SAAB WIS ONLINE

(260-2575) Replacing the O-ring in the coolant pump

Symptom: Coolant leakage at the coolant pump.

MODIFICATION INSTRUCTION
Bulletin Nbr: 260-2575
Date: ........... Juli 2005
Market: enligt separat lista
Replacing the O-ring in the coolant pump

Service Campaign 157 22

Cars in stock must be rectified before delivery.

Cars already delivered must be rectified in connection with a scheduled visit to the garage for service or repairs.

Cars affected

Saab 9-5 M05 within VIN interval 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.

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

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

For fitting the modification identity plate:

12 785 148 Modification identity plate

93 160 907 Cleaning agent Motip Dupli, aerosol 400 ml (sufficient for 50-100 cars)

Procedure

Checking the modification identity plate

Before proceeding, check box A3 of the modification identity plate. From and including M04 there is the table "Table of Modifications" in the car's Warranty and Service Book. A modification identity plate must be fitted in accordance with the section "Fitting the modification identity plate" where local directives require the marking of the car. If the box is not marked, continue as follows.

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 plug or the like to prevent contaminants 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, greased 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.


Marking the modification identity plate

After carrying out the procedure, box A3 on the modification identity plate must be marked. From and including M04 the table "Table of Modifications" can be found in the car's Warranty and Service Book. Mark the box with the number "7" if the procedure was carried out by the importer or with the number "8" if carried out by the dealer.

Fitting the modification identity plate

Note

A modification identity plate must only be fitted where local directives require the marking of the car.


Fit the modification identity plate according to WIS

9-5 M04 - General - General - Technical data - Plates and labels

Warranty/Time Information

See separate information.