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19 January 2011 #1
Saab 9-5 thermostat replacement - V6 petrol/gasoline engine
Take care if the car is warm. The coolant is hot and there is also a risk of burning yourself on the exhaust manifold.
1. Open the cap on the expansion tank and release the pressure.
2. Raise the car.
3. Remove the lower front cover.
4. Drain the coolant from the radiator.
5. Lower the car to the floor.
6. Remove the upper engine cover.
7. Remove the upper intake manifold.
8. Remove the middle intake manifold.
9. Remove the lower intake manifold.
10. Remove the mass air flow sensor and hose.
11. Detach the turbo's intake pipe and move it towards the charge air cooler. Also detach the turbo bypass pipe and the connection to the crankcase breather pipe.
12. Remove the dipstick and the pipe going to the thermostat.
13. Remove the thermostat and thermostat housing.
1. Check and clean the sealing surfaces.
2. Fit a new O-ring to the thermostat and its connecting pipe. Coat the O-ring with a little non-acidic vaseline to facilitate assembly.
3. Fit the thermostat and its connecting pipe.
4. Fit the dipstick.
5. Fit the turbo intake pipe. Also fit the turbo bypass pipe and the crankcase breather
6. Fit the mass air flow sensor and hose.
7. Fit the lower intake manifold. Check the O-ring and coat it with non-acidic vaseline.
8. Fit the middle intake manifold.
9. Fit the upper intake manifold, using a new gasket.
10. Fill with coolant. Do not forget to close the drain plug on the radiator first. Refer to Coolant for mixtures.
11. Vent the cooling system as follows:
Fill the system to the MAX level, close the expansion tank filler cap, start the engine and warm it up at varying speeds until the radiator fan starts. Open the expansion tank filler cap and fill up again to the MAX level. Close the cap and run the engine at varying throttle openings until the radiator fan has started three more times. Switch off the engine and top up as necessary to the MAX level.
The A/C should be OFF.
12. Raise the car.
13. Check for any leakage.
14. Fit the lower front cover.
15. Lower the car to the floor.
16. Fit the upper engine cover.
19 November 2011 #2
THIS was soooooo helpful. I thought I had lost my mind not being able to find a thermostat!
28 January 2012 #3
JaredThe young one
- Join Date
- 05 Aug 2010
- A little town in Indiana
- 2003 Saab 9-5 ARC ( and care-taker of a '98 900SE)
Doing this job tomorrow....wish me luck.
Any idea how long it takes? I set aside the whole day and I hope I don't need it. hahaI don't drive fast...I fly slow
28 January 2012 #4
I hope you got the Thermostat housing & gasket and not just a third party thermostat. The thermostat is part of a housing. It's not the easiest thermostat you've ever done that's for sure! You basically have to take off the top end (intake manifold) to get to it. There is also a bracket in front that holds the turbo pipe, and top radiator hose housing pipe that you'll need to remove.
21 March 2012 #5
30 January 2013 #6
Very good description of the procedure for replacing the thermostat, thanks. I am going to give it a try on my 02 9-5 3.0v6. Can someone verify the parts list for the Thermostat replacement? I have the thermostat housing w/thermostat with O-ring, (kit) and the coolant temperature sensor on order. Do I need any other gaskets? Some Internet postings say the upper intake gasket needs to be replaced, others do not mention it, expect to use RTV sealant. Any guidance ?
Last edited by js8vv8; 30 January 2013 at 19:04. Reason: model clarification
14 November 2013 #7
I'm stuck in same situation.
28 November 2013 #8
Pipe from thermostat housing to rubber hose.
The temp. needle does not drop any more. Heat is good. No more starting problem. I hope it stays like this.
01 February 2014 #9
Additional information on intake manifold removal
Does anyone have a little more information on the disassembly of the intake manifold(s)? The pictures help provide a high-level guidance, but not specifics on what bolts to remove. I don't want to remove more than I have to.
I'm also assuming a new intake manifold gasket kit is needed for reassembly?
Thank you for your help.
09 July 2014 #10
Seeing as how I just removed all of this, I can offer some insight.
The intake gaskets are mostly a rubberized material, with the exception of the one on the fuel rail. I would recommend buying the intake gasket kit just to be safe, but mine all looked to be in great shape (130k miles) and could probably be reused.
Here's the thing... If you're going to tear the motor down this far, you might as well check your head seals all the way around. I found that my front cam seal needs replacing, so now I am in it for new head gaskets and everything. Save the headache of doing it again later and do it all at once.