Replacing The Radiator

[falcon21]

1996 Saab 900 SE Turbo
I have a basic idea of what needs to be done according to this post:

Originally Posted by hkayssi

Since you have the turbo version, access is really tight and it's a real PITA to replace the radiator because you need to remove a lot of parts to gain access.

1. Remove front grille
2. Remove corner lights
3. Remove headlights
4. Remove wiring harnesses to the fog light and remove the temp sensor from the bumper's reinforcement
5. Remove the side bolts holding the cover to the fender linings
6. Remove the bolts holding the lower valance under the bumper and the skid shield
7. Remove the bumper bolts (2)
8. Remove the bumper out of the car
9. Remove the 2 upper brackets holding the radiator to the radiator support
10. Remove the IC and the oil cooler out of the way
11. Remove the wiring harness for the horn and remove the horns
12. Remove the wiring harness going to the AC drier and remove the bracket holding the evaporator then remove the drier out of the way
13. Unbolt the AC condenser from the radiator and move it out of the way
14. Remove the radiator fan assembly from the radiator and take it out.
15. Drain the radiator by removing the lower radiator hose
16. Inspect all the hoses for signs of wear (getting soft and brittle) and replace if necessary

Re installation is the reverse of removal and then fill with coolant. I'd personally replace the thermostat if it's old as well while the system is all drained

My main concern is that my bumper (the actual metal bumper) is pushed in on one side and may cause problems putting everything back together. Does anyone have photos from replacing their radiator? Also any tips would be nice. Thanks.

[earthworm]

http://photo.platonoff.com/Auto/
Pics galore, thanks to and courtesy of Mr Platonoff.
Maybe and indirect, but this site is a must for Saab owners.

[win_k]

Originally Posted by falcon21

1996 Saab 900 SE Turbo
I have a basic idea of what needs to be done according to this post:


My main concern is that my bumper (the actual metal bumper) is pushed in on one side and may cause problems putting everything back together. Does anyone have photos from replacing their radiator? Also any tips would be nice. Thanks.

Just did a radiator on an 2000 9-3, had a few differences from that list. Might be specific to the 9-3 vs the 900, not sure.

The horns didn't need to be moved, both the transmission oil cooler and power steering return hoses were in the way but could be massaged far enough to get the fan and radiator out and the new back in.

You'll need to remove the heat shield from above the turbo/exhaust manifold.

There's a clip that holds the wire for the a/c compressor to the radiator.

Surprisingly fiddly job, a couple of the hose clamps just about beat me up.

Be careful with the A/C condenser, you don't want to move it far, just enough to lift it off the upper hooks on the radiator.

[falcon21]

Thanks for the link and advice! I have successfully replaced my radiator. There was a huge crack down the side and from the six months of leaking a lot of dirt had built up. I have discovered a new coolant leak and I fear it may be the water pump. Where do the cooling lines for the throttle body run to? I'm hoping I will get lucky and that is where the leak is coming from.

[win_k]

Originally Posted by falcon21

Thanks for the link and advice! I have successfully replaced my radiator. There was a huge crack down the side and from the six months of leaking a lot of dirt had built up. I have discovered a new coolant leak and I fear it may be the water pump. Where do the cooling lines for the throttle body run to? I'm hoping I will get lucky and that is where the leak is coming from.

There's a hose nipple between and below the intake rails for cyls 1 & 2 for one hose, the other hose heads to the trans end of the engine and connects to the water rail there.

[falcon21]

Now I have a leak from my expasion tank. The nipple on the top of the tank has a good size crack in it. Is there an epoxy or silicone that can withstand the heat and pressure? RTV? I don't want to replace the tank if I can find a way around it. It would be nice to not have to keep coolant in my car for once.

Also I'm leaking ATF from the top bango bolt on the radiator since I did the radiator swap. I used the old washers so I think new ones will solve the problem. What kind of washer do I need to get?

[win_k]

Originally Posted by falcon21

Now I have a leak from my expasion tank. The nipple on the top of the tank has a good size crack in it. Is there an epoxy or silicone that can withstand the heat and pressure? RTV? I don't want to replace the tank if I can find a way around it. It would be nice to not have to keep coolant in my car for once.

Also I'm leaking ATF from the top bango bolt on the radiator since I did the radiator swap. I used the old washers so I think new ones will solve the problem. What kind of washer do I need to get?

There are radiator specific epoxy adhesives on the market, check around your local auto parts houses. I've had mixed luck with them.

A used header tank from a breakers yard is probably a better bet.

The banjo fitting use soft copper or soft aluminum washers as seals. Occasionally, they'll use a steel washer with a rubber/neoprene insert.

Any of the three will work, but check that the banjo bolt is tight, and that it's not cross threaded first.

[falcon21]

I finally replaced my coolant reservoir. Now I shouldn't have to drive around with extra coolant in my car. The reservoir I got was dirty on the inside so I decided to try cleaning it out with some rice and water. That method works really good, the inside of the reservoir looks almost brand new. If you use rice to clean it make sure you have a small diameter rod to clear out the inlet and outlet as rice will expand and get stuck in there.

[falcon21]

When I replaced my radiator I reused the old washers for the trans cooler lines. The top line is leaking and I want to put new washers on both lines, the only problem is I can't find the washers. Anyone know what type/size washer?

[swill424242]

i need to do this next week

[falcon21]

It's not that hard to do, there are just a lot of things that need to be moved to get the radiator out.

[falcon21]

Originally Posted by falcon21

When I replaced my radiator I reused the old washers for the trans cooler lines. The top line is leaking and I want to put new washers on both lines, the only problem is I can't find the washers. Anyone know what type/size washer?

I got the washers! I decided to pay my local Saab shop a visit and they were able to find them for me. They are steel washers with rubber in the center. They were a little pricey but if it were from eEuroParts I would have been hit with a $10 shipping fee.

I suggest you replace these washers when you replace your radiator.

[falcon21]

I just noticed a black residue on the walls of my coolant reservoir. When I replaced the reservoir I cleaned it with rice until it looked brand new so this residue is very recent, it kinda feels like old grease. I'm also loosing coolant mysteriously. I suppose a new head gasket is needed.

[jakejm79]

A compression test and/or testing coolant for exhaust gases would quickly and cheaply confirm this.

[swill424242]

I like DIY i just replaced my radiator on my Concorde But i think the Saab will be a little more detailed my Mechanic said he would charge me 200 bucks to do it with me purchasing the part iam on the fence

[falcon21]

If you have replaced a radiator before then you should be able to replace the one in your Saab. Things are a little tighter and there are a few things that need to be moved out of the way but it can be done at home. I spent probably around $150 on a slightly used radiator, antifreeze, lower radiator hose, hose clamps, and ATF.