15 lbf ft)

9. Fit the bypass pipe with the valve.

Tightening torque, bypass pipe/intake manifold screw 8 Nm (6 lbf ft)


Note

Fit the new O-ring where the bypass pipe is attached to the turbocharger intake manifold.


10. Fit the engine's lifting eye.

11. Fit the turbocharger solenoid valve.

12. Attach the connector to the solenoid valve.

13. Fit the crankcase ventilation pipe to the turbocharger intake manifold and the camshaft cover.

14. Fit the air hose to the turbocharger intake manifold.

15. Fill with coolant to the MAX level. For the correct mixture ratio see, WIS - Engine - Cooling system - Technical data - Coolant. Close the expansion tank cap.

16. Set the A/C and ACC to OFF position. Start and run the engine to operating temperature without any load, preferably with varied engine speed until the radiator fan starts.

17. Switch off the engine and top up to the MAX level.

18. Check for any leakage.

19. Remove the protection from the front of the car.


Warranty/Time Information

In the case of customer complaint and if the car is within the warranty period , use the following information to fill out the claim:

Failed Object: 26238

Fault/Reason code: 50

Location code: 09 (US=9)

Warranty Type (US): 01

Repair/Action code: 01

Labour Operation (US): 2623801

Labour Operation (CA): J3460

Time: 0.9 hr